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Between 705 & 1200 SQ/FT Tabula Rasa

Workspaces between 705 and 1200 squarefeet.

67CarGuy

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Tabula Rasa
Latin for "blank slate," it is the idea of individuals being born empty of any built-in mental content, so that all knowledge comes from later perceptions or sensory experiences.

This will be a chronicle of my new shop/garage/house build and the projects I get up to in and around the same. If you saw my previous shop/garage, you’ll recall that the garage was rather small and quite inconvenient, and the shop was nowhere close to the size I wanted (and I know from reading countless threads on here that many of you share the same problems).

Well, hold on to your hats, folks…

While this won’t be a Don Long-sized space, or as beautifully photographed (and well used!) as Gregor’s, or as *chef’s kiss* as Jack Olsen’s, hopefully it will provide some encouragement to others, or at least provoke thoughtful conversation (“Jeez, why the hell did he do it that way?”).

A little backstory:
Several years ago (during the pandemic) my wife and I decided that we were sick of dealing with the humidity of the Baltimore/DC area (I know it’s not as bad as it gets further south, but it’s still not enjoyable) and wanted to be closer to family in the New England area. We also missed snow and people using their turn signals. Thanks to the wonder that is remote work, we were both able to keep our existing jobs while moving north to the Boston area. What we thought would be a 1-2 year rental situation while we found a good house (with room for the dog to run around, a garage larger than 8x18, and space for a shop, among other wants and needs) turned into a very frustrating search as seemingly “all the good houses” weren’t available, for all the reasons many of you know. We also didn’t want a 5000 sqft house on a 1/4 acre lot - I grew up in rural Vermont, and after spending the last 20 years of my life living in cities, I wanted to get back to the quiet countryside.

What we eventually found was a three acre lot that was once a field of some sort, overgrown and untended for the past ~40 years. Lots of vines (I thought grapevine was bad until I was introduced to oriental bittersweet!), thorns, pucker brush, you get the idea. A few saving graces: an old stone wall, running nearly due north/south (I haven’t checked it with a compass, but it’s gotta be no more than 1-2 degrees off); an existing sassafras grove; numerous oak, birch, ash, hickory, and other trees that will be kept for as long as they’re healthy; and one ~14 inch walnut tree that needed to come down to make way for a septic field and will become furniture. More on that walnut later.

IMG_1162.JPG
Above you can begin to get an idea of how overgrown the lot was - vines everywhere, which we valiantly attacked with various handheld tools (loppers and chainsaws, mostly) until we had a more complete idea of what we were going to do with the site. Then we brought in heavy equipment. More to come on that, too.

We’ve spent the last ~18 months working with a high efficiency modular home builder to design a house that fits many of our criteria. There have been many, many frustrating moments throughout this process, but we finally have a delivery date (early May 2024!), a GC that actually communicates with us on a (mostly) regular basis, and a cost breakdown that fits our budget. The attached garage will be an oversize 2-car (28x30), while the basement shop will be roughly 13x28. I’ve slowly been collecting tools, projects*, and ideas, and those will slowly unfold and reveal themselves in the coming months and years. I’ll get some floor plans posted up here shortly.


*Pending projects:
  • Panelized garage build & fit-out
  • Basement shop build & fit-out
  • Build a cyclekart
  • Build a Maslow CNC
  • Finish the rebuild of a small block Chevy 400, for an as-yet undetermined vehicle. Brodix heads, rotating assembly from a short-track racecar, Jesel rockers... should be a fun little mill :cool:
 
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67CarGuy

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Garage plan.png
30x28 panelized garage, with storage above. This will be unheated, and eventually I'll probably insulate it just to make it a bit more comfortable to be out there in the winter months. Slab will be insulated as well, although I may just insulate the perimeter.

Basement shop plan.png
Here's the basement shop area, for which I'm still figuring out the layout. Likely will have a set of double doors leading into the shop from the rest of the basement, closer to the stairs (top left corner). This will be fully insulated, and the door on the right will be a walk-out to grade. I couldn't convince anyone else on the project that a door wider than 36 inches would be a great idea for shop access...

Site work should begin sometime in March, so there will be a bit of a delay between now and when things start to materialize, but just be thankful I didn't start this thread 18 months ago!
 
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67CarGuy

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A bit on the evolving shop layout design:
Screenshot 2024-02-27 at 7.59.32 PM.png
I'm not yet clear how often the entry door on the far right will be used. Certainly for loading materials into the shop, hence the location of the material storage rack (sheet goods vertically against the wall, with dimensional lumber stacked horizontally in front). I'm also thinking of something smaller that would be on casters, although it's not clear to me how useful that would be. I fear it will only take up space.

