The Concrete Underground

[ConCretin]

As I mentioned in my last update, we're going to be short handed for a week or two thanks to that pesky concrete contracting business of mine. My skeleton crew managed to get started on the second floor ICF end walls

You can see all the elements of the Arxx ICF system. The 'hooks', 'claws' and 'trusses'. We added the two horizontal #4 bars. The system is surprisingly rigid once all the pieces are in lace.

We added nuts and washers to the 3/4" threaded rods we welded to the top of the steel roof beams. If these things pull out of the walls, we've got big problems anyway.

Here you can see how the second floor ICF end wall runs out over the CIP fin wall. The ICF wall hit my foundation layout within 1/4". Not too bad, considering.

Ok, so progress is minimal so how about some 'beauty' pics. First the evil lair view

The rarely seen ground level view

And finally the wide angle view into a setting sun

Well it's obvious that I'm going to run out of posting material if I don't get production back on track. Believe me when I say that I'm workin on it.

 

[ConCretin]

Can't wait to see this project continue!
Great imagination and problem solving, kudos to you and your crew.

Wow, what a piece of art! It takes some real talent to design, engineer and build such a masterpiece.

This thread is an unbelieveable classroom! What a concept and design problem. Your mind has to be spinning when trying to keep up with all the crazy details that must be perfect. I'm lovin it!!!

So this is my first post on this thread, having discovered it late yesterday afternoon.

And after approximately 5 hours, made it through the entire thread...

When I cam to the last post of the thread, was strangely....sad.

Can't wait as you continue the build on this epic project. Thanks so much for all I've learned.

Gentlemen, I usually don't feel right quoting complimentary posts but your kind words mean a lot to me. Thank you.

 

[JimVonBaden]

A shadow of things to come, but an awesome shadow already!

Jim

 

[Omphaloskeptic]

I don't know just how much concrete and steel has been used here at 'Fort Kennebec', but I'll just bet that NASA, NOAA, or some other government agency has recorded a significant increase in both magnetic and gravitational flux density centered on this build site! lol

 

[geologist]

Firstly, let me say that as someone with a background in geology, I find concrete (and such extensive use of it) fascinating. Secondly, if it weren't for all the glass, you would have the ultimate zombie apocalypse house. Any idea where it will weigh in?

 

[ConCretin]

I don't know just how much concrete and steel has been used here at 'Fort Kennebec', but I'll just bet that NASA, NOAA, or some other government agency has recorded a significant increase in both magnetic and gravitational flux density centered on this build site! lol

Firstly, let me say that as someone with a background in geology, I find concrete (and such extensive use of it) fascinating. Secondly, if it weren't for all the glass, you would have the ultimate zombie apocalypse house. Any idea where it will weigh in?

A quick calculation tells me we'll end up somewhere north of 3 million pounds. Not enough to register w Nasa but more than enough to raise hell with my access road since we're truckin in every pound.

By the way, geologist, there are several locations within the house with concrete cover and clear fields of fire in the unlikely event of a zombie apocalypse. Plus we can always sand bag the windows.

 

[akdiesel]

The build is starting to show some depth. It was hard to visualize the build during the earlier photos. Kind of like a 2 dimensional drawing.
It would be great to be able to come out there and get involved to learn some great techniques.

 

[pertneer]

I am sure any free help would be appreciated at this point.

The build is starting to show some depth. It was hard to visualize the build during the earlier photos. Kind of like a 2 dimensional drawing.
It would be great to be able to come out there and get involved to learn some great techniques.

LLWillysfan,
Great detail on the build. I have been watching this thread since the beginning and it is now getting really good. Can't wait to see the finished piece.

 

[Woogeroo]

By the way, geologist, there are several locations within the house with concrete cover and clear fields of fire in the unlikely event of a zombie apocalypse. Plus we can always sand bag the windows.

Sandbags..?

Yer not foolin' us, we know yer putting in steel blast shields on the sly.

No 'evil lair' is complete with out them...



