The Concrete Underground

[gooned]

I settled on a hangar door.

is that a Shweiss by chance?? This is the exact style door I want to build for my shop,12'x12' -but do to funding I will build my own rather than order one.

Also like your curved wall - did a constant raduis one for our walk-out basement (formed myself) and it turnout out not bad - but my god what a lot of work bending endless sheets of plywood around the curve (it's 30'+ long) I left a reveal aboout 12" up for a string of rope lighting to shine down onto the patio, guess I ought to get it sandblasted and finnished oneday...do you seal any of your exposed concrete walls?

keep 'em coming

 

[ConCretin]

Loving all the concrete work . Can't wait for more. It seems strange to see a US home put together without any wood

Not too many are knuckle-headed enough to try it. I'm not sure it makes economic sense but it will be different and fun to build

Nice cars. Good idea on the overhead crane. That door, wow..

As a mechanical engineer who loves the water.

This is a ********* for me. (get the pun? ) Awesome project.

It's got that 'thread of the year' feel to it.

Thanks for the encouragement. It's actually kind of fun to document the process but it really helps that others are enjoying it too, especially guys that care about this stuff.

Yep, but as LIFESTYLZ

I thought I detected a little HAMB in your comment about the 5 speed. That's fine, I'm pretty much with you. I'm going to make a few concessions where it won't show too much but I think the final result will be acceptable to most.

Considering the quality of the toys you have to work on, I'd suggest you put a 'second shift' on the jobsite so you can get busy on them ASAP! lol

We had a slow spell so I put a bunch of the guys to work myself but I'm already starting to lose some back to the concrete business. Damn.

Now that I'm garage-less, the clock is really ticking. Hopefully the new shop will be worth the delay.

is that a Shweiss by chance?? This is the exact style door I want to build for my shop,12'x12' -but do to funding I will build my own rather than order one.

It's actually a HiFold. A hangar door really isn't cost effective for a small opening like mine but it was what I needed. After looking at it, I thought I could have built it myself as well. It's pretty basic really. PM me if you need any detailed info or pics. Hmmm, I wonder if that's a patent violation. Don't tell anyone, OK?

 

[Buckgnarly]

Wow! I think you need to have a GJ New England meet up at your place when done!

 

[NUTTSGT]

Looks like the shop will be filled with plenty of toys in the near future.

 

[webby94]

Do you have any more details on the overhead crane?

 

[ConCretin]

I've got to do one final post on the dock stairs mostly because that's the only place we've made any progress. I am pretty pleased with the results;

This is my brother in law and very first employee. He's the guy who actually built the stairs and is deservedly proud of his accomplishment. One of the best concrete guys anywhere.

After we had the stairs stripped we fired up conveyor truck to move all that soil we dragged up the hill a couple weeks ago back down the hill.

We used our Link Belt 2800 to feed material into the conveyor. You may note this is a different excavator then the one we started with. The little Cat was a loaner while ours was being repaired.

Once the backfill was complete, we covered the disturbed areas of the embankment with erosion control mesh. You have to do this stuff right when you're in the Shoreland Zone if you want to stay on the right side of the DEP - and I want to stay on the right side of DEP.

Finally a couple shots from across the river;

It's safe to say that these steps will be here long after I'm gone.

Now that we've completed this project, we can move on to excavation for the basement in the main house. The next step in the garage - once the truck is fixed - is to waterproof the foundation walls and start backfilling inside.

 

[ConCretin]

Wow! I think you need to have a GJ New England meet up at your place when done!

It would be a long haul from Vermont but anybody that happens to be in the area is welcome to stop by - just drop me a PM to let me know you're coming and don't forget to bring beer.

Looks like the shop will be filled with plenty of toys in the near future.

Can't happen quick enough

Do you have any more details on the overhead crane?

It's pretty simple really. Two longitudinal beams 28' and 32' long respectively for the lower and upper garages. A third 28' transverse beam (depicted in silver) rides on the these.

A beam trolley similar to this rolls back and forth on the transverse beam allowing me to reach every corner of the shop

I had a local engineer size the beams for me. The beams are W12x28(?) and give me a 2000 pound capacity. I'm not 100% sure of the weight but I'll look it up if you are interested. The only mods are little tabs welded between the web and upper flange to limit deflection.

 

[theoldwizard1]

Wow! I think you need to have a GJ New England meet up at your place when done!

I'll bring a case of brew and my own meat for grillin' !

Maybe even a bottle of Old No. 7 for after !!

 

[Boosted1]

Excellent work on those stairs. They look fantastic.

 

[ConCretin]

I'll bring a case of brew and my own meat for grillin' !

Maybe even a bottle of Old No. 7 for after !!

It's a deal

Excellent work on those stairs. They look fantastic.

Thanks. They were a lot of work and held up the whole damn project but I think it was worth it. The opposite bank and river are the equivalent of our street. Most will see the house from this vantage point so I figure a concrete house should have some concrete to look at.

 

[flybefree]

Those steps are really well done...you and your team are a pleasure to watch at work...makes me proud to be an American.