Based on my experience in my previous basement shop, I know how important it is to have good access around tools, benches, etc. The 2x8 bench along the bottom wall is the same bench I built for my last shop - I've added some uprights and a full 4x8 sheet of pegboard to the back of it, and am looking forward to getting it set in place. And yes, I've moved it around a few times in different iterations of this design while I've been trying to figure out how best to lay everything out.

So what do you see? Anything that seems out of place? Anything you would add? Anything you would remove? I'm certainly not wedded to to this layout - the only things that are certain are the entry door swing on the right, and the location of the stairs and AHU (air handling unit = furnace).

Next up: the garage plan... and some more site clearing shots from last year....
 
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67CarGuy

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A quick trip in the DeLorean brings us to November 2022...

Suddenly, a wild driveway appears!
IMG_1336.jpg
Well, the beginnings of a driveway, at least. Our goal was (and still is) to have a house that's hidden from the street, without putting up a big fence or wall. I know that good fences make good neighbors, etc., etc., but fences also have the habit of getting expensive. And we're going to end up building a fence for the dog later, so... but I digress. Where was I? Right, hiding the house, long driveway, yadda yadda. While this won't be a @ConCretin worthy distance or slope, it's still about 300 ft long, with a nice little bend just after you pull in off the street. It'll be fun to see what I can get my e.t.s down to...

A few passes with the big brush hog (thank you again @Juiced06GTO!) and we've got something wide enough for a semi truck, or a crane...
IMG_1647.JPG

As my father always says, "Hydraulics have been very good to me." Ain't that the truth! I'm very glad we didn't have to try and clear this by hand (we did some early on, primarily for the surveyors, and that was enough!). Here's the view from the cab, mid-clearing:
IMG_1354.jpg
Boy, what a fun machine. And it only took one visit by the service truck for us to figure out how to work the brush hog and use the hydraulic quick connects...
 

ambenz

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Talk about a unimproved lot! OMG!!! Ah, to be young again...I wouldn't attempt a clean start at 50 or 60, and hope you are still young enough for this adventure your partaking in. Should be a interesting lot improvement exercise! Following.
 
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67CarGuy

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Thankfully yes, still young enough to be this foolish :D... While I wasn't looking for a completely undeveloped lot, many of the lots we looked at before deciding on this one had already been cleared of everything. It's like every "developer" or real estate speculator wants to sell a completely bare lot, because they've already sold off whatever timber might have been there, or figure it's easier to sell it when you don't have a bunch of trees in the way. I get it, but it wasn't what we were looking for.

We've managed to save a bunch of hickory, oak, birch, some poplar, and a whole mess o' sassafras that will all help to buffer the house from the road (hence no need for a fence out front). Most of the trees we did take down were either dead or on their way out - many were overgrown with vines and looked like something out of an arborist's nightmares.
IMG_1634.JPG
This is looking east from what will eventually be (roughly) the front door. Several of the stumps on the left of the picture came down en masse - we cut wedges and hinges on at least 3 (maybe 4?) before they all came down in one big whump!, all because of the vines holding each one up to the next. I'll see if I can find the video...
 

Juiced06GTO

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Awesome to see things coming together for you guys!! Was it all the way back in 22 when we had the machine out there?!?! Time sure does fly!!
 

thammel

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Exciting stuff for the future for you! My comments...nothing you haven't heard before here but go bigger. I have a 20x20 house garage and another attached 32x28. I wish I'd gone 36x32 for the "another attached". And I'm surprised your basement workshop is 13' wide. Mine is about 15' wide and feels way too narrow. Perhaps you have other storage areas but I made shelves to hold my 15-16 bins of electrical/plumbing/paint/bike parts. And I also have my well water tank/neutralizer/softener and furnace and water heater in there.

I really like your acreage and keeping trees for privacy from the road.
 
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67CarGuy

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Awesome to see things coming together for you guys!! Was it all the way back in 22 when we had the machine out there?!?! Time sure does fly!!
Thanks! And every time I see a tracksteer / skidsteer or mini-excavator I think, "Boy, the things I could do with that..." Foundations and driveway are supposed to start this month - the town's got the plans, our permit should be approved very soon. Never thought I'd be this excited to spend so much money... :willy_nil
 
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67CarGuy

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Exciting stuff for the future for you! My comments...nothing you haven't heard before here but go bigger. I have a 20x20 house garage and another attached 32x28. I wish I'd gone 36x32 for the "another attached". And I'm surprised your basement workshop is 13' wide. Mine is about 15' wide and feels way too narrow. Perhaps you have other storage areas but I made shelves to hold my 15-16 bins of electrical/plumbing/paint/bike parts. And I also have my well water tank/neutralizer/softener and furnace and water heater in there.

