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Above 1200 Sq/FT Jeff's Mountain Side Shop (Portland)

Wokspaces above 1200 squarefeet.

sponaugle

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Dec 13, 2018
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Portland, OR
Greetings all! I am just starting a new shop/house build, and would love to hear input, suggestions, corrections, and anything in-between. This build will take about 2 years, so I have plenty of time to make bad decisions and hopefully correct them. ;)

A bit of backdrop - I have a current shop (see thread: https://www.garagejournal.com/forum/showthread.php?t=409914 ) that I really love. We had the opportunity to purchase a lot that is about 10 mins closer into Portland from our current house (on the same road actually) that is 20 acres compared to our current 1.5. It is also inside of the forest hills that surround Portland, and it has a view. The building code in Portland combined with the environmental and conservation overlays in this area make it such that I need to build a single building, with the house and shop together. I currently have a detached shop, so I am curious to see how I like having it integrated.

My goal with the new house and shop is to have enough garage space to store 12 cars, plus the other usual shop/vault/server room stuff. The lot itself has an interesting history - It was owned by someone previously who designed a very cool cantilevered house. While the house was not build, the previous owner had started on the excavation and ground work. Due to the design of his house, he had to install bedrock pillars. There are 55 pillars in total, and each pillar is a bit over 3 feet in diameter and goes into the ground a bit over 50 feet. For those who have done pile work like this, you know how much concrete and steel that is. He spent over $500k just on the pillars and the ground work. He never got past the pillar stage as he decided to not build the house, but of course the pillars are still there in the ground. For me, the pillars will provide additional foundation support.

Here is a drone shot of the building area of the property as it was when we started. You can see the excavation work that was done. It is basically a large hole, with an even deeper hold in the back section.

DJI_0050.jpg

From the front of where the house will be, it is hard to see the hole:

IMG_5082.jpg

That red fence is a protective fence so you don’t walk into it.

The driveway out to the house area is about 1000ft:

IMG_5884.jpg

The hole, looking from that edge:

IMG_6217.jpg

You can see the orange paint on the rebar sticking out of the ground for each of the pillars.

Here is a better look at the top of the pillars, with the rebar sticking out:

IMG_1644.jpg

With those constraints in mind, here is what we came up with to build:

We had a 3D model of the entire structure made once we finished with the first pass from the architects, and I was able to create an exportable KML so I could overlay the model inside of google earth, so I could get a better idea of what it would look like:

This is the 3D model. The house is 3 stories, with the shop and ‘lower garage’ on the lowest level, a second upper garage on the second level, and a third living area only level.

IMG_1513.jpg

Put into google earth in the actual location, here is a rough idea of what it will look like:

IMG_1514.jpg

The lower floor (with the shop):
LowerFloor.png

One thing that isn't clear without looking at a side cut is the shop is about 5 feet taller (into the ground) than the lower garage. There is a cutout in the wall between the lower garage and the shop so you can see down into the shop.

The middle floor (with the upper garage)
MiddleFloor.png

The upper floor
TopFloor.png

The 'living area' is about 7000sq ft, and the total garage and shop space is 3200sqft, and the total structure is around 10,200 sq ft. The shop itself is slight smaller than my current shop, but the additional garage space should make up for some of that.

The natural cutout that was done previously serves to make the shop part of the lower floor deeper, so it will have 14’ 6” ceilings. That makes it easier to have 2x 2 post lifts. The lower garage will have 2 4 post lifts primarily to increase car storage.

As part of the build process I have preprogrammed a flight path for my drone, and I will be flying that path every couple of days. Once the house is complete, I’ll be able to make a ‘build video’ in a time-lapse format, but with the camera panning around the house while it is being built. Should be fun!

Last, but not least, you can see Mt. St. Helens and Mt Adams from the property.

IMGP2814.jpg


More to come! (The first few updates will be up shortly, as I am a bit behind in getting this posted).
 
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LXCam

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AZ
Wow that's going to be quite a project. You can count me in following along.
 
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sponaugle

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Dec 13, 2018
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368
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Portland, OR
As far as the shop layout itself, I have done some initial work, but this is just a rough start.

The entrance to the shop is at the very back of the house, underneath the deck (although the deck at that location is about 15 feet up. I have still not decided on how to place the lifts. The 2 post lifts get used a lot, and the reason for 2 lifts is so I can do maintenance on a car while a longer term project is on the other lift.

The 4 post lifts in the ‘lower garage’ are just for storage maximization.

Here is a 2D layout:

ShopLayoutModel0.png

And that layout converted to 3D:

ShopLayoutModel1.png

ShopLayoutModel2.png

ShopLayoutModel3.png

As I mentioned above, the shop itself it about 5 feet lower than the lower garage, which gives it much more ceiling height. (14’ 6”).

