Through the last 2 weeks of November and into the first 2 week of December, work progressed on installing the corrugated metal decking to close in the roof from the elements. Work finished around the 12th along with the installation of the upper windows and door to the attic. Patient Chickadee is now closed in and set for winter!
Andersen Windows
Though installation of the windows and doors posed its own issues, selecting the window and door material proved almost daunting. Our canary is highly reactive to soft woods – one of the main reasons this first build is concrete and steel. As most standard wood windows are made from pine or other softwood, an extensive search was conducted for manufacturers …
Windows and Doors
The first 2 weeks of November were unusually warm with temperatures approaching 70 degrees. Taking advantage of the good weather, the doors and first floor windows installation was completed. The upper-level attic openings frame bucks were prepared and installation awaiting completion of the roof substructure (corrugated metal decking).
The Eaves and Fascia
The next task in preparing the structural roof was to add the eave extensions between the gable walls. This was followed by connecting the metal fascia, a somewhat difficult task as parts of the eaves had a 90% flange and others a 45% flange requiring intricate and detailed metal cutting. The roof was now ready for the corrugated metal sheafing. …
The Roof Valleys
Installing the roof valleys was somewhat demanding. It required measuring 4x’s before cutting, then adjusting so that the plane of the rafter roof lines matched the plane of the valley beam. Three valley beams ran the length from the main ridge beam to the attic floor, and 3 others intersected with these long beams. Once set, the valley ridge beams …
The Roof Begins
After the ridge beam was set, work began on fabricating the individual rafters. It is a laborious, time-consuming activity. After measuring the length, the 16” steel beam is cut on the 45 degrees at each end. Then a further 45 degrees cut on the bottom is made creating a square face flush with the outside joist of the attic floor. …
Ridge Beam Set
To assist the 2-man work crew, a Genie boom lift was rented. It allowed the easy lifting into place of the steel material. After the top plate was complete, the Ridge Beam was set and placed. Measurements were taken and the cutting of the rafters began. There are about 90 rafters to cut and 3 gable ridge beams to set …
Surprise Results from Changing Steel Suppliers
One of the first steel member to be installed is the top plate. The metal stud fits in a grove created by pouring the concrete 1 ½” below the top of the ICF block. This width in the ICF block is 6”. The 6” steel obtained from the alternate supplier actually was 6 1/16” wide. Unlike a wood stud, you …
Structural Roof Material Arrives
Unexpected delay for steel delivery arose; August is not the time to be expecting quick receipt of material. The delay was compounded by the fact that the original steel supplier could not provide the 16” wide roof rafters. The largest they manufactured was 14”. Sizing down was not an option due to the depth needed for the required healthy insulation. …
The Concrete Floor Pour
Due to material delays the decision was made to proceed with the concrete pour as the forecast was for a 5-day sunny period with temperatures in the 70’s. The pour was successful and will cure for 28 days before addressing the appropriate time for the concrete staining.