I really like your acreage and keeping trees for privacy from the road.
Appreciate it - I did think very seriously about going bigger with the garage (I'll get to the shop in a moment). So my folks have a 28x28 2-bay attached garage, built when I was 8 or so. It has continued to seem like a pretty decent size - at various times, it's held 2 daily drivers and a Model A (turned sideways); 1 daily + a lifeboat off a steamboat; 1 daily + my avatar while pulling the engine; plus a sunfish/sailfish sailboat, and a giant wooden Old Town canoe, etc, etc. All that to say that it seems like an appropriate size for what I'm hoping to do in that space.

I probably could have gone bigger, which likely would have just been a deeper building (32' instead of 28, or maybe 36'... even when we all know it'd be better if it were 60' to 100' deep or so...:D). Any wider than the 30' I have now would have thrown off the rooflines and made the interior height less than ideal. As it is I'll have a 10' interior height to work with, which will be enough for my purposes.

The real answer to the garage size issue is that we're already planning to build a second, larger garage in a few years, once our finances recover from this current adventure. That one will need to store at least 3 vehicles that are already in my extended family, plus there should probably be some work space(s) not taken up with vehicles, and maybe some space to relax... But again, that's several years (or more) away, so I've got to work with what I've got (you all know the tune!).

Re: the shop. Yes, I'm also concerned about the shop width. The line of lally columns in the basement make an ideal dividing wall, and it may turn out that I want a different room layout. I've played around with a tape measure and some existing spaces I have to try and get a sense of what it will be like. I know I've got to have a wall that separates the shop from the furnace, more to keep dust away from the equipment than anything else. Once the foundation is poured and exterior walls are up I may decide that more space is needed, which will be a fun ;) discussion with my wife.

Final plans are in hand, engineering stamps are all signed, now we're off to the town for final approval. Hopefully we're moving dirt in another week or two!
 
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67CarGuy

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Best Laid Plans

Wouldn't you know it, the fates still have more wrenches to throw? Since we last left our fearless (witless?) hero, two wrenches in particular have been lodged in the wheels of progress (apologies if I'm mixing my metaphors here, I'm feeling a bit punchy).

Item 1: Applying for a building permit in our town gets you a complimentary visit from the conservation commission, who wants to make sure you're not disturbing endangered tree frogs, etc. And while it's not shown on any maps (local, state, USGS, FEMA, etc.) they managed to find "wetland conditions" in one corner of the property. Even the survey company we hired before we ever bought the lot didn't find this. So, this means there are now Do Not Disturb (30 foot buffer) and Do Not Build (50 foot buffer) zones, and the DNB line cuts right through the middle of the garage. &*#!)&^${

We've now had two meetings with the commission, one preliminary and one functional, and we think (and hope!) that once we have approval from the state (because they need to review it too, it's a "wetland" after all - well, really it's just a ditch that used to be a road, that was abandoned by the town decades ago, and has a town culvert at the high end that drains a bunch of water into the low end, and over time it's created wetland-like conditions), we'll likely get approval from the town to proceed, hopefully without actually moving anything. And no tree frogs will be hurt in the process. Regardless, still nearly a month lost to this. But that's not all!

Item 2: Our window company, who we put an order in with back in November of 2023, gets their windows manufactured in Ireland. They're supposed to be really good windows, great energy efficiency, look historic-ish, and at a price we could afford. Supposed to be delivered in late March 2024. No prizes for guessing what happened...

Well, after taking $40k of our money, they have apparently declared bankruptcy. No money, no windows, and no way to contact them. We're trying all avenues we can think of, including lawyers, but it's not looking good folks. Unless one of you knows a good lawyer in Ireland...

So now we're scrambling to find windows that will do the job and not cost 2x what we were budgeting, because despite some appearances we're not made of money. Running down to the big box window store to grab some el cheapo Andersens won't cut it either, and of course nearly all of our windows are custom sizes, because with the now-bankrupt company they weren't going to charge us more for custom sizes. As my Minnesotan friends would say, "Oof-da."

Hopefully there will be better news in another week or so, after our third meeting with the conservation folks. Don't try this at home, kids...
 
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67CarGuy

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Well, another week has turned into another month, but that's nothing new with this project. :rolleyes: The good news is - we have a building permit! We finally got our various blessing from conservation (albeit with strings attached - there are always strings, aren't there?), so we can finally proceed without running afoul of the law. Hopefully this means we can make some site progress later this week!