-W

p.s.

The Top 100 Things I'd Do If I Ever Became An Evil Overlord - so you can get into practice

 

[CoconutPete]

Starting to look so cool!

If there ever is a zombie apocalypse, this would be the place to be.

By the way, becareful. I saw this guy sneaking around in the woods aorund your house, I think he may try to sneak in!

 

[ConCretin]

My skeleton crew is actually doing pretty good. We've got most of the second floor end wall ICF up and have started work on the bucks.

Speakin of bucks, here's one with anchor bolts installed. This buck closes off the end of the wall and provides a mounting surface for a door.

This is wall was added to provide some lateral stability to the second floor and fills in the last window bay.

In the opposite bay we're keeping the window but adding a cross brace. Steel rods will connect via a clevis at end to a lug welded to the structural steel and one cast into the concrete of the ICF wall.

This thing has cantilevers upon cantilevers. Even the second floor walls cantilever out over the first floor.

That's all I've got for now. Cheers everybody!

 

[mr. h]

okay why am I so excited about someone elses build?? I don't even know you and this is exciting...is that weird?

 

[Omphaloskeptic]

okay why am I so excited about someone elses build?? I don't even know you and this is exciting...is that weird?

Weird? With close to 500,000 visitors to this thread, if you are excited by this thread's progress, then you are not alone in your weirdness!

I'm looking forward (excitedly so) to see how this massive project turns out!

 

[landroversforever]

okay why am I so excited about someone elses build?? I don't even know you and this is exciting...is that weird?

Certainly not weird

 

[Justanoldguy]

Just weird that you think it's weird ... lol

 

[Speedfreak5150]

Just wondering wat you are planning to cover the internal and external faces of the Arxx ICF system? Eg are you just going to render over them?

 

[kevin20v]

I would like to complement you on the amazing work in this project, I've been a follower since the beginning!

 

[duggie]

I'm always impressed by the speed of construction when using ICF's.

It's all progressing nicely !!!

 

[BeachBoy]

This thread on the 3rd page? Come on!

Something to remind us just how strong concrete is (in compression of course)

 

[gordyy]

that was an amazing display!!
I remember touring a product testing lab many years ago where they put new products thru there paces, the coolest thing was the amazing strength of an egg in this huge press that had sensitive enough controls to shut down at the first crack, it was so small they had to put the egg in dye to find the crack.

 

[ConCretin]

So as some of you have noted, I haven't updated the thread in a couple days. I didn't have a lot of progress to show you due to my skeleton crew but I did plan on posting a few pics of yesterdays' second floor ICF placement. Well we got the placement off as planned but unfortunately there are no photos. More on that later but here are a few shots of our final preparations.

Over the prior couple days we finished up the remaining bucks;

Here's a shot of the little piece of ICF wall on the side of the door opening - it's basically a column so that's how we formed it using our modular forms to hold all the pieces together.



The bucks on the ends of the walls were built to reduce the wall thickness at the ends for architectural reasons. The floors, walls and roofs all are held to a consistent 11 1/2" thickness.



Here's the lug that connects to the steel rod cross brace that will provide lateral stability to the front side of the second floor.



This is the top lug. We removed the ICF foam to thicken the concrete core for additional strength.



As I mentioned in the first paragraph, we placed these walls yesterday. I didn't get any photos for reasons that will become obvious so I'll attempt to create some pictures with words. As you read this think Keystone Cops.

Snow was predicted for Friday morning so we scheduled concrete for 8:00 am and I told the 3 guys still working with me to call me at 6:00 if the weather was bad.

Friday morning turned out fine and the concrete arrived right on time but the crew didn't. A panicked phone call confirmed they had inexplicably decided to stay home until they heard from me.

After telling them to get their @ss's down here, I started placing the concrete. They were about 90 minutes away and the concrete wasn't going to wait.

