"Purple Rain"
I know, I know, once again I am late as it is now three weeks since my last update on Sunday 3rd September. I've been a trifle busy and had much frustration in terms of keeping contractors both active on my site and aligned, plus booking others in, so I can get the house to lock up and certain critical jobs completed before running into cold weather. Before I start a write up of the last three weeks, the photo below is the house as it was at the end of my last update with the roof over framing in place ready for the subsequent spray foam insulation.
My fireplace suppliers spent two days fitting the metal insulated chimney. While the installation of the wood burner fireplace is a long way off, the chimney also needs to be in place before the remaining work on the roof is undertaken. This next photo is the heat insulated collar that goes through the loft floor above where the wood burner will eventually be sited. Much of this collar will be hidden in the floor joist space by subsequent ceiling finishing.
It then goes up through the loft bedroom above between the main central column and the loft bedroom framed wall, and goes around the ridge beam, exiting through the shed dormer roof. The chimney up here consists of the 8" double skin inner flue, surrounded by 2" of heat and fireproof insulation, encased in a 10" outer stainless steel tube as you can see here ...
... and then an additional crinkly sleeve as shown below.
All of this chimney structure in the loft master bedroom suite will be hidden by a subsequent framed wall, while deliberately leaving the big black metal plate that connects the top of the main column to the ridge beams fully exposed. That aim will be achieved, but on Jason returning to my site the day after the chimney was fitted, he thinks we may have to swap the door from the loft gallery that you see on the left of the column ,with the internal window on the right, in order to ensure the framing does not interfere over the top of the door. Not a big change but nevertheless a shame in terms of what I wanted for my loft layout.
Next two photos show the chimney and flashing collar that will be tied in with the metal roof.
My plumber also came on site for a half day to rough in both the radon and plumbing vents through the loft floor, up through a stud wall (my ensuite toilet) and on up through the roof prior to the spray foam insulation. Those more observant might note that the 2"x4" framed wall is not quote sufficient for where the vents had to be sited (this was due to the position of the over-framing above), so this wall will have to be furred out another inch or so to allow for drywalling over these pipes.
The spray foam insulation contractors team arrived Thursday 7th September for a job that was anticipated to take just under three days, but ultimately took four (more on that later).
The main roof over the internal living spaces was planned to be sprayed from above to six inches depth using closed cell spray foam (better insulation than open cell foam, does not soak up moisture and acts as a vapour barrier and airtight seal) in order to give a minimum of R40 insulation value, both to keep the heat in during winter, and solar heat out during summer. Below is a photo taken from the rear of the house just before the job was completed at the lower end. You can see the radon and plumbing vent to the left, now encased and sealed by spray foam.
Two of the metal roofing team, ever cheerful and joking in their work, and clearly in their element at altitude.
Over the last three weeks, Jason's team, already depleted for two weeks by the one with metal swarf in his eye, have only been on my site for less than half of this time, spending the rest of their work days on the 40'x30' garage build for a client at Sweetwater. Outside the roof plywood sheeting, the other work they have undertaken that is nearing completion, is the framing of internal stud walls in the daylight walkout basement. In this next photo, looking from the front of the basement to the right hand rear, you can see the newly framed front wall to one bedroom, and within it, and more apparent in the second photo, the en suite bathroom and closet (wardrobe to my UK readers).
This last Friday also saw delivery and unloading of all my windows into the garage, the result of extensive research of eight companies to get the quality of window I want, but at a price that was within $10,000 of my original budget planning assumptions. These windows are made by a company in Calgary called Lux Windows and Doors, and are externally clad in dark aluminium frames with internal Fir wood frames. Jason's team should start next week on the installation of these.
This photo below is taken from the top of the loft shed dormer looking along the roof to the front of the house. The spaces without any spray foam are the eave overhangs at the side and the 11' deck overhang at the front of the house, where there is no requirement for insulation.
Below we are looking down the front valley and over the porch dormer.
The inside of the porch dormer also has spray foam to the same thickness over the enclosed house living space, as shown below.
The shed dormer for my master suite, as shown below, being of a different construction to the heavy timbered roof, was spray foamed from below to the same six inch minimum (R40) thickness. This type of roof, subject to a vapour barrier being provided below (probably to be drywall) does not need venting - colloquially known as a "hot roof" this is a complete misnomer, and the correct term is an unvented roof. Meanwhile the walls of the shed dormer and the rear gable were sprayed to 4 inches thickness, providing R24 insulation value, the same as my ICF walls, and significantly above the R17 building code requirement. I had considered using batt insulation (the traditional fibreglass/wool insulation matting used in mass construction) as this is far cheaper, but batt installation is a much slower process to install, will sag with time leading to cold spots, and the alternative materials that are required with batt to provide an air and vapour seal are both time consuming to install and never as consistent as the spray foam in maintaining a seal.
