Our building shell carpenter crew

Now that the shell is complete, I’ve been meaning to write a retrospective. What was good about our wall assembly and what wasn’t. What we learned and what we'd do differently next time. I’d like to get some input from the guys who actually built it: Justin, Mark, Blair, Tyler and Kyle from Cornelis Grey. Look for it soon. But for now, I just wanted to give our crew a shout out.

Hats off to them. They were great to work with, super professional and genuinely nice guys. Even our neighbours have commented on how courteous they’ve been, which is a huge bonus (gotta keep them in our good books seeing as how we are borrowing power, water and do need to live beside them eventually). Justin Corkum led the team. Mark really enjoyed working with him. They had a great dialogue back and forth and were able to forge a strong, trusting working relationship. Justin is moving on to another company. While we are keeping most of the crew, we are sad to see him leave. Thanks for all your help Justin!

Justin working on our temporary door — check out the routered handle!

Justin working on our temporary door — check out the routered handle!

Building a house is akin to giving birth

housebaby

This past weekend, the Chelsea Passive House clients of Mark’s, invited everyone who worked on their home over for a wine and cheese mixer. It was really special and in many ways, the carrot at the end of the stick for me. I asked Mrs. Chelsea Passive House, ‘was it all worth it?’, because if you read my last blog post you will know that I’m a stress-case at the moment. Her response was on-point. She said, “it’s like asking a pregnant women while in labour if it’s worth it”. Couldn’t have said it better myself :) Right now I'm in the thick of a really long one...

Construction week 28 — kitchen design

 

We’ve been finalizing our kitchen design. Check it out! Mark had originally designed the kitchen to fit Ikea components, in case we decided to go that route (for economic reasons). But after meeting with a couple kitchen designers and weighing the pros and cons, I think we’re going to go custom. And we were casually browsing appliance stores this weekend when we stumbled upon a built-in refrigerator at an ultra discount floor model price. It’s the same price as the other non-built-in option we were contemplating and has all the nice design features and benefits that we were looking for. So, yay!

We approached several kitchen designers with our initial design. They were able to bring some outside perspective to our layout. Kitchen design is something that architects do as well, but kitchen designers really know their products and details like under sink garbage options and drawer vs. door that really help. I wouldn't say they 'designed' out kitchen, Mark did, but they helped work through the details with us.

Deciding on our appliances also weighed in on our decision making. I’ll write a separate post about the appliances, because it requires one (Passive House limits our options in this area). We went back and forth on a few items. Wall ovens vs. island oven and pantry space. Pantry space was important to me. Even though I like the idea of a wall oven, pantry has a higher priority for me in terms of chest-height accessibility. We have ideas for finishes, but that will all be worked out once we design which company we’re going to go with. Both are great options, it will likely come down to cost and who we like working with.

As an aside, we aren’t basing all of our decisions on cost alone. It definitely weighs heavily, but we also want to work with people with whom we actually like. Mark wants to build long term relationships and find people he would feel comfortable referring his future clients to as well.

And on to week 28...

Our crew started on interior wall framing and have been going around the outside of the house on scaffolding sealing and taping the wood fibreboard spots they missed when they had to stand up the walls. Mark also did some more interior air barrier sealing with that Siga tape.

We’ve also been busy pulling quotes together and meeting various sub-contractors on site for things like siding and ceiling insulation. Starting to make some headway…
Our roof is getting insulation this week. Walls continue to go up. Hopefully Mark will be able to perform our first blower-door test and we’ll begin the service cavity walls as well.

 

Construction weeks 26 & 27: windows and air barrier

gaulhofer-lift-and-slide

We have windows! The Hermann’s installed those that could be man-handled and lifted into place by hand on week one, and the remainder on week two with the help of a crane.

Getting the house sealed in and weather proofed is holding us back at this point so it feels good to have them in place. And damn they’re fine. Feels like a legit house now. It’s a thing of beauty.

The crew also finished off the wall cavity insulation and started installing the air barrier, which is a layer of OSB (oriented strand board -- comes in sheets like plywood) that gets taped at all the seams with a special Siga membrane tape.

And some photos:

Window delivery

Window delivery

Our glass

Our glass

Mark and Andreas trying to give high 5s while holding up a 2000 lb window in place

Mark and Andreas trying to give high 5s while holding up a 2000 lb window in place

The thickness of our triple-pane kitchen window. NO backyard baseball games.

The thickness of our triple-pane kitchen window. NO backyard baseball games.