So I've got the first wall filled to the top and am vibrating the top lift when the concrete level drops. Not the nice gradual drop that tells you the ******** is consolidating the concrete but the sudden kind of drop that tells you you have a problem.

A quick look tells me we've overlooked an unsupported seam, the forms have bulged significant'y and are in danger of coming apart completely - 30 feet in the air. Since you are no doubt more observant that I apparently am, you might see the problem in the photos above.

No problem, don't panic I tell myself. You've been here before. I jump down and start scurrying about the jobsite collecting materials for an emergency repair (key Keystone Cop theme music)

I drive some threaded rod thru the styrofoam and install strong backs, nuts and washers. I'm able to support the seam and get most of the bulge back. I figure I can fix the rest later since it's covered up anyway.

I'm getting ready to start placing the other wall when it hits me - we've got the same problem on the other wall. I recommence my scurrying and by now I'm actually hearing the Keystone Cop soundtrack myself.

I reinforce the second wall so it it won't move and I'm just about ready to start placing again when the boys finally show up - none too proud to see what the boss had been dealing with. I was surprisingly calm as I gave them some quick instructions and we continued the placement. Fortunately, the rest of the day went off without a hitch.

I'll get some photos of the aftermath later today and put them up. If I had taken the advice of those who suggested video or time lapse, we'd have a classic on our hands.

 

[novaman854]

This entire thread is amazing! I am finally finishing an entire house remodel and garage addition, and I know more details about your home than I do my own. Thank you for tirelessly keeping us updated with details and pictures, and I will continue to be consumed with this project until it is finished.

 

[ConCretin]

Just wondering wat you are planning to cover the internal and external faces of the Arxx ICF system? Eg are you just going to render over them?

The interior face will be drywalled. The exterior is covered with a combination of cement fiber clapboards and panels in a rainscreen configuration very similar the the upper garage, which you can see starting on page 26.

I'm always impressed by the speed of construction when using ICF's.

The way we are using the ICFs doesn't do them justice with regard to speed of installation. You could do a good sized foundation pretty quickly.

This thread on the 3rd page? Come on!

I blame myself BeachBoy. I've been slack on the updates. Thanks for the cool video!

 

[Oggy]

Sounds like you had a rough Friday... Glad to hear you got it all worked out though. I can only imagine the sh!t storm your guys were expecting to hear from you when they realized what they had left you with. You've been great with posting photos, so I guess we can let you slide with not having any of the "incident" for today...

 

[SiGmA_X]

That does sound like a rough Friday! I gotta say, when I was scrolling the pictures I thought it was weird that whole long wall was unsupported...And then I read the details! I hope the end result comes out as you want it LL! Any estimate as to how much it bulged?

 

[OHSCrifle]

Hey LL,

Just staring at your avatar photo. Are you going to build the 2nd floor above the attached garage now? What going up there - guest room or office or something?

 

[Omphaloskeptic]

Flying solo 30 feet in the air, a tardy skeleton crew, a blowout waiting to happen with an unsupported wall, concrete curing in the truck, and the threat of more snow; can it get any more exciting than that??? The only thing missing was having Buster Keaton as the truck driver 'helping' with the pour!

 

[saceone]

Gotta love those Friday pours...!!!

 

[Leyenda30]

Well I guess that pour was your stress test for the year. You are a cool headed boss for giving your guys a break in a difficult situation and the kind I would want to work for as I'm sure they do. It just shows you metal...titanium in this instance. I am glad it came out well. Looking good. JP

 

[ConCretin]

First off, let me catch you up with some photos of last Fridays ICF placement. Here's a shot of the 'column' and wall on the South end.



Here's a shot of my emergency repair.



This is the reinforcement I added to the second wall to avoid another blow out using the fiberglass tie system.



We also placed the little concrete column where the house and garage come together



Today we started setting the structural steel for the garage roof



We used one of our knuckle-boom cranes because we could get up close for each pick - no need to bring a big cranes down our little goat path unless we need to.