The purple colour in my bedroom is so very 1960's, and being a 1962 baby I joked I might actually be tempted to maintain the purple theme. But perhaps not, recalling a recent BBC tribute to the Duke of Edinburgh on his retirement from public duties which listed his many funny gaffes. One of those was on his seeing plans in 1988 for the Duke and Duchess of York's house at Sunninghill Park, where he said "It looks like a tart's bedroom."
My front and stair gable framed spaces around the future windows were also sprayed to four inch (R24) thickness ...
My front and stair gable framed spaces around the future windows were also sprayed to four inch (R24) thickness ...
... as were those joist spaces where floor joists actually sit on top of ICF concrete walls, such as at the rear of the main open plan floor or in the garage ...
... or in the framed insulation spaces where the 6"x12" rafters sit on top of the rafter carrying beams astride the concrete walls.
Throughout this activity I could not get out of my head the lyrics to "Purple rain" by the artist once known as Prince, especially
Earlier I mentioned this work was supposed to take up to three days but ended up taking four. Why? With the over framing being nominally 2" x 8" lumber (actually after planing at a mill this becomes 1.5" x 7.5") and the blocking all the way up between main frames being 6" depth, I made it very clear to the installer that he must leave an inch gap above the spray foam in order to allow air venting flow above the insulation. This ensures any moisture ingress and subsequent condensation is removed by natural venting above the insulation and below the sheathing, preventing risk of subsequent rotting over time of the sheathing. Perhaps he thought he was being helpful in giving me a little extra insulation, but I doubt that! Whatever, on my checking their work I found huge areas that were too thick and would obstruct venting. Quick discussion on the phone with the "High R Expectation's" company owner, who had no quibble with my saying the excess would have to be cut back using a grinder. That, even with my own time assisting in this task up on the roof, added a days work, and resulted in loads of fine granular polystyrene flying around. This too had to be removed, otherwise it would later block the vents. In the photo below you can see where the suns strong UV (in spite of the smoke haze from wildfires blotting out the sun) has turned the purple to green over a couple of days, but the areas we cut back show through in purple (until later sun bleached).
Throughout this activity I could not get out of my head the lyrics to "Purple rain" by the artist once known as Prince, especially
"I never meant to cause you any sorrow
I never meant to cause you any pain
I only wanted to one time to see you laughing
I only wanted to see you
Laughing in the purple rain"
Earlier I mentioned this work was supposed to take up to three days but ended up taking four. Why? With the over framing being nominally 2" x 8" lumber (actually after planing at a mill this becomes 1.5" x 7.5") and the blocking all the way up between main frames being 6" depth, I made it very clear to the installer that he must leave an inch gap above the spray foam in order to allow air venting flow above the insulation. This ensures any moisture ingress and subsequent condensation is removed by natural venting above the insulation and below the sheathing, preventing risk of subsequent rotting over time of the sheathing. Perhaps he thought he was being helpful in giving me a little extra insulation, but I doubt that! Whatever, on my checking their work I found huge areas that were too thick and would obstruct venting. Quick discussion on the phone with the "High R Expectation's" company owner, who had no quibble with my saying the excess would have to be cut back using a grinder. That, even with my own time assisting in this task up on the roof, added a days work, and resulted in loads of fine granular polystyrene flying around. This too had to be removed, otherwise it would later block the vents. In the photo below you can see where the suns strong UV (in spite of the smoke haze from wildfires blotting out the sun) has turned the purple to green over a couple of days, but the areas we cut back show through in purple (until later sun bleached).
The spray foam job was eventually completed end of Tuesday 12th September, and despite the issue of having to cut back insulation where it obstructed the venting, adding a days work, I have to say I was pleased with this contractors work, and the final bill reflecting 100% the quote. Jason's team returned next day from their garage build for another client, and cut the vent holes between each over roof chamber, sideways and vertically up the slope and in the valleys ...
... prior to sheeting over with 4'x8' ½" thick plywood.
Roof now sheathed, you'll notice a gap along the top of the roof in this next photo. This will subsequently be covered as part of the metal roof by a ridge vent, while at the bottom of the roof in the T&G underside at the roof overhang (no insulation in these overhangs) I will have a number of 4" metal circular soffit vents fitted.
