Construction week 51: the final countdown

The one week (less than!) countdown begins. Our official move day is Friday, September 2nd. My daughter's 4th bday. Sure to be a memorable one.

Our ceilings aren’t the only destination for wood in our house. Wood on the outside, wood on the inside. I’m starting to think of our house as the ‘wood box’: where a simple, honest shape meets a simple, honest material. Anyways, this week was focused on floors and stairs. Both receiving the full white ash treatment.

Stairs
Our super-awesome-carpenter-guy Graham was tackling stairs. The stairs are three inch thick slabs of white ash (from the Wood Source). They have been designed to be supported by the stair metal brackets Mark had made and installed. The wood requires a small channel carved into its ends, so it can slide onto the bracket, sandwiching it, and hiding it so that the wood ‘floats’.

And this is where I segue over to Graham praise. He goes above and beyond. We are incredibly lucky to have him on our project. He possesses the same passion and care for quality and craftsmanship as does Mark. For instance, in order to carve our stair channels, he needed a better tool for the job, a Festool. He couldn’t find one in Ottawa, so he drove to Kingston to purchase it (hour and a half drive), drove back, and took a lesson on how to properly use it that same night. He was on site the next day figuring our how to precisely carve these channels at varying subtle angles, in order to get them just right. And he did. He also makes a great DJ. No Chez 106 on our site.

The only stair hiccup was a small mistake made by Mark with measurements. One floor riser was ⅜” taller than others, which apparently isn’t ‘to code’. I’d bet none would be the wiser if we kept the ⅜” difference, but to the uncompromising Mark Rosen, this surely wouldn’t do. So we had all the stairs planed down ¼” so that each step is now at 100% equal height. Unfortunately, we had to bring them back to the Wood Source to get them done. So all the work on the stairs won’t pay off until early next week and the temporary stairs had to get reinstalled. Wah-wah.

Floors
Drumroll…

No squeaks! Rejoice rejoice!

A full glue down was the trick for our 5” white ash, site finished hardwood. We used two different polyurethane flooring glue because the local supplier, Dragona, didn’t have enough in stock to do all in one brand. We used both Maipei ultrabond eco 995, and Roberts 1540. We also stapled, but only when necessary to keep the boards toight.

Mark, Graham and Sebastian have been working on the floors, burning the midnight oil. Working until midnight the last three nights in a row. We rented some machines to sand the floors down ourselves too. We were going to hire out the finishing job, but we’d have to wait until Wednesday to do so. And with our September 1st move-in coming up, we just couldn’t.

Everyone unanimously vows, repeatedly, that this would be their first and last glue-down hardwood floor + finishing install. The glue was the worst. Thankfully, they are also in unison upon the fact that they look bloody fantastic.

Oiling the floors happens this week.

Appliances
With the exception of our laundry machines (because the wood floor has to come first), all our appliances have been installed! So what appliances did we choose for our Passive House build? I’ll write a separate post on this. For now, just know they are in. Mark was boiling water every 10 minutes, and timing it, on our new induction cooktop. He even took video to show me, on the first night in was installed, and now I’m posting it here for everyone to see. It's just about the least exciting 4 minutes of your life, but not for Mark. lol.

Temporary railings
We had to install some temporary railings to get occupancy. Must admit, we cried a little on the inside putting the hideous, weathered plywood up on our mostly finished house. But at least it’s safe and will get us to permit. It should only be a few weeks of us living with them in this state until the permanent railings are ordered and installed.

Yard cleanup
I wish I had thought of Kijiji earlier on in the build. I used it to get rid of all our extra building material. And it was so easy! People will take anything. Especially if you say it’s free. It would have saved us a whole dumpster of waste, at least. Lesson learned. Now that most of the extra building material is off the lawn, it’s starting to feel like a proper house (our landscaping is on hold, so it’s a massive weed garden, but it’s better than a building supply lot).

Plumbing
Toilets, faucets, showers, bathtubs, drains, heat exchanger connections, floor drains, condensation traps, backflow valves. We’re ready to pass our plumbing final inspection, which will take place on Monday. Our diswasher and espresso machine still need to be hooked up, but aren’t required for occupancy. I’d like to take a moment to admire Nathan’s skills. Our mechanical room is a work of art. Look at all the cool copper handiwork. It really adds to the engine room feeling of the house. Of all the beautiful spaces in our house, it might just be Mark’s fave :)

Occupancy
And finally, our occupancy. We called for the city to come on Tuesday. Usually they are required to come within 24 hours of a request. But for some reason, they were overbooked, and we couldn’t get anyone out this week. So someone should be coming on Monday. We were really hoping for someone to come on Friday, to give us an idea on what our weekend ‘occupancy to-do’ list would but unfortunately, no dice.

