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Roof, glorious roof.

4/20/2015

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It felt like it took forever. It wasn't forever, but it wasn't exactly as planned. Another delay. What a surprise. I should be used to it. But I'm not. And every morning I looked out the window, hoping...now?
We have a stairwell running top to bottom of our box. Every time it rained, downstairs filled up with water, much like a swimming pool. Moreover the frames were sitting with their bellies out in The Weather too and while they're up to it, getting them wet just means we have to get them dry again. We wanted that roof on. But of course it rained. And rained. And then hailed with massive thunder storms. And it rained some more, with some swift norwesterlies. Not exactly roofing weather. And then, like it does in Auckland, The Weather completely changed and our glorious Black Dimond Roof practically danced it's way up thanks to our nimble footed roofers. That's the best part about the Dimond roofing products. Once The Weather is willing, the stuff goes up super easily, and super quick. And once up, it stays up, a long time and with super low maintenance. Something Mr Building Boxes is very pleased about. So, yep, on stuff this week, I'm talking roofing. A lot.
I mentioned the testing process out at Muriwai for our Colorcote steel, which is then roll formed by Dimond into the shiny new Veedek you see above. What I didn't say was that apart from trying to lead the world in greener technologies, these guys are getting passionate about our little slice of the planet, getting behind a documentary up at Mount Bruce. The little Building Boxes are very chuffed about that. Fox likes birds. Of course he does with a name like that, right?

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Marcus checking out the airflow shafts beneath the Veedek roofing.
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The plastic cavity batons also mean we need extra long screws. Marcus thought they were a bit of alright too.

Because we're using a Pro Clima system in conjunction with our super delux Earthwool Glasswool R5.2 ceiling insulation, the cavity batons are on top of the building wrap, and they're also plastic. I won't go into it too much here because I'll go through the whole wrap and air tightness membrane system when we've got it all up, but I will say that our roofer was impressed. "Smart" I think he even said.
In a nut shell, having the cavity batons on top of the nonporous building wrap means that the wrap and the insulation can sit side by side and work together, much like a goretex raincoat over a wooly jumper. Nothing like keeping all the heat in. But the thing is breathable so we don't sweat (unlike your standard wooly builder's apparel). And having plastic batons, with open cells, means that the air can travel the full length of the tin underneath, rather than getting trapped by timber batons on the way. Breathable top and bottom but snug as a three year old in a wooly jumper wearing his gortex jacket....Good right? Best part? It's stopped raining.
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Winter is coming...

4/13/2015

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Okay, so you're probably all sick of Game of Throne references, so let me just say that if this cold snap is all a stunt by some advertising agency to hype up Jon Snow and his band of scruffy men then...it's a good one. For us, it's a little on the nose though. We have been pushing to get the roof on and get closed in, Mr Building Boxes even taking time off work and conscripting a mate to give us a hand to get more of the Knauf XPS up. And then, as if to taunt us...the weather. Watching builders huddle, as the rain makes any hope of using power tools downright insane, is a little depressing. And knowing that that last little scrape with the digger that would have finished off the driveway is impossible when the world is a sea of sticky clay aint so hot either. Sigh. So close!
Over on Stuff.co.nz this week I'm talking about all sorts of spanners that can get thrown in the works. Oh and an apple tree. The good news is that we moved it and it is probably loving all this rain!
What I want to be talking about though is the roof, going on. Today. It's going to be today. After about three false starts, it's got to be today...right? Although looking at the weather, I'm pretty glad I'm not stuck up on the roof.
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The apple tree (center) in amongst the sea of clay mud
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Sharing is caring

4/6/2015

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This week on stuff I'm talking about the stuff that gets in the way of building - the disagreements, the breakdown in communication, the what were you thinking moments that seem to ALWAYS come with building. I suppose it was inevitable that we would have them at some point - Mr Building Boxes and I have pretty different ideas about many things, including when the colour orange is appropriate. Still, we've had a relatively smooth process with all of that, and Our Man of Hammers - Mike - is still smiling (and chuckles when ever I mention a "discussion" I might have had with Mr Building Boxes over something.)
Which brings me to my point. Many of you have emailed in with questions related to the build. About how we did the office, why we chose a particular building material, how we wrote our consent documents, or even what to do when things go bad with a professional involved in your build. Thanks for asking! I am totally up for answering any questions you send my way (unless you want to know the colour of my underwear, in which case you are really browsing the wrong sites). I do not, however, profess to be an expert. In fact, I'm always keen to hear about things you've done on your build, so if you have a story to share, feel free to post it up on the Building Boxes Facebook page. And if you're shy, you can email it in and I can post it for you. Thanks for visiting - happy #newbuildlove dreams.