Jason and one of his crew of two worked hard for two days undertaking the sheeting. The third member, as I have previously mentioned, often prone to not turning up for work once a week because he doesn't feel like it, has been genuinely off work for the two weeks as a result of his getting some metal particles in one eye (this was while working on Jason's other work site I hasten to add). Watching the other two, I now understand why builders do not generally run, cycle or go to the gym, as this two days proved just how physically demanding their work can be. Even without my fear of heights, I could not have kept up with either individual working all day lifting those heavy 4'x8' plywood sheets, carrying them across to the ladder and then climbing up onto the roof and fitting them. Exhausting. That said, Jason did strain his back, so he took the Friday 15th off, but he returned on Sunday morning to complete the sheathing of the rear valley so that the roof was ready for the metal roofers on Monday 18th. With Friday being a day the team were not on site, I drove down to RBM Lumber in Columbia Falls, Montana, to discuss the search for a stain match for my front door so that it ties in with the stain planned for my cedar siding (cladding). (They don't want to use the make I am using on my siding due to their own warranty cover on my door - ??!!?? - if it's rated as very suitable for my siding I am perplexed why they don't want to use it on the door, but whatever)!
The metal roofing team of four from Casey's Flashing's, led by Casey himself, brought in their equipment late morning of Monday 18th once they had completed another job in Fernie. My search for a metal roofing contractor has been a tortuous one in terms of both cost and reputation for quality. The metal roof is partly driven by the Koocanusa Ranch strata rules based on fire safety, as whatever the supporters of the more typical asphalt shingles generally used in Canada claim, even at Cat A fire grade, these are more prone to fire risk from burning embers that might be expelled from a chimney, bonfires or a wildfire. Being 30 minutes away and outside the cover provided by the Jaffray fire hall (fire station to my readers back in UK) one has to accept in the event of a fire you would lose your home, but at the same time seek to mitigate those risks both to your own home and the risk of it spreading to a neighbour, or vice versa - hence the strata rule. (We do have our own self help hydrant main system with fire hoses all along our private road, but this relies on enough neighbours in from Calgary at a weekend to have any real hope of dealing with a house fire). Outside that strata requirement, metal roofs, if constructed correctly to avoid ice damming, last considerably longer than asphalt shingles. Those in UK, used to tiled roofs that last the best part of a 100 years, would be shocked to know that in Canada it's normal to replace asphalt roof shingles every 15 - 20 years. "Nuff" said!
In terms of metal roofs I have gone for the more expensive hidden fastener interlocked system over the exposed fastener cheaper option, for three reasons. First, there is less risk of damage if snow melt turns to ice and catches on exposed fasteners in a slide. Second, in a country of seasonal climate extremes (+36C in summer and -25C or worse in winter) the expansion and contraction of the sheet metal would eventually lead to potential problems with exposed fasteners working loose. Third, the hidden fastener system looks much neater. As for colour, I have chosen a charcoal grey which will blend into the background far more easily than some other colours, such as red. Would you believe it, but our strata rules even allow yellow! Yuk! I am glad to say nobody here has gone for that colour.
Casey's team have so far been impressive in their work flow and good humour, although work was suspended for the equivalent of nearly two days this week due to rain, making it unsafe to work on wet slippery plywood on a 8:12 roof slope. (The weather turned much cooler and at long last brought much needed rain as of a week ago, bringing a welcome gradual reduction in risk in this record BC wildfire year).
A few photographs. In this first one below, taken from the rear of the house, you can see the plywood is first covered in a blue water and ice protective membrane, prior to each longitudinal metal panel being interlocked in place on one side to the previous fitted panel, and screwed on the other side to the underlying plywood roof sheeting. (I could have used cheaper OSB (Orientated Strand Board) to sheet the roof but plywood has much better holding power, and for the difference of $1,000 in materials I felt this additional cost worthwhile).
In terms of metal roofs I have gone for the more expensive hidden fastener interlocked system over the exposed fastener cheaper option, for three reasons. First, there is less risk of damage if snow melt turns to ice and catches on exposed fasteners in a slide. Second, in a country of seasonal climate extremes (+36C in summer and -25C or worse in winter) the expansion and contraction of the sheet metal would eventually lead to potential problems with exposed fasteners working loose. Third, the hidden fastener system looks much neater. As for colour, I have chosen a charcoal grey which will blend into the background far more easily than some other colours, such as red. Would you believe it, but our strata rules even allow yellow! Yuk! I am glad to say nobody here has gone for that colour.
Casey's team have so far been impressive in their work flow and good humour, although work was suspended for the equivalent of nearly two days this week due to rain, making it unsafe to work on wet slippery plywood on a 8:12 roof slope. (The weather turned much cooler and at long last brought much needed rain as of a week ago, bringing a welcome gradual reduction in risk in this record BC wildfire year).
