Week ending 28 Aug. 2015

Ron Dahlke from Ranserve files this week’s summary:

This week:

  • Received final shower pan
  • Set remaining plumbing for inspection
  • Installed sheetrock at mud room walls
  • Started insulation
  • Continued on outside masonry
  • Met with welder on site
  • Installed cedar siding at front porch
  • Ordered tile

Next week:

  • Meet with Miki on the Green Build program
  • Continue and finish insulation
  • Call in for insulation inspection
  • Receive and install remaining shower walls
  • Continue exterior paint
  • Shim reveals on windows
  • Finish cabinet specs and start production

Steven adds:

  • Steven approved kitchen cabinet plans
  • Steven asked architect Brett Grinkmeyer to draw plans for potential third garage bay
  • Steven continues hunt for company to install network, AV, phone and low-voltage wiring systems.
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Cleaning up the boneyard

Lumber, brick and other recyclables taken out of Emerald Hill were piled on the driveway at Emerald Hill, creating a boneyard of sorted material piles, with each material chucked into a specific dumpster on a specific schedule to help meet Green Build requirements and properly recycle the waste.

Today, above, Matt from Ranserve has cleaned it all up — and there’s still room in dumpster #7.

And at the end of the day Matt hauls one final bag of trash off the driveway -- which has not been this clean since day 1 of demo. There are still piles of metal and unpainted drywall to sort and properly recycle.
And at the end of the day Matt hauls one final bag of trash off the driveway — which has not been this clean since day 1 of demo. There are still piles of metal and unpainted drywall to sort and properly recycle.
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Taking a brick to it

While the insulators are spraying foam inside, the masons are back to continue patching the holes in the exterior brickwork.

At the kitchen window.
At the kitchen window.
Moving across to the wall between the kitchen window and side door.
Moving across to the wall between the kitchen window and side door. Using a string line to keep each course of brick level — and to match the mortar lines with the existing brickwork.
Tapping a brick into place between the window and door.
Tapping a brick into place between the window and door.
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The back side of the chimney

As purchased by the Leons, the back side of the chimney was flashed with metal to prevent water running down the roof from penetrating the brick.

After 50 years, it’s time to approach this problem differently — because water got into the brick and ran down the brick and down the interior framing. Mold grew against the tar paper sheathing inside the walls. As we discovered when Ranserve opened up the walls during demo.

As a first line of attack, the roofer built and installed a metal "cricket" at the back of the chimney, inserting the metal under roof tiles. Instead of water cascading down the roof, slamming into and through the chimney brick, the V shape of the cricket diverts water away from the brick.
As a first line of attack, the roofer built and installed a metal “cricket” at the back of the chimney, inserting the metal under roof tiles. Instead of water cascading down the roof, slamming into and through the chimney brick, the V shape of the cricket diverts water away from the brick.
Inside bedroom 4 upstairs, Matt from Ranserve steps back to examine the tar paper sheathing he tore away from the backside of the brick. After 50 years, the tar paper rips easily and is dried out; it crumbles, actually. Water stains run down the brick and paper. Ron will spray the brick and lumber with bleach to kill any mold.
Inside bedroom 4 upstairs, Matt from Ranserve steps back to examine the tar paper sheathing he tore away from the backside of the brick. After 50 years, the tar paper rips easily and is dried out; it crumbles, actually. Water stains run down the brick and paper. Ron will spray the brick and lumber with bleach to kill any mold.
After applying the bleach, and letting it evaporate, Ron and Matt stapled Tyvek sheathing to the studs and up against the chimney brick. Two of the foam insulation installers suit up for the next step.
After applying the bleach, and letting it evaporate, Ron and Matt stapled Tyvek sheathing to the studs and up against the chimney brick. Two of the foam insulation installers suit up for the next step.
One of the installers sprays a light coat of foam against the corners of the Tyvek and studs. This pushes the Tyvek tightly into the corners and seals the joints.
One of the installers sprays a light coat of foam against the corners of the Tyvek and studs. This pushes the Tyvek tightly into the corners and seals the joints.
With the joints sealed, the installer begins spraying the entire stud bay.
With the joints sealed, the installer begins spraying the entire stud bay.
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Insulation begins

It’s a big day. Ranserve is insulating Emerald Hill. Framing is done.  Plumbing rough-in is done. Drywall comes next.

Eleven years ago, when we built Sea Eagle with Hagy Custom Homes, we were one of the first homes in Austin insulated with BioBased spray foam.

Spray polyurethane foam (SPF) is a spray-applied plastic that can form a continuous insulation and air sealing barrier on walls, roofs, around corners, and on all contoured surfaces. It is made by mixing and reacting unique liquid components at the job site to create foam. The liquids react very quickly when mixed, expanding on contact to create foam that insulates, seals gaps, and can form moisture and vapor barriers. SPF insulation is known to resist heat transfer extremely well, and it offers a highly effective solution in reducing unwanted air infiltration through cracks, seams, and joints. Spray foam makes sense.