So many fingers and toes crossed...
 
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67CarGuy

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Finally, we've got something from the good news department! Apparently Santa works in June, too:
IMG_2656.jpg
Yes, the keys were in it, and I was oh-so tempted to fire it up and move some dirt around... :bounce:

And a few days later, we've got a bunch of soil moved!
IMG_7764.jpg

Still plenty of digging to do, but seeing as how we were expecting to be here this time last year (if not earlier :rolleyes: ...) this is progress we love to see. Not sure what's next: Utilities getting trenched in, driveway work, foundation to dig out...
 
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67CarGuy

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We've got a little bit of dirt to work with...
2024-06-08_Dirt pile 1.jpeg

I was out of bananas, so added an excavator for scale...
2024-06-08_Dirt pile 2.jpeg

Only two or three (small) boulders so far, which holds true to the abandoned farm field theory. We'll look to incorporate them into the landscaping somehow.

A philosophical (if not geological) question: When does a pebble become a stone become a rock become a boulder?
 
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67CarGuy

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More dirt's been moved! This is the garage foundation getting dug out - the excavator is sitting in the gap between the garage and the house (sort of - you'll see ;)).
IMG_2730.jpeg

Footers are set, foundation/basement walls should get poured in the next two weeks. Capillary break applied to the house footers - I want this to be the driest basement this side of Death Valley!
IMG_2843.jpeg
 
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67CarGuy

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Foundation forms set and filled! Should be stripped tomorrow or the day after, weather permitting.

2024-07-19_Foundation forms 1.jpeg
This is soon to be the garage, with the main house entry on the right.

2024-07-19_Foundation forms 3.jpeg
And pivoting slightly right, looking down the long wall(s) that will soon hold the house up.
 
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67CarGuy

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There are walls now! This is looking so much better than some wooden stakes in the ground...
This is the garage... a lot of backfilling to go! My idea of a second garage below the normal garage has been met with eye rolls so strong they may have caused a tidal event.
2024-07-24_Foundation walls 1.jpeg

And the rest of the house, running down the hill...
2024-07-24_Foundation walls 2.jpeg

There's about 4 feet of fill needed inside before we can begin laying down insulation and vapor barrier.
Here's an interior shot from the other end:
2024-07-24_Foundation walls 3.jpeg
Pads are for lally columns. It's great to see it really starting to come together!
 
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67CarGuy

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2024-07-24_Foundation walls 1.jpegNo, this is not a repeat of my previous post... well, the image above is, but everything after is new ;).

So I've got a garage here (32x28), with rather tall foundation walls, that will need to be filled in with...fill before we can prep for the slab. The area to the right is under the entry/mudroom/laundry area, and will be fully accessible from within the rest of the basement. I'm trying to determine what, if anything, I can realistically do with the under-garage area. Secret lair? A true Gentleman's Activity Bunker? Stacked storage for more old cars?

It's likely out of the budget to do anything with the volume except fill it in, but I'm curious how you might go about using it, and what approach you would take. I'm pretty sure that anything I would want to do with that space will start with an engineer and some steel, but beyond that my imagination is too busy. So I ask you: how would you use that area?
 
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67CarGuy

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And then there was damp-proofing!
IMG_3847.jpeg

Followed by some dimple mat (possibly my favorite mat, with welcome a close second :lol_hitti).
IMG_3020.jpeg

Backfilling started this week, slab insulation has been delivered... things are moving forward!
 
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67CarGuy

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My lack of updates here has not been for a lack of progress on site, thankfully!
IMG_2940.JPG
Gravel down, perimeter insulation in, lally columns in place, and exterior basement walls framed out. This left side will be the basement wood shop, from the wall to just about where the photo was taken from.

IMG_3120.jpeg
Here you can the insulation stacked up, waiting to be laid down before the slab is poured. Since this photo it's been installed, and vapor barrier installed on top of that. Pour is scheduled for this coming Wednesday.
 
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67CarGuy

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How to build a house in a day (and 2+ years)
A little rain a day or two before to help settle everything...


IMG_3226.jpeg


Bring in a big crane...
IMG_3224.jpeg

Add some boxes that look kinda house-ish...
IMG_9782.jpeg

And in a day or so, you've got a house with a 2-car garage!
IMG_3277.jpeg

I had to keep stopping myself from "helping" as I would have just been in the way. So I took a bunch of photos and videos instead.
It was quite impressive to watch the 4-man crew clamber around the pieces and parts and get everything lined up. Still to come:
  • Power run in from the street (trenching to come)
  • Water run in from the street (same)
  • Garage slab prep & pour
  • Windows arrive next week
  • And a hundred + other things that will need to happen before we can actually move in...
But we made some actual progress this week, which is such a fantastic feeling. :D
 
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67CarGuy

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wow, that's speedy - a lot of pre planning though I bet
Like you wouldn't believe!