Move
Meanwhile, while Mark’s working on site into the late hours, I’m at home packing boxes. I pulled the trigger and managed to find a moving company less than a week in advance of the move date. The thought of moving all the boxes and furniture ourselves, with all the work remaining at the house and all the work to date, was enough to shatter me into a million pieces. Phew! When my mom was visiting last week, she was with her Australian boyfriend, who trained with their military once-upon-a-time. He expressed concern that we were starting to show signs of severe exhaustion akin to his military training where they push you until you break, and then keep pushing. Maybe. But at least we have our new spa to unwind in at the end of the long day :)

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Construction weeks 47 and 48: sprint to the finish

We’re in the midst of the push-for-occupancy phase, which I mentioned in my previous post. There are many moving parts that need to come together. Our biggest challenge has been staying on top of things and ensuring that the things that need doing, get done. Which is why I’ve been MIA on the blog. There’s a ton to catch up on.

But first, we had a rooftop picnic with the girls tonight (on our newly finished rooftop deck!). When we arrived back at our just-ok rental house a few blocks away, Josie started crying. She said “I no want this house”. Ha! I guess we’re all getting a wee bit anxious.

Stairs and screen wall

Climbing plants to be installed at a later date :)

Our stairs are designed to float between the wall and a 2 storey metal screen wall. So before the stairs themselves can go in we had to install the screen wall and metal bridge. Mark tackled this over a couple of weekends with some great help — huge thanks to Rob Villeneuve, Steve Dufresne, Mike Davis, Graham Dorey, Nick, and Gary Sharp (again! Gary, we owe you so much for all your help on our home). The metal screens support the bridge and the stair treads, and the bridge and stair treads stabilize the screen. Mark installed temporary treads so that the stairs are usable until the finished treads can be installed.

Kitchen install

View of the pantry wall (with our fridge in the way)

We have a kitchen! And it’s gorgeous. Ordered our kitchen from Astro and had Kosta do the install. He was a pro. Took him 3 days. We have a combo of a white, glossy laminate for the functional kitchen drawers and a brown ash, sandblasted finish, on the doors facing the living space. For more on our kitchen design and layout, read this post.

Our counters will be installed next week. We decided on Caesarstone, in a dark cement finish. The counter is from Solid Decorum. And we have some beautiful ash butcher block from the Wood Source for the sill-come-counter under the window.

Tiles

The majority of our floor tiles have been laid. With the remaining to be completed and grouted over the weekend. We have quite a bit of tile in our house. In our bottom floor entry, and our main floor living space, we went with a dark, larger-format tile, arranged in a staggered pattern Mark designed. We’re really happy with them. In our upstairs bathrooms, we opted for a 1” x 3” black tile on the floor, which conveniently hide our linear drain in the master bath. And a larger format white subway tile on the walls. We’ve got a lot of wall tile in our master bath because of our sloping ceilings. Really look forward to seeing it go up – next week.

We’ve also been very happy with our choice in tile contractors. Flowtopp. Highly, highly recommend them. Tiles was sourced from Ceragres. We used Gate on the main floors (in Licorice), Unit on the bathroom floors (black), and I forget for the bathroom walls…

By the way, we aren’t concerned in the slightest that we’ll have cold toes on ceramic tile. We won’t have any thermal bridging thanks to Passive House. We also have a lovely area rug we purchased on our Moroccan honeymoon (years ago now, wow) for the living room, to soften up all the hard surfaces.

Priming and painting

Looking down the void our bright white walls

The house has been primed and painted. Quelle difference. It’s starting to feel like a finished house. We went with Benjamin Moore, Chantilly Lace, in a flat finish (aka. white). We understand that an eggshell finish cleans more easily, but wanted to make sure that when light washes against our walls, they’ll look smooth and dreamy. Flat does a better job at hiding blemishes. We enlisted the services of Michael Fenton, who helped us paint our last house as well. This man knows his paint.

ERV and heater install

Mark is nearly finished installing the Zehnder ERV and ground source heat exchanger. The units are hung in place and most of the ductwork is connected. Our 4kW Thermolec duct heater is also in place. This is the heater for the whole house! It’s small enough for our 3 year old daughter to hold on her lap while she eats ice cream. Nathan from Ackland Plumbing will be priming our ground loop and connecting it this coming week.