Sea Eagle is tight, comfortable, efficient. We believe our utility bills run about half that of nearby homes built about the same time that use conventional fiberglass batts.

So we planned from Day 1 to insulate with foam.

Before Energy Guard Foam Insulators pulled up to Emerald Hill this morning, Ron and Cris from Ranserve walked the house sealing up small penetrations with cans of spray foam. They also took the time to spray behind every electrical outlet in every exterior wall — “because the big guns the insulators use don’t always hit behind the electrical boxes,” said Ron.

An example of the attention to detail from Ron and Cris as they prepared the house for insulation -- spray foam applied behind every electrical box in every exterior wall, sealing any air gaps.
An example of the attention to detail from Ron and Cris as they prepared the house for insulation — spray foam applied behind every electrical box in every exterior wall, sealing any air gaps.

To spray two liquids that instantly react to create foam, you have to have a surface to spray — so Ron and Cris installed drywall on the shared walls between the mudroom and garage — the first drywall screwed into Emerald Hill!

Ron, left, and Cris, right, in the garage, with drywall wrapping around the mudroom.
Ron, left, and Cris, right, in the garage, with drywall wrapping around the mudroom.
Downstairs, in bedroom 1, the insulation team begins installing sound insulation -- fiberglass batts designed to attenuate the transfer of sound between rooms and floors. Expanding foam insulation is not as efficient at reducing noise as the loose batts, which trap sound in voids and fibers.
Downstairs, in bedroom 1, the insulation team begins installing sound insulation — fiberglass batts designed to attenuate the transfer of sound between rooms and floors. Expanding foam insulation is not as efficient at reducing noise as the loose batts, which trap sound in voids and fibers.
The batts come squeezed into sausage-like bales.
The batts come squeezed into sausage-like bales.
Here's the back end of the pumper truck. Blue barrels of the liquid foam components on the right side of the truck. Batts waiting to be used on the ground, still in protective wrapping.
Here’s the back end of the pumper truck. Blue barrels of the liquid foam components on the right side of the truck. Batts waiting to be used on the ground, still in protective wrapping.
About one hour later, most of the ceiling in bedroom 1 is insulated with sound-absorbing batts -- and, already, noise reverberates significantly less.
About one hour later, most of the ceiling in bedroom 1 is insulated with sound-absorbing batts — and, already, noise reverberates significantly less.
The East and South walls of the master bath, foamed. At right is the wall between the master bath and master closet, with plywood blocking installed to support the shelving and storage that Jacquela plans.
The East and South walls of the master bath, foamed. At right is the wall between the master bath and master closet, with plywood blocking installed to support the shelving and storage that Jacquela plans.
Liquid parts A and B mix just ahead of the spray nozzle. As the mix hits the wall, it's a liquid. In seconds, it begins expanding into every corner that conventional insulation would never reach.
Liquid parts A and B mix just ahead of the spray nozzle. As the mix hits the wall, it’s a liquid. In seconds, it begins expanding into every corner that conventional insulation would never reach.
The installer moves quickly from stud bay to stud bay in the master bedroom.
The installer moves quickly from stud bay to stud bay in the master bedroom.
Overhead, a second installer has begun spraying foam against the underside of the roof decking. When this job is done, the attic and exterior walls will become one system, sealed and insulated with foam -- a cooler turned upside down, pinned against the concrete slab, able to keep drinks and humans hot and cold for long periods of time with minimal use of energy.
Overhead, a second installer has begun spraying foam against the underside of the roof decking. When this job is done, the attic and exterior walls will become one system, sealed and insulated with foam — a cooler turned upside down, pinned against the concrete slab, able to keep drinks and humans hot and cold for long periods of time with minimal use of energy.
The model train room gets foamed.
The model train room gets foamed.
And here's the train room after the installers shift to the next-door loft.
And here’s the train room after the installers shift to the next-door loft.
The loft, foamed, with one of the spray guns hanging from the ceiling rafters.
The loft, foamed, with one of the spray guns hanging from the ceiling rafters.
Ron asked the installers to spray a "loaf" of foam against a plastic sheet. Ron will use this to seal any holes he has to make in the house as construction continues after insulation is complete. He will slice out chunks as he needs them. The foam weighs almost nothing. This loaf is probably four feet by eight feet and you can pick it up with one hand.
Ron asked the installers to spray a “loaf” of foam against a plastic sheet. Ron will use this to seal any holes he has to make in the house as construction continues after insulation is complete. He will slice out chunks as he needs them. The foam weighs almost nothing. This loaf is probably four feet by eight feet and you can pick it up with one hand.
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HVAC change

Mark Rehberg called this morning. Early. Ranserve fired the HVAC installer. Everything at Emerald Hill will be removed. Mark will bring in a new installer. We start over.

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