While prepping the tower and mezzanine, we also worked on the bedroom eyebrows. It was just too big for one video. More on what “bedroom eyebrows” are after the video.
The Video
Bedroom Eyebrows
Bedroom eyebrows are not some sort of double entendre that only earth sheltered home builders get after a long hard day. They are simply the structures we used to keep dirt off the windows while still having a hilly appearance. You see them in Peter Vetsch earth shelters all the time. However, I suspect (from construction photos) that Peter’s eyebrows are big heat radiators that drastically reduce the thermal efficiency of his buildings. I wanted to avoid that problem, so I needed mine to be thermally isolated from the actual home.
I did this by separating the shotcrete into two phases. After completing the bedroom shotcrete and waterproofing it, I added a saddle of 4 inch thick XPS Foamular 250… This is the kind that can handle 25 psi of pressure and is intended for burial. Above the XPS, I build another rebar framework and put shotcrete over that. Or at least, that is what I wanted to do.
In more practical terms, I used tapcon screws to mount treaded wood 2x4s directly to the bedroom shotcrete. Then I drilled holes in the 2x4s to hold the rebar framework… So there is a little edge all the way around where I sacrificed long-term insulation for a more buildable structure. I have since considered other ways I could have done this and may do it differently if I ever had to do it again, but I don’t think the performance will be too bad. Certainly still better than a more traditional house.
The Gallery
I am tired of typing, you may be tired of reading, so let’s just skip to the gallery.
Various stages of progress
Bedroom south eyebrow rebar
John helping with the rebar above the hall roof
Sherri and I often have end of the day discussions that get caught on timelapse
David was almost 13 and going thru a bit of a goofy phase
Another goofy David Pic
Even Sherri decided to get in on the goofy poses. Maybe it was the heat?
Hunter leaving me an Easter Egg to find. This is the appropriate punishment.
Not to be outdone, Michael also made a number of goofy pics
Michael again
Sherri and David posing for the time lapse cam. They like to leave these little Easter eggs in there for me to find.
Lots of turtles around
Office Apse viewed from the roof of the garage. This big area was going to get a bit water tank, but I ended up deciding it wasn’t worth the money.
Kids playing on the office apse jungle gym
After putting the french drain for the office apse, this time before the shotcrete so we wouldn’t have to deal with any mess
Kids playing on the office apse jungle gym
The eyebrow for the master bedroom apse was the most elaborate
The style of the home is something my wife and I are calling “Modern Tuscan“. To us, this means a stucco and stone exterior. While the majority of the Quonset hut will be buried, the Fox Block ICF endwalls would be visible (and prominent) and need to be stuccoed. But first, we would need to attach lath to hold the stucco. Since the work was pretty standard, I decided to hire a professional to take care of the actual stucco work. This is the story of how that all came together, but first, the video.
The Video
Lath overlap
As always, this is a journal of my progress, not a “how to”. I don’t always do things the right way at the start, although I do usually learn from my initial mistakes. For the lath, I read about attachment details like how often to put screws in each direction (and then I exceeded it), but I didn’t pay too much attention to the part about overlapping the lath and just butt jointed everything so the surface would be flatter for the stucco. Probably I was also thinking about saving on lath. At a later point, I changed my mind, so the later pieces are properly overlapped… Either way, the professional stucco guys said we did a good job and only needed to add some J-pieces to form the bottom edge.
The window
With such a large and prominent wall, I knew I needed a window to break up the space. Personally, I think a square window would have looked stupid, so I bit the bullet and budgeted for a nice round window. At least I went with a standard diameter window so it wouldn’t need to be custom.
However, when I finally got to this stucco stage, I wasn’t ready to order the windows. I want to order them all at once to get the bulk discount, and I wanted to build all (or most) of the bucks before I order, so… In the meantime, I decided to go with polycarbonate Lexan. This is pretty basic stuff that you can buy from Home Depot less than 1/10th the price of a window. The R-value is also pretty similar to a double pane window. I figured it would at least give us a temporary solution that would keep the inside dry over the winter.