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Framing frames and the Rvalue dance

3/30/2015

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PictureThe 140mm overhang
This week on stuff I mentioned that our frames (the external framing not the internal partitions) are slightly thicker than standard: 140mm rather than  90mm. It’s only a marginally different cost for a big impact to our overall plan: it solves both a structural and insulation issue – they can be cantilevered over the edge of the concrete base, and it means we can pack in more insulation to ensure we keep our thermal envelope intact.
Because we have 50mm of XPS on the concrete block walls below the top timber framing walls, we wanted an overhang to make top and bottom sit together like a nice neat box. If we'd had standard 90mm frames, we'd have had no ability for the frames to cantilever out - they wouldn't be structurally strong enough. Having that neat box, where the external skin of both the top (timber) and the bottom (concrete block) parts are flush, allows us to keep our thermal envelope in one clean, easy line. 
140mm also allows us to pack more Earthwool/Glasswool insulation
The surprising thing is that it's cheaper to fill this 140mm frame with R3.2 Earthwool/Glasswool than it would be to fill a 90mm frame with R2.8 or even the minimum R2.6. I know, even my eyes are crossed at this point. But it's a win win for us. We can offset the cost of the cheaper insulation against the slightly more expensive cost of the timber and at the same time get a better R value all round. It doesnt quite come out even as the timber is slightly more expensive than the saving on the insulation, but still, it's pretty close and we get a much better insulation solution, especially as we needed the external insulation to dove tail in top to bottom anyway.
For those of you completely lost and not sure how to tell your Rvalue from your XFactor, its simply a matter of numbers. The higher the Rvalue of your insulation (and the same goes for windows if you're looking at double glazing etc), the better the effect. So the 3.2 means we get higher insulation properties from our walls. The reason, Mr Building Boxes tells me, for this seeming discrepancy (usually better is more expensive, right?) is that the lower R value in the 2.6 and 2.8 also comes with a corresponding increase in density for the product, so it can be squeezed into those standard 90mm walls. There's more product, packed into a smaller space. So it's more expensive.
Got it? Good...If you have any questions, feel free to let me know...and I'll get Mr Building Boxes to do his technical arm waving explanation dance for you.

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The Speedfloor lid

3/23/2015

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To get that big heat sink we've been banging on about for our passive design, we needed some serious thermal mass. As you know if you've been following the story, (and there's more this week on stuff) we've chosen to have a concrete floor take on the role. The trick for me was that I didn't want the downstairs to feel like a rabbit warren of supporting posts. To get the open span we wanted then, we only had a couple of options and when Mr Building Boxes decided he really liked the look of exposed concrete ceilings, we actually only had one choice left.
Speedfloor is a proprietary system that is super simple and can span big distances without supporting posts. It's the slender steel beams that do the trick and of course there is a bunch of mesh in there too. When I say it like that it sounds like the most un-environmentally friendly thing we could have thought of, and it certainly wasn't cheap. But the plus side is that it will keep the house at a pretty constant temperature when combined with the insulation and ventilation systems, and will save money in the long run on heating. 
Unlike other systems, Speedfloor doesn't rely on a permanent metal tray to pour the concrete into, instead having ply as the base, which is then popped out to reveal the smooth concrete finish. And this is, coupled with the seven meter span, was what we were after. Like I said over on stuff, I'm not sure if I'll paint it or not yet, but Mr Building Boxes love it.
Me, I loved it with the water on it. With no wind, blue skies, it was an infinity pool to no where and everywhere. Shame there isnt one of those in the budget...
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Getting that successful sale