Shaun

 

[ConCretin]

Those steps are really well done...you and your team are a pleasure to watch at work...makes me proud to be an American.

Shaun

Thanks Shaun. That is high praise indeed. From one proud American to another, my favorite part of the whole stair build is the flag pole. I've ordered a nice 20' pole and can't wait to get it installed. I've always had a flag in my front yard and this house will be no different.

 

[shopnut]

Two longitudinal beams 28' and 32' long respectively for the lower and upper garages.

A bridge crane in each garage? I had to chime in and officially say "You ****!"

Great build. Keep the great documentation coming.

 

[KAP1978]

Love this thread!

 

[-Brent-]

I've framed a simple set of stairs to be poured before but haven't done much else than that. The joint I circled is very interesting to me. Since I looked at the pour photos, I cannot figure out how you set this up. Was this top pad poured first, along with the dock pad section???

If so, that makes sense to me. If not, I'm stumped.

 

[cderalow]

if you read back, he poured the pads then the stairs if I recall correctly.

 

[-Brent-]

if you read back, he poured the pads then the stairs if I recall correctly.

Yep, I'm seeing that now. That's a neat trick, I've never noticed that before, not that I've ever really paid attention.

This is going to be an amazing place.

 

[fergus]

Following this build has made me want to be a concrete contractor, just for excuses to own those pieces of equipment. Using that conveyor truck and the excavator to backfill? That was FREAKING awesome. I know, I know, but this is coming from the guy who does everything with a shovel and wheel barrow.

 

[ConCretin]

This wet weather is getting old. As we say up here in Maine the site is a slough hole. We worked through a steady rain to try and make some progress. Started by placing gravel for the future path to the dock stairs.

We're not going be be able to get back after the house is started so an hour with the conveyor will save me a lot of hours with a wheelbarrow later

While that was going on we one-sided our second attempt at a retaining wall at the end of the garage structure.

As you can see we're using MDO plywood and loop ties for something closer to 'architectural' concrete. This is similar to the method we'll use for the exposed concrete inside the house and garage.

We got the formwork closed up.

and placed

We also placed the spiral retaining wall at the other end of the garage

I let the boys go home to dry out and stayed to finish the top of the wall. Took this pic as I left a couple hours later.

We didn't get as far this week as I'd hoped thanks to the weather but most of the foundation work for the garage structure is complete and we've gotten up from the riverbank so we can start excavation for the main house followed by backfilling and slabs in the garage.

 

[ConCretin]

The joint I circled is very interesting to me. Since I looked at the pour photos, I cannot figure out how you set this up. Was this top pad poured first, along with the dock pad section??? If so, that makes sense to me. If not, I'm stumped.

if you read back, he poured the pads then the stairs if I recall correctly.

Yep, I'm seeing that now. That's a neat trick, I've never noticed that before, not that I've ever really paid attention.

You guys have it figured out. The photo is a little deceiving in that it looks like the joint is angled somehow. It's just where one form panel imparted a little different color than the next.

Following this build has made me want to be a concrete contractor, just for excuses to own those pieces of equipment. Using that conveyor truck and the excavator to backfill? That was FREAKING awesome. I know, I know, but this is coming from the guy who does everything with a shovel and wheel barrow.

Thanks. Glad you're enjoying the thread. This would be a much tougher job without some of the tools of the trade. Gotta move quick before they all leave for a payin job

 

[ConCretin]

A bridge crane in each garage? I had to chime in and officially say "You ****!"

Great build. Keep the great documentation coming.

Thanks shopnut. A "you ****" from the someone with a shop like yours is a big compliment.

The bridge cranes aren't too bad to install if you put them in when you build. I already have a bum back and I know I'll appreciate having them in the future.

 

[Mr onetwo]

Holy Boys!!!(as they would say up in the "county") You guys are doing some fantastic work....I love this project!!!I am curious about the permit process you had to endure for the stairs down by the river....was it as bad as I think it was?Maine has a bad rep for that sort of stuff.Good luck with the weather...keep up the good work!

 

[Krokodil]

Wow, great progress. Loving your build!

 

[CHRIS P]

Wow, this is an amazing build so far. Keep up the updates and pics, it helps my saturday mornings at work go buy when i have long post to read.

 

[ConCretin]

I am curious about the permit process you had to endure for the stairs down by the river....was it as bad as I think it was?Maine has a bad rep for that sort of stuff.

It does, but oddly enough, the permit was easy cause I didn't get one........No, just kidding. You are allowed to build a 4' wide stairway through the buffer zone, which in my case is the area 75' back from the high water mark.

It is done through the permit by rule process, You send in an application with some basic information about the project and if you don't hear back in 14 days you're good to go. You just have to follow all the rules regarding run-off, erosion, etc.

 

[Omphaloskeptic]

That stairway is a very good looking piece of work; your BIL should be proud.