It ended up looking so good, I might just decide to keep it this way. We will see how well it holds up to UV. Obviously, if it yellows or cracks over time, I will switch to glass. But it did claim to be “UV stable” and has looked fine so far, so I am optimistic.
Still, I wanted to make sure that the window opening was ready for proper glass so that the stucco edge would all be done correctly. We used wood strips to form a curb, and then put two layers of the tar paper to protect the wood and then a strip of lath to hold the stucco. Lots of screws…
Getting a Contractor
I have had many struggles with getting contractors to work on the more unusual parts of my build, but I was surprised to even have trouble getting something as basic as “stucco over ICF”. Very few of these companies advertise properly, probably because most are kept busy by professional builders and are not actually looking for work. Eventually, I went to the stucco supplier and asked for a list of names and recommendations. One of those paid off, but even then I had to wait quite a while to fit into the schedule.
Of course, the contractor, Hoffman Plastering, did a great job in terms of how nice and flat the wall was (they certainly had to compensate for my less than professional ICF job). Their classic worm finish was also excellent.
Cracking
However, in the months after the stucco was applied, we did get a bunch of fairly obvious cracks in various places and we have not been able to get them to come out and take a look. On the phone, they said that it was probably my fault. Essentially, they blamed the copper cap and said that water probably got behind the stucco and froze, but I was able to find pics showing the start of the cracks before the first freeze, also the cracks look more like ones that are caused by expansion and contraction of the stucco its self. Basically, I imagine that if the south wall expanded in the sunshine, this narrow region would be the highest stress concentration and the most likely to crack. The inspector thought it may have been that the top layer was applied too soon after the brown coat. The contractor may have rushed that step because the work was done in October. The cracks are not wide enough to get the edge of a coin or screwdriver in there, but are still concerning. The conclusion of this story is still on hold, but I should probably do something before winter when water might actually get in thru those cracks and cause further problems when it freezes.
Future Stucco?
I wish I could hire a contractor to stucco the rest of it. Their work was excellent (other than the cracking) and the quote to handle the rest of it was probably fair per square ft. The problem is just the large number of square ft required. The majority of the cost is the professional labor, the actual materials are a very small fraction of the cost. Therefore, I am guessing I will need to do it myself. With any luck, my skills will grow quickly.
Gallery
As per usual… A collection of pics related to the lath and stucco.
Lath is ready on the north side…
Working with Hunter Mitchell often made me smile.
A view thru the Polycarbonate Lexan window
The window ready for stucco
I put a septic hookup on the front of the house for friends with campers.
This was the stucco setup. Scaffolding ready in the back and a stucco mixing station in the front left.
I took pics of the ingredients. Basically, it was just cement, hydrated lime and masonry sand. I’ll probably have to do this myself next time.
The bags of hydrated lime looked pretty old ;^)
The stucco sample. I would say it looks pretty much exactly like the final work.
Scratch coat near the ends of the walls.
Scratch coat with the light base.
Scratch coat near the north garage door.
Scratch coat on the north side
Since I couldn’t come out (busy working to pay for the stucco), Sherri and Boys would go out to check on things and set up my camera.
Sherri and David posing while they set up the camera.
The wide angle GoPro always makes things look different.
Brown coat, first 7 ft.
Hoffman plastering did a great job with the stones.
Stone arch is in. Note the stones are not really wedge shaped, but it still looks good.
Stone arch is in
Scratch done.
A little progress pic of the brown coat, scratch coat and final stone work all in one shot.
Brown coat finished on the front.
This is a section on the north side by the garage door that was still only scratch coat 3 days before they were totally done. I suspect they rushed these last steps and the result will be that the final stucco will crack along with the base coat instead of being applied after it cracks.