Hot water tank install
Nathan from Ackland Plumbing also installed our Stiebel Eltron heat pump hot water tank. It’s an 80 gallon tank that uses an air source heat pump to heat the water (meaning super energy efficient). It looks cool too.

Siding
Our siding is finished and looks fantastic. Thanks to Graham Dorey.

Roof deck

Our rooftop deck also looks amazing. Thanks to Graham Dorey. Who struggled with a strained knee, from a football accident and not the house, these past couple days. Going up and down a ridiculously high ladder with decking materials.

We have yet to install a railing, which we’ll need for occupancy. The building inspector nay’ed our initial design, because it didn’t meet the building’s code definition of safe. He considered it climbable. He did say, however, that if we built a mock-up, he’d come look at it and assess the climbability in person. So that’s something we’ll be progressing next week. And/or we’ll look at redesigning it.

Front deck

Our front deck build is underway. Step one was to get some helical piles drilled into the ground to support the structure of the deck. Why helical piles? To minimize root damage to our big tree out front. A more typical deck pile requires digging of a hole much larger than the post itself. Whereas, a helical pile requires a hole only as large as the diameter of the pile itself, which you see in the picture is quite small.

Step two was to lay some landscape fabric and gravel for underneath the deck. Mark did all the gravel moving himself in the humid, sweltering heat that is Ottawa in July. Deck build is set to start this weekend and continue over the course of next week, with Graham on the job.

That’s all folks. I’m sure I’ve missed things so I’ll be sure to write more frequently over the final weeks to come. If for some reason you don’t hear from me, it’s because we’re building a house, and are busy building it.

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Construction weeks 37 & 38: electrical rough-ins and drywall

Mark is full-time at the house these days, including weekends, and it will likely continue this way until move in. I’m pulling double-duty with the rest of life, so all I can muster today is a point-form update. Words, sentences and all the things are feeling difficult. Please forgive me.

Mark finished running the flex ducting throughout the house.
Graham and Sebastian continue to install siding. And continue to do an outstanding job of it.
Yves, started and finished all the electrical rough-ins. Since he has a stellar reputation with the ESA (Electrical Service Authority), we quickly passed the inspection over email.
Prepared for drywalling, with the help of Brian Rosen, Gary and Alex Sharp.
- Carried 40 sheets of 12’ long drywall boards up stairs and between rooms.
- Moved and re-installed our construction stairs away from the wall so the drywall could run past.
- Since the house is going to be so quiet (outside noises disappear with our thick walls), that means we’ll be extra sensitive to any inside noises. To counter this, we've taken a couple additional steps.
  - Installed resilient channels on ceilings. These are metal strips that the drywall gets screwed into. They reduce foot step noise from floors above by reducing the contact surface area between the drywall and wood structure.
  - Added extra Roxul to our ceilings to further buffer any sound between floors.
Started hanging drywall! Ceilings throughout the house and the girl’ bedrooms are finished.
Added structural blocking for our floating stairs — the top two staircases. Some extra structure was added between existing studs to anchor the metal brackets that will hold the treads.
Ordered custom metal for the interior of the house. Including a metal screen, which will support the other end of the stair treads, and our bridge that spans the open space over the dining room. Both will be powder-coated white.
- The metal screen will span the height of the main space and frame the stair cases. As you wander through the house, it offers glimpses of the void and of our tall vertical window flanking the opposite side. We’ll hang pants off the screen, and transform it into a bit of a greenwall to breathe more life into the main space.
Nathan installed 1 of 2 bathtubs. The master bath is going to be a tricky one. The space is tight and looks like we may have been sent an incorrect part.
Mark ran another air test to the same result of 0.4 air changes per hour. He was hoping to improve upon our last result having filled some known gaps. But with new gaps made for electrical and plumbing, even though there were properly sealed, they may have balanced each other out. Or it might be the OSB that’s ‘leaky’ — it is a construction grade material after all, so at this level of tightness, maybe it just doesn’t stand up 100%. We’re hopeful that after drywall, our result may improve. However, Mark’s not holding his breath. He warned me that even though, in a typical build, an air-test post-drywall can improve 20–30%, it’s unlikely our will because we’re already dealing with such small numbers, and there’s little room for such impressive movement. Still keeping our fingers crossed.

That’s the gist of it. We’re managing many moving parts at the moment, but it’s finally starting to feel like we’re getting close to the home-stretch. The building inspector won’t be returning until it’s final occupancy time. Mostly finishing from here on out.

One more thing before my head hits the pillow: don’t miss Mark’s virtual tour this upcoming Thursday. We’ll post the video on the blog afterwards, in case you miss it. Oh, and check out the photos below.