The concrete in all three garage/shops are the same configuration - 6-8 inches of 4500psi concrete, with #5 rebar 8 inches on center (which is a lot of rebar, but will help prevent cracking under high load). The 8 inch spacing is a bit excessive, but you can only do it once.

The 6-8 inch depth is important for supporting 2 post commercial lifts. The rebar spacing will mean that when I install the lifts I will probably need to drill through some, which is a bit of a pain. If I knew the exact location of the lifts ahead of time I could have made dedicated pads (with bigger rebar spacing), but alas I’m not at that point yet.
 
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sponaugle

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Portland, OR
Wow that's going to be quite a project. You can count me in following along.

Thanks! I'm looking forward to getting it done! The permitting process too a lot longer than we thought it would, so now it looks like 2020 for move in.
 
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sponaugle

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Portland, OR
Impressive. Sub'd.
What does the wife think?

She is very happy with the whole project.. except she would really prefer it be done sooner than the end of 2019! We also have a 6 years old daughter who is also very enthusiastic about it.

Jeff
 
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sponaugle

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Dec 13, 2018
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Portland, OR
Update 1 - Excavation

We started with the excavation work to widen the footprint, and get some levels lasered.

And overhead view:

DJI_0132.jpg


Digging in the hole..

IMG_1641.jpg


A week later, it is starting to look like a place you could build something.

IMG_3538.jpg


IMG_3571.jpg


We also had to dig up and demolish the tops of some of the existing pillars. After doing our second geotechnical review, there is some concern that the foundation settlement will be different than the already settled pillars, so we need to primary foundation footers to have at least 18” from the top of the pillars.

Measuring the level of the tops of the pillar concrete:

IMG_1659.jpg


Demo of the concrete and rebar:

IMG_1663.jpg


Lots of rebar tops;
IMG_1684.jpg


Lots of dirt to move:
IMG_3617.jpg


We also removed a few trees that were going to be close to the house. Since these trees were 25-32 inches in diameter, and between 60 and 100 feet tall I had someone do it who knew what they were doing. ;) Oddly enough the tree code in Portland means that I can’t ‘remove’ the trees from the property, so it looks like I will have lots and lots of firewood.

IMG_3605.jpg
 
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JDMjunkies.ch

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Dec 27, 2016
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Switzerland
Wow, this is my kind of project. what a Property, what a view and great Plans for the house / garage too!
Subscribed :)

isn't it risky to start spending money on digging / excavating, while you still wait for the permission? What if you have to change your plans?
Why did the previous owner stop to complete the build when he already spent half a million on the support posts?
Though it's great for you to have additional reinforcement "for free".

Seriously i'm a bit envious about the great property!

Lol, sometimes those "Codes" (or what we call "the law" here) just don't make any sense, right? I guess it's good you have planned a fireplace then :)
 

1953mercury

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Steamboat Springs CO
Might think about having someone come in with a portable saw mill and have those trees cut into slabs for furniture, beams, etc., for the house. Would be kind of cool knowing they came from the property. Should be quite the place when your finished. Mike
 

Boosted1

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Nov 25, 2007
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Georgetown, KY
Very nice views you have.
Looking forward to see your build.
The 3D rendering of the garage with 2 posts lifts looks like there may not be space to put work bench in the corner for the tools you'll use working under hood.
Have you measured / planned you work bench layout?

I realize this is probably the least of the things you are concerned with at this point.. Lol.

Good luck with the build.
 

jeepxj

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High loading on the concrete? You're just putting cars on it? Are they full of lead?
 
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sponaugle

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Portland, OR
isn't it risky to start spending money on digging / excavating, while you still wait for the permission? What if you have to change your plans?
Why did the previous owner stop to complete the build when he already spent half a million on the support posts?
Though it's great for you to have additional reinforcement "for free".

Seriously i'm a bit envious about the great property!
Lol, sometimes those "Codes" (or what we call "the law" here) just don't make any sense, right? I guess it's good you have planned a fireplace then :)

We have full permits now, which took about 7 months to get. We were a little bit lucky as the previous owner had a team of lawyers and they were able to get a development plan approved, and since they technically 'started construction' that development plan was still considered open. We had to adjust some things to comply with the updated city tree code, and we have to plant about 70 trees as 'mitigation' for the forest disturbance. It is interesting as most of the city code is oriented towards more typical lots that might have 5 or 6 trees on them. As such, removing a tree is a big deal as the city would make you plant a replacement somewhere else on the property. The form used for reporting that has a place to indicated how many trees are currently on the property, and it has checkboxes for 1-5,5-10,10-20, and other. I put 'about 5000 trees' in the other box, which made a few people laugh.