A few photographs. In this first one below, taken from the rear of the house, you can see the plywood is first covered in a blue water and ice protective membrane, prior to each longitudinal metal panel being interlocked in place on one side to the previous fitted panel, and screwed on the other side to the underlying plywood roof sheeting. (I could have used cheaper OSB (Orientated Strand Board) to sheet the roof but plywood has much better holding power, and for the difference of $1,000 in materials I felt this additional cost worthwhile).
In the photo below, at a later stage, we are looking at the rear valley. Here, due to it being an area where rain water will inevitably flow into, and where snow might accumulate, the underlying water and ice shields are doubled, using an enhanced thicker material before overlaying with the same material used over the rest of the roof.
A view from the back of the house as the work progresses. I reckon that looks very smart!
Casey, the business owner and man in charge of this crew, working below undertaking the critical job of rolling out and accurately measuring the 26 gauge flat steel sheets, which are shaped and printed by that machine, ready to be passed up to the three lads on the roof.
Below is Casey's chariot. He arrived first day in one of the company old pick-up trucks, second day in his 5 series BMW (probably about 5+ years old, leading me to think he is not making too much of a fortune out of his business), and then in this beat up relic with it's totally (and I suspect deliberately enhanced) rusting body. Note the ambulance sign - a coincidence I hope in his trade, rather than a reality.
A view taken from the front of the house late Friday afternoon, with two of the team of three visible on the roof giving a cheery wave for the camera.
Due to a late start last Monday after they completed another clients job, and rain stopping work for part of the week, what I've shown you is about three days work. While talking with Casey on completion of work Friday about the various deliveries of materials I have booked next week, he reckons (weather allowing) that they will complete the job next Tuesday PM but more likely Wednesday.
Over the last three weeks, Jason's team, already depleted for two weeks by the one with metal swarf in his eye, have only been on my site for less than half of this time, spending the rest of their work days on the 40'x30' garage build for a client at Sweetwater. Outside the roof plywood sheeting, the other work they have undertaken that is nearing completion, is the framing of internal stud walls in the daylight walkout basement. In this next photo, looking from the front of the basement to the right hand rear, you can see the newly framed front wall to one bedroom, and within it, and more apparent in the second photo, the en suite bathroom and closet (wardrobe to my UK readers).
In the next photo is the framing for the ensuite bathroom and closet for the left hand rear bedroom (a slightly different layout due to the position of the egress well window). They have yet to frame that bedrooms front wall.
In the next photo we are looking from the front door to now framed walls to the rear mechanical room, and a newly built half way landing.
Further framing in this area for the under stairs half bathroom (toilet and sink) and under stairs storage will only be possible when Bob Damstrom returns from his client in Saskatchewan and installs the Fir lumber stairs in October. I am anticipating that Jason's team will finish the second bedroom wall as well as some minor framing still required in the loft master suite early next week, as I have my plumber and then my electrician coming on site to start their major roughing in through all these walls.
This last Friday also saw delivery and unloading of all my windows into the garage, the result of extensive research of eight companies to get the quality of window I want, but at a price that was within $10,000 of my original budget planning assumptions. These windows are made by a company in Calgary called Lux Windows and Doors, and are externally clad in dark aluminium frames with internal Fir wood frames. Jason's team should start next week on the installation of these.
I also anticipate delivery next week of four external doors from a local Cranbrook supplier: one for the back of the house from the kitchen, one from the laundry area and one at the main floor stair landing, both onto the over garage deck, and one from my loft master bedroom suite onto the small 4' rear deck. Pick up date for my front door from RBM Lumber in Montana remains to be confirmed. Subject to no hidden surprises, I would hope that on my next update, be that two or three weeks from now, with a roof completed and external windows and doors fitted, the house will be at what is generally known as lock up. i.e. weather tight - a significant milestone in any build.
