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No turning back now... d*** it.

by Jeffrey Rous posted on 06-18-2007 22:22 last modified 07-24-2007 10:42

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It's been a while since the last posting. Partly because we've made little progress, but also because the story so far has been depressing enough that I don't care to relive it. Then again, we started this project over three years ago so why should our luck be changing now! Here is the latest.

1) After three years of near drought, the rain has returned to Dallas. At this point of the year, we should have 1/2 our average annual rainfall -- this year we are already at 2/3 of the annual average.

2) The foundation contractor from Hell. Our builder was looking for a new concrete guy so I got a name from our engineer who seems to have a great reputation and works on a lot of big, expensive homes in Dallas. Because of the rain, progress was slow. But this didn't stop DP the foundation guy from submitting invoices for work done, but before he had gotten to one of the contractually agreed upon stage. For example, he had the forms up and the steel on site, but not yet installed in the hole. He wanted to get paid for the form work and for the cost of the steel, even though it was not yet installed. The contract said he was to get paid once the steel was all in. When he didn't get $$$ within a couple of days, work would stop. Then we would get the bank out to decide how much they would release and the builder would make up the difference to get him moving again. You may ask why he wasn't fired the first time. Well, he had $5,000 of start up money and then he threatened to pull out his forms and the steel if we didn't pay him. Looking back, maybe cutting him loose would have been smart, but he kept claiming that the issue was he didn't have the money to buy the rest of the steel or any concrete until we gave him more money. On the strength of the engineer's recommendation, we thought we should stick with him as _we thought_ we understood his bind.

Finally the big day was upon us: the pour. Storms were approaching, he claimed he had time to get the slab done. Rain was to go on for days. I got the latest from weather.com and ran to the lot to stop them anyway. As I was making the case to wait, the first trucks arrived. We decided to go for it. They actually got the slab finished - eight hours later - just 5 minutes before the rain hit. I thought all was great. Well, on our 40'x40' slab, there is 1.6" deflection from the high to the low point. This is especially troubling along the perimeter because we are using steel SIPs which are made square. Second, caps on piers that are to be exposed in the back yard look terrible and will have to be replaced if we cannot bury them. Third, the surface is not really as smooth as it should be. So instead of simply sealing the slab for the finish floor, we may have to grid it down (about an extra $2,000). Fourth, a cut out in the garage slab for the big door is too narrow so we will have to switch from an 18' to a 16' wide door. Fifth, we designed steps in the slab around the atrium to hold the sliding doors. The door units are 6" deep so we wanted the steps to be 6 1/2" deep. DP made them 6" deep. This simply means we will have to chip out anywhere the concrete oozed into the space, but still. Finally, a hot and cold water line were pushed against the slab, exposing them to the outside air. These lines will have to be re-run.

The builder still owes DP $1,000 but DP never paid for the concrete ($4800) so we have a bit of a game of chicken going on. We can sue him (we have a pretty strong case), but DP tells me he owes the IRS $230k so we can just get in line.

Oh, and here is the best part. The total foundation contract was for $30,700. DP now tells me that he should have charged us $34,000 so we can use the extra $3300 he didn't charge us to fix the problems.

3) SIPs, the next great headache inducer! Oh my goodness. I thought we had it all worked out. First the slab is finished. Then we get the structural steel, followed by the wall panels, followed by the roof panels. So, how did it work? The walls arrived four weeks before the slab was done. The roof panels arrived a week later. Then the slab was done. Three weeks later the structural steel arrived. Not perfect, but at least we can get going. Ah, but wait, we still don't have and instruction booklet or sheets which describe which panels go where. So we essentially have the worlds largest jig-saw puzzle. Now the rain has slowed down the welder, so the structural steel isn't going up yet, but pretty soon this is going to be a big problem.

Anyway, here is what you have been waiting for, photos.

The courtyard is not yet set up to drain well. For a while it was filled with tadpoles, but now only an occasional few bubbles come to the surface... with the effect of making us feel like we are playing a part in a really bad horror movie.

Structural steel on the ground -- panels in the background.

This page Copyright © LiveModern, Inc. and by the Contributing Author(s) above, if any. Rous, J. (2007, May 26). No turning back now... d*** it.. Retrieved November 23, 2008, from LiveModern: Your Best Modern Home Web site: http://livemodern.com/Members/Rous/blog/blogentry.2007-05-26.7340013338.
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A start is a start...

Posted by Ed at 06-19-2007 07:32
Oh dear... I thought this was supposed to be the easy part of the project! It does sound like the situation and contractor from hell. Unfortunately there is no really definitive litmus test for contractors; it is such a leap of faith. So you win some and lose some... I hope that the odds will now turn in your favor now that you've gotten one of the "losers" out of the way. And there are a lot of losers out there!

I can only handle one loser at a time.

Posted by Jeffrey Rous at 06-19-2007 15:11
Thanks Ed, You're certainly someone whose been there -- I bet the two of us could write a book about what we have learned and would do differently. I think the moral to the story is to either A) only use standard building techniques or B) have a busload of money and just hire the freakin best people that exist.

I really like...

Posted by Gregory La Vardera at 06-19-2007 14:20
...your steel joists. I don't know what brand they are but I love the repetitive wide openings in the joists - it makes them look like small trusses, like bar-joists. I know they are going to be covered up, and I know light guage metal framing really is not the prettiest material and it would be over the top to leave them out, but at the same time when I look back at Case Study House 8 you gotta know that in its time the Eames were doing just that with their bar joists.

Mega-joist!

Posted by Jeffrey Rous at 06-19-2007 15:16
The people who made the panels call them "Mega-joists," but I think I heard them mention that they make them at their shop. The do seem to be custom made to length. I would not hesitate to leave them exposed in the right situation. However, we are going to have a lot of electrical, HVAC and plumbing running between the floors and all that will be a bit too messy. I think they would be great for a vaulted roof structure.
And actually, the ones supporting the back deck will be exposed.

Steelform Building Products

Posted by Gregory La Vardera at 06-19-2007 22:00
A little digging reveals the manufacturer. They may have several manuf. locations so no telling where they came from. They do studs with the same pattern of openings.

http://www.steelform.ca/

Lt Ga Steel Joists

Posted by Mark Meyer at 06-20-2007 09:49
Dietrich also makes a similar joist in their Trade-Ready joist system. The nice thing is that you can easily reduce the structural depth of the floor system with the lt ga steel joists. The allowable spans are quite impressive. When I've used them before the limiting factor on joist depth was the sizing of the HVAC ducts not the allowable spans.

I know the Dietrich..

Posted by Gregory La Vardera at 06-20-2007 22:19
.. joists - used those before. They have the oval openings spaced further apart than this brand. The studs are particularly interesting since they reduce thermal transfer.

Exposed joists

Posted by Jeffrey Rous at 06-20-2007 22:09
Other than as supports for an insulated panel roof, I cannot figure out where you could leave these exposed. I was thinking about the space over the passage, but it is going to have to be insulated. I even thought about putting lighting up there and then covering the ceiling of the passage with polygal. Still, insulation is the issue... that and having to take the ceiling down to change a lamp. They look especially cool when doubled up back to back.

don't need to rethink

Posted by Gregory La Vardera at 06-20-2007 22:20
what you are doing Jeff. I just like the way these look.

Repeat after me, stop thinking Jeff

Posted by Jeffrey Rous at 06-23-2007 13:11
Yes, there are still decisions that have yet to be made, but I do need to stop coming up with NEW things to consider. They are great looking though, and in teh right context, I would leave them exposed -- they really are great looking.