Construction week 29 – interior walls

Interior walls somehow make the spaces feel bigger

Interior walls are complete. We are holding off on building our service cavities until Mark can perform an air test. He can’t perform the air test until the shell is completely sealed. He can’t finished sealing off the shell until he gets more tape, which he ran out of late on Friday. So...the air test will have to happen next week.

It’s important that the air test happen at this early stage because if we find gaps now, they’re easy to fix. If we wait until after we build the wall cavities, we’d have to take them apart to get at the leaks. The air test is important because the performance of our house hinges on it being of a certain value. Any amount we exceed this value, drastically improves our energy model. Our target is very aggressive, so we’re not expecting to beat it by much. But we hope so. We hope it breaks records ;)

Mark is contemplating whether or not to Periscope the air test. If you want to see it, let us know! Once we’ve run it, we’ll write another post going into a bit more detail.

What else happened last week?

• Our flat roof was insulated. Mark spec’d a ‘dense pack’, but the installer gave us more of a ‘pillow pack’. So they had to return and fix it. Which goes to show it really helps to have a general contractor who knows what to look for. Good job Mark!
• We installed the air vapour barrier against the basement walls, which forms part of our continuous air barrier line.
• The plumbing vents rough-ins went in.
• AND we settled on the lighting for our open space. It’s been a major design dilemma. And had the potential to cost muchos dineros. We got clever and are designing our own lighting system, which you shall see when it comes together in real-time. We’re very excited about ticking that one off the list.

Next week: air test!

Basement air and vapour membrane

Plumbing vents through the roof (pre-insulation)

Attic insulation (blown-in cellulose)

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!

Building a house is akin to giving birth

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

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

Our glass

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.

Kitchen window install -- Justin and Andreas

Rear elevation avec les windows

Front elevation with temporary door

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 Lift and Slide door in operation

After a successful day of installing some very big windows on Friday, I wanted to share this short video of the operation of our big 16' x 8' lift and slide door from Gaulhofer.

This window makes me very happy!

Watch this space - we will soon be sharing a video of the crane hoisting this window into place.