Kitchen window install -- Justin and Andreas

Kitchen window install -- Justin and Andreas

Rear elevation avec les windows

Rear elevation avec les windows

Front elevation with temporary door

Front elevation with temporary door

The loft window lift-and-slide

The loft window lift-and-slide

What else of news?

There have been some headaches around getting our second construction mortgage withdraw because our unconventional build is being treated as conventional. We hope things have been ironed out, but have yet to receive the monies in our bank. This is a longer blog post for another time. Argh.

Now our shell is 95% complete. There are still a few items outstanding:

  • our attic and flat roof need insulating (blown-in cellulose)

  • some wood fibreboard is missing on the outside (because of how the walls were lifted)

  • some weather-proof taping to be done on the seams of the wood fibre board

We need to start making decisions ASAP on a lot of things. Our kitchen will need 10–12 weeks at the factory, which means we are already behind the 8-ball. Our lighting and plumbing fixtures need sorting too. We have yet to make these decisions and already decision fatigue has set in.

If I’ve made light of building a home, in any way, you have been misguided. It’s not for the weak of heart or will. One the one hand, I’m ecstatic to see our home coming together and to reach these huge milestones. One the other, there is still so much to do. It’s a massive source of stress. In some ways though, it feels like the homestretch (before the homestretch). And when I walk into our home, I am in complete awe. I love it so much, which definitely helps to ease the stress. Looking forward to ticking some key decisions off the list.

 

Gaulhofer windows on site!

After sitting patiently in storage for the better part of 8 months, the first set of our beautiful Gaulhofer windows were delivered to site today! Some of you may have caught a 2 second Periscope I tried to do earlier today before my phone died in the cold. So I took some video with my DSLR and have compiled it here! The video shows the installation of the frame of our dining room window, discusses the install detail and the Hannoband expanding tape being used, and shows some of the profiles prior to installation. You can also catch a glimpse of Andreas and Adrian Herrmann from Herrmann's Timber Frame Homes working on the install.

The team from Cornelis Grey continues to work on the shell, and offered a helping hand in lifting some of the heavy glass units into place. Handling the glass units when they are out of the frames is delicate work. The glass is tempered, so any sharp bump on the edge could be catastrophic. Many hands make light work! 

Keeping warm and holding one of the triple glazed glass unit that will keep us warm soon!

Keeping warm and holding one of the triple glazed glass unit that will keep us warm soon!

Upper glass goes in.  5 guys for this lift!

Upper glass goes in.  5 guys for this lift!

Looking up at the finished window in the dining room. 

Looking up at the finished window in the dining room. 

Viewed from the outside. 

Viewed from the outside. 

Window install continues tomorrow, and we will also be doing a pretty cool install of some Pavatex wood fibre board on the flat roof, using some very long screws!

Grand Designs

A Passive House in England, designed by architect Richard Hawkes

A Passive House in England, designed by architect Richard Hawkes

I was reminded of a great UK tv show after speaking with one of our tour-goers. Britain's first Passive House, amongst others, have been featured on it. It's such a great show – Grand Designs. I really wish our HGTV had something more to offer... Host Kevin McCloud documents self-builds of particular architectural interest. It's in it's 16th season now and has off-shoots in Australia and 'Abroad'. It's worth checking out (although I noticed most of the videos have recently been removed from YouTube :( I found a couple for you through other channels:

Britain's first Passive House
http://www.dailymotion.com/video/xm279a_grand-designs-s09e04-the-eco-arch-kent_tech

A Passive House in the Cotswolds:
http://www.dailymotion.com/video/xm0zu1_aaf-grand-designs-s10e02-pdtv_tech

And my all-time favourite Grand Designs episode:
http://www.dailymotion.com/video/x2jmjo3_grand-designs-series-14-4-of-10-the-shipping-containers-house_tv

 

Construction week 24 & 25: lots of snow shoveling

We had record snow fall in Ottawa last week. Apart from shoveling, here's a quick summary from the last couple weeks:

  • roof sheathing, membrane, and metal roof 
  • truss blocking
  • window bucks installed, reinforced and double-checked for size
  • insulation started

Earlier today, Mark gave our first public tour of the house. We had around 15 people brave the construction site and cool temps to listen to how our house is coming together. Thanks to all who came out. Hope you learned something.

Here's Mark introducing our home on the tour.

Here's Mark introducing our home on the tour.

This upcoming week, Mark will finish insulating. And our windows are getting installed. EeK!!!