The previous guy was starting building in 2007, and when the US markets crashed in 2008 I suspect he thought it wise to reconsider building the house he was building. It was a cool house, all glass and concrete with a very cool cantilever design, but I would guess it was a >$6 million dollar project. With no idea where the bottom of the market would land, it was probably a wise idea. He sat on the lot for 9 more years before selling it. Another bonus is he had power, water, natural gas, cable, and telephone brought all the way from the street to the house location, which is about 1000 feet of trenching.

Jeff
 
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sponaugle

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Portland, OR
Might think about having someone come in with a portable saw mill and have those trees cut into slabs for furniture, beams, etc., for the house. Would be kind of cool knowing they came from the property. Should be quite the place when your finished. Mike

That really is a great idea.. and something I need to think about. There is a lot of wood there that could be turned into some cool furniture! I suspect the hardest part is getting a saw that can cut the really big parts that are 32 inches in diameter.

IMG_3752.jpg


Those trees could make something for sure!


Jeff
 
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sponaugle

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Portland, OR
Very nice views you have.
Looking forward to see your build.
The 3D rendering of the garage with 2 posts lifts looks like there may not be space to put work bench in the corner for the tools you'll use working under hood.
Have you measured / planned you work bench layout?
I realize this is probably the least of the things you are concerned with at this point.. Lol.
Good luck with the build.

Great comment, and no, I have not done a good job of planning that yet! We will have the slab for the shop floor poured pretty soon, and as soon as that is done I am going to do an onsite layout on the floor so I can get a better idea how the space feels. You are right that it is important to consider tool location, as I am constantly going from the tools to the lift and back. In my current shop the tool box is only a few feet from the front of the lift.

Jeff
 
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sponaugle

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Portland, OR
Update 2 - Time for footings.

With the excavation underway, we have started the footings buildup. Here is the starting forms with the upper garage and tree garden walls.

IMG_3562.jpg


IMG_3584.jpg


The first load of rebar for the foundation footers:

IMG_3618.jpg


The lower foundation takes form:

IMG_3627.jpg


IMG_3650.jpg


Rebar gets put into the footers. The footers are pretty large, with a surprising amount of rebar, but that is partly because of the three floors of load, and partly because of earthquake design. The foundation guys we used are actually commercial foundation people, as they have a bit more experience with this type of construction.

IMG_3678.jpg


IMG_3686.jpg


IMG_3755.jpg


IMG_3775.jpg


Here is an overhead shot of the footers before pouring:

DJI_0203.jpg


We had to get some gravel into some spots that were hard to get to, so we used a very cool truck that shoots gravel. I had not seen one of these in action before, but it was very cool!

Here is a video of the rock shooting truck:

http://www.sponaugle.com/newhouse/IMG_3853.m4v

It is impressive that it can shoot 3/4 minus like water! The guy in the yellow is driving it remotely.
 
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jeepxj

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True.. but in the future there might be a lathe and a mill involved!

Jeff

Still way over kill. by a lot. Unless you plan to put a 50lb steam hammer in the garage its just a waste of money.

Did you have an architect do the layout or is this your design? My wife would kill me having to walk the entire length of the house with groceries.
 
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sponaugle

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Portland, OR
Still way over kill. by a lot. Unless you plan to put a 50lb steam hammer in the garage its just a waste of money.

Did you have an architect do the layout or is this your design? My wife would kill me having to walk the entire length of the house with groceries.

Oh yea, we had a kick *** set of architects for the design, plus a structural engineer for the core structure, and a geotechnical engineer for the site and foundation placement work.

The long hallway from the front garage was a limitation on the footprint we were allowed to build in due to the development plan we are using. Even though the lot is 20 acres, the conservation and environmental overlays means we can only build in this central, longer than wide area. Since the ground goes away pretty fast on the sides it really narrows the house. If we wanted to change the outer envelope, we would have been forced to do a development review, which would have been over a year to get completed. The particulars of building in a forest inside the city of Portland are pretty crazy.

We went back and forth about having the kitchen closer to the front of the house (which would reduce that distance), but in the end she really prefered the kitchen on the far side with a great view and close to the key living area. It is an interesting question, but we considered that taking things into the kitchen is an overall smaller part of the kitchen workflow compared to actually doing things in the kitchen. On the other hand since it is all hardwood and flat from the garage to the kitchen, I suspect a cart of some kind is in order!

