Loose Ends

So if you have been reading the blog for a while you know that one of the main things we are doing is trying to make a more energy efficient structure. A (relatively) new phrase in the construction industry is "build tight and ventilate right." The catch is that not too many know how to do it...including my crew. This could be because I didn't communicate very well or because they didn't really care to take the time. There were plenty of times I told them things two, three, four times and by the third or fourth time I really did feel I was getting through. However, next thing ya know...things aren't being done right again. Was part of it the "newness" of panel construction? Maybe. Was part of it not wanting to learn or understand new or correct ways of doing things...you be the judge.

So here we are at the rear window. Now keep in mind the panels are filled with expanded polystyrene insulation and we have been harping on energy efficiency all along. So when you frame up a window wouldn't you think it might be important to insulate around it? Well...we had to take off the OSB plywood to gain access to all the cavities they left here.

...and here...

...and here....

The really bad think was that I found a local expert in panel construciton. Todd Helton works for Habitat for Humanity here in Lenoir City and has helped ORNL build half a dozen experimental panel homes in Loudon County. He is a union carpenter and has literally written the book. That is he has written the training manual for union carpenters on constructing panel homes. He came out and looked at the project and found some significant things we had to fix. Now its not like the house was going to fall in or anything, in fact he gave the framing crew a score of 80 out of 100. Which I thought was pretty good for what all we had been through.

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First off, Todd found a bunch of panels that hand not been nailed off properly. That was the most structurally significan't thing and all it took to fix it was...a bunch of nails. Again though, my "crew" thought they were done three times before they actually were. They had me come over and inspect when they first thought they were done. They had put up all their equipment. They had to drag it all back out and go after it again. Then they made the same mistake...putting up all their equipment before they were done. This time two or three of them started hammering by hand instead of dragging it all back out. Then they thought they were done again. Next they had all 6 or 7 guys nailing all over the place. So...after four tries they finally got it right. They were nice as peach pie the whole time and didn't seem to mind going back again and again...but why not do it right the first time?!!!

The next think that Todd found was a big stack of caulk. The conversation went something like this:

Todd: "What's this? Did you buy this?"

Drew: "No, the panel company sent it out. Louis brought an extra case when he came out to the job site."

Todd: "They NEVER give you enough caulk. This is an awful lot to have left over. Are you sure they have caulk in the corners of all the panels and a continuous bead on each spline?"

Drew: "I'm sure they don't actually"

OOPs! So Todd goes on to tell me that I need to caulk or foam all the seams from the inside and then tape over the seams with some sort of mastic tape. This is to keep interior moisture from entering the panels and thereby causing them to delaminate. Now, I can tell Todd is a perfectionist, but I can also tell that he knows what he is talking about....so.....

You can see in the two photos above the foam at the top seams and the black mastic tape. Underneath the foam we are having a friend of our (Dan Szvetecz) help out with the caulking and taping. He is very, very thorough. If I had him on site this whole time I think things would have gone much smoother....oh well...I think we are all learning as we go. But you would think an experienced framing crew would already know some things. For instance...how to install windows and Tyvek.

I've learned there are any number of things wrong with the installation of the Tyvek around this window. First off, you can easily see on the left where the black mastic is stuck onto the OSB plywood instead of the Tyvek because the Tyvek...well it's well short of the window. In fact it ought to be not just wide enough so the tape will stick to it, but wide enough so it is folded back into the window sill. The Tyvek should be done this way at the bottom of the window as well (that is it should be folded over onto the window sill prior to the insertion of the window). The top of the window recieves (should recieve) different treatment.

The Tyvek at the top of the window should be folded up prior to window installation (NOT down around the window sill). Then after the installation of the window AND the tape the Tyvek is folded down over both. Now I didn't know this before I started this project...but I do now. I don't think my crew (or most crews for that matter) really know how to do it properly.

Notice the gap in the Tyvek wrapping around the corner in the a few feet to the upper left of the window. All over the house the seams of the Tyvek should be taped. I know most don't think it should be taped. They feel that taping it will cause the house to be tighter and retain moisture. Or it will trap moisture in behind the Tyvek if it ever penetrates. Well, they are right...house will be tighter, but remember the saying, "build it tight and ventilate right." Most builders and HVAC companies haven't really had proper training on how to deal with a tight home AND because of that tight homes DO have moisture problems. It has taken me quite a long time to find a couple of firms that have the experience and knowledge to do what needs doing...but before they do...I've got to get my Tyvek fixed!!

This is the back window off the Nursery/Study...does the Tyvek there look like it is wrapped into the window frame on the sides and the bottom? Not I didn't think so.

Then look how it's nailed off?!! First off, you should typically be using roofing nails when installing windows. A roofing nail has a very large head compared to a framing nail. In the photo above...that ain't no roofing nail. Can you see the little horizontal slots along the bottom edge of the window flange? That's where the nails should be. Those slots allow for expansion and contraction of the window. With the nails in as they are there is no space for that (see picture below as well).

So the question remains...should I let my original crew in to finish the job (and this ain't all the stuff folks)? OR let someone else come in and clean up these issues and the rest? Leave a comment on the post with your opinion.

Windows...the eyes of the home

When I worked at The Container Store I remember the CEO saying something like "windows are the heart of retail" or something like that. I don't really think they are the heart of a home...I'll save the kitchen for that...but they are important...and they are in!

We used Simonton Windows. You may have never heard of them (we hadn't), but they are owned by the same parent company that makes Moen faucets and Master Lock. We are using a good quality vinyl window. E-Star rated, low E coating, Argon gas, etc. They also have wood clad windows as well.

Once we installed the windows the inside of the house just seemed different. Even with the doors not installed it suddenly became lots more comfortable inside. When the humidity is bad it is hot everywhere, but on days that are even a little dryer there is a HUGE difference in the temperature inside the house vs outside the house...and we don't have air conditioning installed yet!

How do you make holes in a solid wall?