I opened this update with a comment about frustration. The project is now two months behind what had been expected, both in my own mind and in terms of what my two prime contractors (Jason Olesen and Bob Damstrom) had anticipated and told me when we signed contracts. i.e. with footings going in the ground early April, we had expected the roof to be complete by end of July latest. Not helped by a late start as a result of an unusually heavy winter, that excuse is a little lame as one was supposed to be ready by end of May with his timbers and wasn't until late July (and the winter wasn't 2 months late in ending). Nor by the fact Jason has to deal with an unannounced sporadic decision of one of his workers not to come to work for at least a day each week, plus two periods of two weeks off by each of his workers due to genuine health issues. My perception is Jason perhaps also slightly underestimated the task. (That means his profit margins are reduced, but it doesn't change what I pay him). Progress has not been helped though by the fact in early August he started the Sweetwater site big garage build, partly to keep his crew out of the way while Bob was building the timber roof, but I suspect from then on partly to keep that other customer off his back. I understand that predicament but it's not helping me. Further, Bob Damstrom also over extended himself, as having two contracts agreed early this year with myself and another local client, he then got another contract (and one rather better on the profit margin) with a client in Saskatchewan. Again I understand, but I am irritated by the fact it seems to me, having signed as his second client this year, my work is being delayed in terms of the stairs and the build of my decks, combined with the mistake I highlighted two posts ago about the position of the sonos and front deck line under the porch dormer (13 Aug 17: Problems and Solutions) which has necessitated removing that cross deck walk way structure and re-siting the sonos. We poured concrete into the new sonos last week, but the design mistake and delay in getting a small delivery of concrete (on the back of another delivery so I don't incur part load and delivery charges) has impacted on my need to build up and compact the land in front of the house for the concrete patio and front entrance steps prior to concreting. I now have a race against time to get that work done so concrete can be poured before the weather turns too cold at night. In sum, having been advised at start and planned accordingly to be able to get an occupancy certificate and move into a shell of a house (i.e. functioning bedroom, bathroom and kitchen plus safety rails but still much unfinished work to do) mid to late September, I am now thinking we are still 10-12 weeks off. Irritating but one has to continue to work through.
In the meantime I will leave you with the current view of the house from front, metal roof nearing completion, ...
I opened this update with a comment about frustration. The project is now two months behind what had been expected, both in my own mind and in terms of what my two prime contractors (Jason Olesen and Bob Damstrom) had anticipated and told me when we signed contracts. i.e. with footings going in the ground early April, we had expected the roof to be complete by end of July latest. Not helped by a late start as a result of an unusually heavy winter, that excuse is a little lame as one was supposed to be ready by end of May with his timbers and wasn't until late July (and the winter wasn't 2 months late in ending). Nor by the fact Jason has to deal with an unannounced sporadic decision of one of his workers not to come to work for at least a day each week, plus two periods of two weeks off by each of his workers due to genuine health issues. My perception is Jason perhaps also slightly underestimated the task. (That means his profit margins are reduced, but it doesn't change what I pay him). Progress has not been helped though by the fact in early August he started the Sweetwater site big garage build, partly to keep his crew out of the way while Bob was building the timber roof, but I suspect from then on partly to keep that other customer off his back. I understand that predicament but it's not helping me. Further, Bob Damstrom also over extended himself, as having two contracts agreed early this year with myself and another local client, he then got another contract (and one rather better on the profit margin) with a client in Saskatchewan. Again I understand, but I am irritated by the fact it seems to me, having signed as his second client this year, my work is being delayed in terms of the stairs and the build of my decks, combined with the mistake I highlighted two posts ago about the position of the sonos and front deck line under the porch dormer (13 Aug 17: Problems and Solutions) which has necessitated removing that cross deck walk way structure and re-siting the sonos. We poured concrete into the new sonos last week, but the design mistake and delay in getting a small delivery of concrete (on the back of another delivery so I don't incur part load and delivery charges) has impacted on my need to build up and compact the land in front of the house for the concrete patio and front entrance steps prior to concreting. I now have a race against time to get that work done so concrete can be poured before the weather turns too cold at night. In sum, having been advised at start and planned accordingly to be able to get an occupancy certificate and move into a shell of a house (i.e. functioning bedroom, bathroom and kitchen plus safety rails but still much unfinished work to do) mid to late September, I am now thinking we are still 10-12 weeks off. Irritating but one has to continue to work through.
In the meantime I will leave you with the current view of the house from front, metal roof nearing completion, ...
... and returning back to my lodgings at Chris's house, a view of some of the friendly locals on Chris's neighbours front lawn.
As hunting season started a week or so back, once the rain came and the fire risk reduced enough to reopen the back country, the deer seem to have returned to Koocanusa Ranch. There is no hunting access allowed on our gated private strata development, and I think these mule deer have it all worked out our ranch is their safest bet.
That's all for now. I'll plan either to write a post again for publication weekend of 8th or 15th October, depending on work progress.
That's all for now. I'll plan either to write a post again for publication weekend of 8th or 15th October, depending on work progress.
Funny that, Bob the Builder being so popular, who'd have thought it? 😝
ReplyDeleteSome of these contractors certainly test a mix of the need for diplomacy and a time to be rather more direct!
DeleteI was half expecting you to make a comment on the purple bedroom!