As for the concrete, the rebar design was done by the structural engineer, and the floors are part of the load transfer between the foundation walls (that is to say we can't build the house on the foundation without the floors being poured). I'm not surprised that it is more than needed, but in the grand scheme the cost difference isn't that much, and I did tell the engineer that at some point I might want to to have some machining equipment, so perhaps he was envisioning a steam hammer!

Jeff
 
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Pluribus

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This is going to be amazing!

Kind of puzzled about the 50' deep pillars. Is there something that showed up on the geotech study that warranted the concern & need for those?
 

Bruce 993 SEA

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This is very cool! And in the city to boot.

Reminds me a little of the cement underground epic build thread from back east somewhere.

Cheers!
 
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sponaugle

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Portland, OR
This is going to be amazing!
Kind of puzzled about the 50' deep pillars. Is there something that showed up on the geotech study that warranted the concern & need for those?

Great question, as the base bedrock is very solid. I think the primary reason was the cantilever combined with slope stability. There were two cantilevers going out at least 30 feet, perhaps a tad more, using very large steel beams. I have the original geotech from back in 2007, and it suggested the piers be used. The firm that did that work, as well as the architect, were both very large firms in Seattle that typically build cities, not houses... so I suspect there was a significant amount of overengineering. Our geotech, as well as the city one, was surprised by the previous decisions. There is always risk in hillside development from slope stability , although in this case the water paths go to the sides and there is not a lot of land that is taller.

Jeff
 
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booch

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CT Shoreline
Jeff, this looks pretty epic! I'm really looking forward to seeing how this comes together, although like your wife, I don't want to wait so long for it heheh
 
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sponaugle

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Portland, OR
Jeff, this looks pretty epic! I'm really looking forward to seeing how this comes together, although like your wife, I don't want to wait so long for it heheh

Thanks! I have 5 more updates I need to post, so the next few days will seem like weeks compressed! Unfortunately after that we are on the slow real time train. On the other hand it gives me more time to think about, and fix things.

Jeff
 
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sponaugle

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Update 3 - First Foundation/Footer Pour Day!

With the footers ready for concrete, we got the trucks lined up and the pump truck ready:

Here are a few shots from above with the boom pushing some concrete to the lower forms:

DJI_0218.jpg


DJI_0213.jpg


The trucks backed down the side driveway to dump into the pump truck.

IMGP1311.jpg


It is pretty cool to see all that concrete go so fast.

IMGP1332.jpg


IMGP1340.jpg


IMGP1375.jpg


We were just able to reach the far end of the footers with the boom. Next pour we will need a bigger boom.

Here is a short video of some of the footer pouring:

http://www.sponaugle.com/newhouse/IMGP1357.m4v

Here is a video of the very upper edge getting poured:

http://www.sponaugle.com/newhouse/IMG_3921.m4v

Total Pour on the first day was ~150 yards of concrete.
 

buildingup

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Holly Mi
Very cool project and can't wait to see it all come together! What are the plans for the driveway? Also, how did you stumble across this property?
 
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sponaugle

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Portland, OR
Very cool project and can't wait to see it all come together! What are the plans for the driveway? Also, how did you stumble across this property?

I'll pave the driveway once construction is done, and actually that is required by code. It will be 5" asphalt over rock, which is a pretty typical driveway for something like this. The surface and path for the driveway is already cut and has some rock, plus all of the under-driveway conduit.

This property next to my wife's parents, so we have known about for many years. By chance we drove down the entrance and the for sale sign had just gone up. We jumped right on it, as there are probably no other 20 acre undeveloped lots in the city of Portland, and might not ever be any more due to the way lot development is done.

Jeff
 
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buildingup

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Holly Mi
Ever thought about putting a deck off the master bed room. Looks like you could do it with the covered terrace from the prints
 

billspit

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Gee man, you have a problem. You need to see a Doc about that brown car fetish.
 
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sponaugle

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Portland, OR
Ever thought about putting a deck off the master bed room. Looks like you could do it with the covered terrace from the prints

Yea, I noticed the same thing, and in fact that is in the direction of the views. I'll have to look at the loading of that roof, but the beams going down are steel so I would suspect they could handle some small additional load. I doubt we could put a hot tub on it, but some decking might work.

Jeff
 

jeepxj

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Whats the home wifi/network going to be like? I can see a need for at least 3 APs for coverage.
 

buildingup

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Holly Mi
Yea, I noticed the same thing, and in fact that is in the direction of the views. I'll have to look at the loading of that roof, but the beams going down are steel so I would suspect they could handle some small additional load. I doubt we could put a hot tub on it, but some decking might work.

Jeff

Small deck for two comfy outdoor chairs and and table would be great. Private hang out area for you and the wife early morning or evening without having to put pants on!
 
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