Power pole got placed and trench dug on Thurs/Fri this past week, now we wait for the inspector... unfortunately the trench is not where it's supposed to be per our wishes and the site plan, so we need to talk with our GC about moving it. Already planning for the second garage / car barn...
IMG_3294.jpeg

Garage roof getting buttoned up, with underlayment and shingles to come.
IMG_3301.jpeg

We expect the garage slab to get insulated and poured in the next week or two, then they can build stairs up to the storage area above.
Not sure when the water line gets trenched in from the street, that's still TBD.

It's amazing to me that we're still in hurry-up-and-wait mode after all of this though!
 
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67CarGuy

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Well so much for the garage slab getting poured in the first week of October. Apparently other things took precedence.

Garage slab prep is done! Now fully insulated, taped vapor barrier is down... ask me about wrestling sheets of rigid insulation in the box store parking lot, while the wind blew 10-15 mph gusts, and I was trying to tie them down to the roof rack of the family huckster... (thanks to the two random dudes who jumped out of their cars to help!).

IMG_3098.JPG

IMG_3101.JPG
Pay no attention to the windows strapped to the wall... apparently they're heavier than our GC expected, and they're waiting for the slab to be placed before they cart them into the house.
 
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67CarGuy

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Thinking about saw cuts for the pending slab, and looking for ideas. 28x30, two 9x7 doors on a 30 ft side... I'm waiting to see what the concrete sub is going to recommend, but have some of my own ideas. Curious what you all think:

Garage plan.jpg
I tried to get fancy with some triangles or trapezoids, but realized simpler = better most of the time. Plus I'm guessing that the points of saw cut triangles are just asking to break.
 

mfg0772

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@67CarGuy - what you drew works. You generally want to stick with squares or rectangles if you need to. If going with a rectangle, the general rule is to not exceed a 1:1.5 ratio for length to width. Your joint spacing should also be about 2-3 times your slab thickness. Assuming you have a 4" slab, anywhere from 8'-12'.

Stay away from triangles or trapezoids. When I poured the deck around my pool, I wanted it to look a bit better than just random joints so I planned my joints to match with the joints in the bluestone pool coping and rotated them 45* from the axis of the pool to create more of a diamond visual although they are still just squares at the end of the day.

I grew up doing concrete sawing for my dads business and am now an engineer so I've seen a lot of concrete work and I always find myself reminding people that the only guarantee when it comes to concrete is that it will crack. Hopefully it will be where you put the joints but even with all of the right planning and preparation, sometimes it cracks where it wants to. Making sure that you the joints are cut to the proper depth helps too (1/4 of the slab thickness). I've seen many instances where it is not deep enough and is essentially worthless although going too deep is not good either (need to keep reinforcing in tact).
 
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67CarGuy

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Thanks @mfg0772 , I appreciate your input! :beer:

I totally get that cracks happen, just trying to find some design that's not visually jarring and isn't so crazy a design that my concrete guy will actually do it.
 
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67CarGuy

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Pour is on for tomorrow! Wire mesh gets put down on my salvaged patio pavers, 4000 psi mix arrives shortly afterwards.
Now to bug my GC about getting the overhead doors scheduled...

If anyone has other opinions about saw cut layouts, I'm open to ideas until about 6AM Thursday :willy_nil
 
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67CarGuy

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Pour went smoothly, saw cuts were done as shown above, and we've already moved a bunch of our stuff in (with plastic sheeting underneath). I wish I could have waited longer before loading it up, but the timing with our move just didn't allow for it.
IMG_3135.jpeg
The plywood on the far wall is protecting the large and very heavy windows that our GC hadn't installed as of the pour :oops:. The windows are now in place, and the overhead doors are scheduled for installation later this week. They'll wait until the driveway is brought up to grade before removing the forms in the foreground.
 
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67CarGuy

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No photos this time, but garage doors are in! The shop is covered with various offal from the various trades, as well as the bits of scrap lumber I've tried to save. We'll see how much actually survives until I can do something with it... not being on site very frequently, it can be difficult to control what leaves the site or gets cut up and put in the dumpster.

Water should get trenched in this coming week, and that will put us that much closer to moving in. Still lots to do, though - siding, plumbing connections, upstairs HVAC, tiling, floors...
 
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