Caledonia Home (Completed November, 2008)

Technologies implemented:

-Durisol basement (14" w/ mineral wool inserts= R14 block)
-Bio-based 501 insulation
-Solar Hot Water system
-Standing-seam steel roof
-Sarnafil roofing
-Triple-glazed windows (U .16)
-Cork flooring
-Trex composite decking
-Low-flow fixtures, dual flush toilets
-PEX plumbing
-Non-VOC paints and finishes
-Formaldehyde-free plywood
-Energy-star certified appliances
-Full jobsite recycling

Photonarrative

Project is permitted, and the site is prepped for construction drive.

Excavation is completed and the footings crew moves in.





When the footings are complete, we set rebar.  



Durisol requires vertical rebar every 4', this project is engineered for rebar every 1' in the house area, 2' at the garage.   When the sun goes supernova, this home will not be moved.







The Telehandler is ready for Durisol arrival.  



The Canadians have arrived, and Serge is unloading the Durisol.  (Durisol is manufactured in Hamilton, Ontario)  



View from the cockpit.





Durisol is staged around the pit for "easy" access.







"Durisol at Dawn"

Footings are then pumped out.

Layout is set, footings cleaned and a capillary break is rolled out to prevent any moisture from wicking up the wall through the footing.   

Next we move block into the pit.  Lots of block.

Ramps help.  We either catch the block or slide them into straw.  We don't want to weaken the block and risk blow-outs during the pour.

Charlie risks Pragmatic's camera to bring you this action shot.

Everyone's favorite activity- hauling pallets.

and its time to stack.

Check for plumb as we go...

Where the plans do not have a wall designed on 2' modular increment,  (Durisol blocks are 2' x 1' x 8,12 or 14") we have to make cuts.  We use a circular saw with a fiber-cement blade, or a sawzall for this.  The process does eat more blades than we like- but at least we can recycle dead blades.

First 5 courses are laid, plumbed and squared.  We then brace them for the coming pour.

Pump truck arrives

over 85 feet to the far side- maxed out...

We use a 9 slump with pea gravel.  The mix is loose enough that the walls do not need to be vibrated to ensure the concrete flows through all cavities.  

Long view

Finally, we set our second set of vertical rebar and let the wall cure for the weekend.



Next courses stacked, plumbed and braced up for the final pour.





"Turn on the pump!"



"OK"...our laconic pump truck operator- thats all he said the whole day.



Not sure what Steve is trying to signal here.





Adam and Steve take a break between trucks.



Serge ready for the second pass.  We did this pour in two passes as the pump truck did not arrive with an "S" bend on the hose (though we requested one.)  Thus the concrete comes out pretty quick, increasing your chances for a blowout.  With two passes this is minimized.



Art shot/ advertising.



Top of wall finished off and j-bolts inserted to hold down the sill plate at the framing step.



A few days later, the concrete has cured and the Durisol has been plastered with type M mortar and sprayed with Tuff-n-Dry waterproofing.  Next step is to pull the forms.






Framing begins





Time lapse... framing is underway, and winter has arrived.  The camera doesn't work so well in subzero weather- but here we go.

A nice blurry picture of the home partially framed.



Another angle



More framing pics







Here you can see the Warmboard subfloor that will accommodate the radiant in-floor heating tubing.





It is cold.



Sunrise.



Weather has been against us, but progress continues.












Foreshadowing the great view to come.











Rough framing is complete.





Roof Ice-and-Water shielded and skylights installed.





Rough electric, plumbing and HVAC proceed.



Windows installed and wrapped with Vycor.



TIMELAPSE!



Tar paper installed and siding proceeding.



Gutters being installed.











Composite decking installation begins.



Rough mechanicals go in.







Drywall commences- install by Superb Drywall







Copper trench drain detail completed

















Sarnafil roofing



Steel roofing detail



Bronson lays out the screening for the porch.





Painting is completed.





Radiant tubing awaits gypcrete.







Under-stair reminder of Durisol foundation.





The mechanical room- seven zones!



Solar hot water heater tank.







Furnace





HRV



Siding almost completed.



Solar hot water array brackets installed.







Finish grading almost completed.





Timelapse... to the finish!  Here is the final series.













Permeable driveway is in.







Cork installed with dual-flush toilets.











Serious zoning for radiant in-floor heating.



Mechanicals and the Durisol basement wall.















Screen Porch













Composite decking.







Solar hot water panels aimed to South.



The end.