Most of the garage roof beams sit in beam pockets on bearing plates we cast into the wall. We used a wire brush to clean up the bearing plates to facilitate welding before we set the beams because getting into such tight spaces later would be difficult.



We also ground the primer from the weld surfaces for the same reason



The header over the 18' overhead door consists of a steel beam because the span wasn't practical to do in concrete.



Two of the garage beams are W16's with angles welded to the webs to support the LiteDeck roof. A bridge crane will run on the lower flange that extends below the roof system



Finally here's a shot of the completed steel roof framing



Despite the lack of crew, I'm trying to make progress wherever I can. Looks like 2-3 weeks before I'll get the bulk of my crew back.

 

[ConCretin]

Thanks for the comments about Friday's trials and tribulations. It was an interesting day to say the least. I can't say I wasn't pissed that the crew didn't show up but yelling and screaming wouldn't have accomplished much at that point.

Hey LL,

Just staring at your avatar photo. Are you going to build the 2nd floor above the attached garage now? What going up there - guest room or office or something?

The second floor of the garage houses the second bedroom, which we'll use as guest quarters.

 

[Leyenda30]

Even with the problems Friday you have had very few problems with the complicated build. Apparently you do alot of homework to avoid the issues before they happen. We are in the middle of a 60x80 build using a contractor and I'm still awake late going over the details in my head so as not to have it bit me from lack of planning on my part. I managed to have a heart attack last Saturday while doing some painting but was lucky it wasn't severe...kinda makes you reevaluate things. JP

 

[ConCretin]

Yikes JP. I'm really glad it wasn't worse but for God's sake, take it easy for a little while. There aren't a lot of things more stressful than a building project.

I've got my hands full but I think it's easier when you have direct control over the outcome. Dealing with a contractor adds a whole new level of angst.

 

[Cemoto]

Finally here's a shot of the completed steel roof framing

It looks like you could land a chopper on that.

 

[gooned]

First off, let me catch you up with some photos of last Fridays ICF placement.
_

Two of the garage beams are W16's with angles welded to the webs to support the LiteDeck roof. A bridge crane will run on the lower flange that extends below the roof system





Despite the lack of crew, I'm trying to make progress wherever I can. Looks like 2-3 weeks before I'll get the bulk of my crew back.

So with the shop crane are you setting recessed pot lights or do you have room for more traditional ( for a shop ) surface mount lighting?

Looks like your steaming along nicely for the lack of crew and yes yelling at the boys doesn't help in the big picture does it!

 

[red]

It looks like you could land a chopper on that.

I was thinking maybe a second story garage. That will exit into the backyard. There's never enough room you know.

 

[Holedgr]

With all due respect...did you/your architect plan for all door openings to accommodate wheelchair access? I realize it is a sensitive subject, but reality is what it is. I am assuming of course that you plan on retiring in this masterpiece...

On another note...I personally FIRE guys for even being late to a concrete placement. Although, I must say alot of my guys haven't been with me for long and usually aren't, so I see your foresight with the relationship is priceless. Honestly, I wouldn't want to place on a day like Friday with the impending weather...Good god!!

You Sir are teaching many of us invaluable lessons! Keep up the excellent work.

-Tony

 

[Jagmandave]

I assume you were doing those ICF pours in lifts, right? About 4 ft, then let it set up a bit, then come back and pour the next lift?

I was *this* close to building an ICF house when my wife was taken down with breast cancer. The good news is she's a 10 year survivor now, the bad news is we never got to build our last home, and I never got my shop.

I'm another who's been following this build silently, just wanted you to know that even tho we're trying not to fill the thread up with useless and time consuming comments, we're still watching the build.

It's looking wonderful too!

 

[Burgerkong]

Don't know what else to say, I just spent hours rolling through this entire thread.


IT

IS

AWESOME

 

[NUTTSGT]

You make a panicked phone call for your crew, but don't chew their ***, pour the concrete yourself but don't get over excited about a blow out. That's the sign of a good and patient leader Doug, your guys follow your lead.