This ugly spot will be covered over by window trim, but I wanted to show you how the guys from Hoffman plastering went the extra mile. The back wall had some issues with being plumb and straight near the rear windows. I thought it was just the way it was going to be, but they just went really thick (~2 inches) until they got it all nice and plumb again.
Suddenly, final stucco
Final stucco coat
The final job looked really excellent.
Stones above the door.
A close up of the top of the column between the stones. The white patch is just the electrical box for the lighting.
Final stucco near the round window. They did a great job on that edge.
A close up of the final stucco
A little while later after adding the lights and copper trim… (notice cracks are already starting to form to the left of the light)
The skid steer just barely fits under the stone arch… I hold my breath every time I go in or out.
Cracks started to firm. Here is a pic with my hand for scale. This is on the north side.
On the south side, the main cracks were across this narrow space between the corners of the doors and the outer edge. I can imagine that this is due to expansion finding the weakest part to crack…
Similar geometry on the South West corner leading to a similar crack.
Its a short one this week, and the end is rather abrupt, but here it is anyway…
Why a Quonset hut?
My house design is an experiment with a variety of different arch forms. Since it is a self build, I kept most of my spans shorter than 15 ft. The exception is the garage. I wanted a 3 car garage for practical purposes and decided to use a Quonset hut to form the wider span.
The quonset hut could probably support a significant earth load, if it were carefully distributed, etc. But in my design, it is really just fancy formwork to hold up the rebar and shotcrete that will actually support the earth.
My build also required a workshop to build the other components, and the Quonset hut is something that could be erected quickly, early in the construction, and provide that place. I have used it to weld steel arches, store materials, and most importantly, to form my large concrete ribs.
Why build it in two stages?
The rib forms needed to be built on a large flat surface, out of the weather. But we would also need to use a crane to move them to where they needed to go. The ribs weigh 5000 lbs each, so I couldn’t roll them out across the gravel or dirt. Instead, I needed to keep them on the slab, but also needed open sky above them for the crane.
The solution was to build only 2/3rds of the Quonset hut on the slab floor. I could use that sheltered space at the back to form the ribs. I would then jack them up and pull them forward to the open 3rd where a crane could lift them up and over to where they needed to go.
When the crane came out, it did lift them straight up and over, but I noticed that it actually had a telescoping arm. I asked the operator and he said that he could lift them up and pull them out of the building if I finished it…
The ribs were taking me a long time to make and closing off the building would save me a lot of hassle, so that seemed like a good idea. It had been almost a year since the first 2/3rds were erected.
The final 3rd
My parents came down to visit and to pick up their camper. Anyway, it was windy and we didn’t want to try erecting Quonset sections with just the three of us. However, that is a good number for assembling the steel arches, so we spent most of the afternoon doing that.
The following week, I put out help requests on Facebook and at work. The first few days, I was worried that I wouldn’t have at least 4 people there at one single time. By the end of the week there were lots of people volunteering and I was buying a few extra half inch sockets and wrenches so there would be tools for everyone. One co-worker even volunteered his whole family of very capable teens.
The steel ribs went up very quickly. 7 in under two hours. We were actually done before the Pizza lunch I ordered arrived. No worries, we had other work to do (not captured on film).
Mistakes
Because these new steel arch sections were were bolted to the rest of the Quonset hut, which was already bolted and concreted to the slab, and because they were very heavy, I wasn’t too worried about the new section blowing away. With 13 people working in parallel to bolt the sections together, I didn’t want to interrupt that flow and make everyone stand around while I drilled and bolted the steel sections down. I figured I would come back and take care of the anchor bolts next time…
However, by the next time I went out there, I found that the wind had lifted the front third of the Quonset out of the groove. We ended up wasting several man hours and a lot of sweat getting it back into place.
I should have known better because this is a pretty typical fluid dynamics problem that I had to do several times at school.
Another “mistake” that I pretty much accepted was that my building was a little longer than it should have been and ended up hanging over the edge by a few inches. I ended up cutting that off so it wouldn’t get in the way of the end wall, but that is another story.