Well, it sounds like the 'accounting dept.' won't OK the powerhouse, sluice way, mill wheel, or the 'marine incline'. How about a 'beverage trolley' on a zip line to the main house? The flagpole could do double-duty if it's stout enough. lol

 

[Bib Overalls]

Someone is going to be living in your house in 4,000 AD.

 

[NUTTSGT]

Stairs came out looking great.What are you using for railings ?

 

[Woffski]

This is one Sa-Weet thread!!! Awesome job!!!

 

[abstamaria]

Fantastic, LLWillysfan. I am envious! And eager to see the garage!

Andy

 

[gooned]

It is done through the permit by rule process, You send in an application with some basic information about the project and if you don't hear back in 14 days you're good to go. You just have to follow all the rules regarding run-off, erosion, etc.

NICE!! this actually makes alot of sense, wish more government worked this way - think of all the BS red tape we would save...

Looking FW to seeing your curved wall after stripped & finnished. I'll PM you when I get closer to that door build with any questions -thanx

 

[Thedoc14]

Woooowho!!! It seems a shame to bury such lovely crafted concrete after all the hard work and effort.
But that's why its concrete its the only stuff that can be trusted to last.
Your right that place will be one of the hangouts for whoever walks this earth in a few thousand years from now. Or the fish will love it if you believe global warming.

Nick.

 

[ConCretin]

We finally had a nice dry sunny day. Started the day be stripping the retaining walls that flank the garage structure. The curved wall came out pretty good. You can see the 1" brick-shelf we formed to accomidate the thin veneer stone overlay we'll apply later.

Here's a view from across the garage. You can see the 4" line for the water closet and sink in the garage. The sleeves higher on the wall are to bring the underground utility lines into the electric room.

We also stripped the little retaining wall that we hammered out and replaced. A much better result the second time around.

We'll partially fill the ties holes but leave them visible rather than try to conceal them. No real reason other than to add a little interest. This is probably the finish we'll do on the exposed architectural walls inside the house.

Speaking of the house, we finally got started on the excavation for the basement section.

The structure traces the topography of the site. It starts out in the back with the garage built into the hill. The middle section is on frost walls and the section nearest the water has a full basement. The lowest footing is at elevation 27.00 and the highest roof is at 60.00.

Started by cutting the entire basement to slab sub grade. This elevation provides for 8" of gravel and a 4" slab.

Then we excavated for the footings. Up here in Maine, we need at least 4' of cover for frost protection. You can just see tha top landing for the dock stairs in the upper left corner.

Shocking but it's supposed to rain for the next three days. I know we are supposed to be building a garage here but I can't backfill and move ahead with garage until we can waterproof the foundation. Finally got the waterproofing truck running but now we need to wait for another dry day. Serenity now!

 

[ConCretin]

Someone is going to be living in your house in 4,000 AD.

Assuming I have it done by then

Stairs came out looking great.What are you using for railings ?

That matter is still being discussed - translation - the wife hasn't told me yet.

This is one Sa-Weet thread!!! Awesome job!!!

Thanks Woffski

Fantastic, LLWillysfan. I am envious! And eager to see the garage! Andy

Thanks Andy. I feel the same away about your fantastic home.

Well, it sounds like the 'accounting dept.' won't OK the powerhouse, sluice way, mill wheel, or the 'marine incline'. How about a 'beverage trolley' on a zip line to the main house? The flagpole could do double-duty if it's stout enough. lol

Now that may be doable

NICE!! this actually makes alot of sense, wish more government worked this way - think of all the BS red tape we would save...

I've actually found the authorities pretty easy to deal with - and I'm not fan of government.

Woooowho!!! It seems a shame to bury such lovely crafted concrete after all the hard work and effort.
But that's why its concrete its the only stuff that can be trusted to last.
Your right that place will be one of the hangouts for whoever walks this earth in a few thousand years from now. Or the fish will love it if you believe global warming. Nick.

I've always thought it was kind of shame to bury a lot of really nice concrete but you gotta take pride in what you do whether anybody sees it or not. We do have plenty of exposed concrete planned, including some exterior walls with internal insulation.

My basement is 10' above the 100 year flood level. Hopefully that will hold up until it's someone else's problem.


Thanks again to all for your interest and positive comments

 

[Omphaloskeptic]

I'll bet your crew was really happy to work in the sunshine for a change. Looking forward to the next installment!

 

[NUTTSGT]

Ladder rack in the background ?

 

[ConCretin]

I'll bet your crew was really happy to work in the sunshine for a change. Looking forward to the next installment!

We all did - for one day at least. Springtime in Maine is wonderful, but damn it rains a lot

 

[ConCretin]

Ladder rack in the background ?

Yea. Not sure what prompted that. Got back to the site after everyone left and there is was. Apparently the boys wanted to get a jump on organizing my garage.

 

[Boosted1]

Looking good. The curved wall came out nice.

 

[-Brent-]

We'll partially fill the ties holes but leave them visible rather than try to conceal them. No real reason other than to add a little interest. This is probably the finish we'll do on the exposed architectural walls inside the house.

I know this is jumping way ahead but is there no color being proposed for the interior or exterior?