3/16/2015

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This week on stuff is the follow up about private sales.  Happily, our process was a pretty straight forward one and I've had numerous people contact me since with questions. Hopefully this weeks article gives a pretty good idea of the hows and whats. But I thought I'd just add a few details in case anyone else is thinking of selling their house themselves. 
There are all sorts of columns about how to style your house for sale, declutter, make it smell good. I am not a stylist, a personal organizer or a culinary genius able to make my home smell like freshly baked bread, coffee, chocolate and caramelized onions all in one. But we did sell the place successfully, so I can tell you what we did.
First - we had one massive sort out. This was helped by the street wide garage sale - in fact we timed putting the house on the market for the week after as we figured we'd have a bunch of people checking out the street that weekend - and we did. We put about three car loads of stuff in storage, sold a lot and gave away everything else that was surplus. In itself that made a big difference to the feel of the house. Cupboards were suddenly "magazine" full rather than crammed and there was plenty of space to show off the beautiful Tawa floors.
Second - we put some stuff back in. It's all very well decluttering, but I think you don't want the place to look empty. We borrowed pot plants, a chair and a few cushions from friends and filled in the gaps. Now that I have given those things back, its obvious just what a difference they made - the house felt dressed (without the cost of a professional stylist)
Third - we got some good photos. We already had a bunch for the fabulous Larnie Nicolson from our time in Your Home and Garden, but the rest Chris from Homesell took for us - it only took an hour - and I think it made a big difference to how many people come through - and traffic means interest - something that helped our auction process I think. If you dont know a professional photographer and you want to get absolute top dollar for your property, especially somewhere like Auckland, I personally think paying to have photos done is worth it (and they come as part of the package with Homesell).
As an aside, if you're not worried how long or how much you're going to get, and you just want to sell with zero effort and zero drama, you can just put a listing on trademe and put up a sign. In fact our neighbor literally put a homemade sign up by a bus stop. That's it. And he sold, easily, for what he wanted.
Fourth - we tried to be super approachable, super nice and super organised. Like I said in the stuff article, we were saving money doing it ourselves so I approached it as a job. I answered ALL the phone calls, ALL the time and had all the documents ready to go. A LIM costs about $265 in Auckland, nothing in the great scheme of things - and something you usually pay for if you have an estate agent anyway (on top of fees etc) so having it ahead of time made things streamlined and easy for potential buyers.
Finally - we were open to approaches from buyers - we would have gone down an offer route if it worked best - but happily for us (not so for some of the buyers obviously) the auction route worked well for us. You definately dont need to go to auction - it might just be an Auckland phenomenon at the moment, but it did give buyers an easy, clear way to buy - and THAT was what we were after.
And so....it's on with the build. Things are hotting up (before they slow down again) so I'll have some serious progress to show you next week!

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The end of the diggers is nigh...ish

3/9/2015

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So this week there is only one teeny tiny digger on site. The twelve tonner has been gone for a while, but the big orange and the mighty compactor have gone too. It feels quiet without them. Okay, that's not strictly true, there is plenty of banging still going on. But it's not diesel driven. 

This week on stuff we get the first glimpse of what our house might actually feel like as the bottom slab goes down. Its an interesting process. The place feeling big, then small, then big, then...who knows. The retaining walls for the driveway will go up next, and the top slab which will create a lot of the thermal mass.

At the moment though the boys are just happy playing in the dirt - the fact that a building is reaching upwards is completely lost on them. The concrete trucks are cool - that is a given. And the giant concrete pump was great, for about two minutes. But now, they just want to climb the giant piles of topsoil. It's a nice way of putting things in perspective. Especially as I have been completely consumed with selling our current house. I'll talk all about that next week - hopefully. Because paying for this whole thing....that's another whole story. Best I just go and enjoy the dirt for a week.
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Now, to keep the heat in

3/2/2015

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We water proofed her, then we’ve insulated her – our back wall is a pretty special lady. We’re going to insulate the whole of the block box with Kanuf Climafoam XPS and then we’ll dress it with Colorcote corrugate or Cedar (depending on which wall it is) over the top. But because there is going to be scaffolding and general bashing happening until we get that cladding up we’ve only put the insulation on the backwall. If you’ve read this week’s stuff piece, you’ll know why we’ve chosen this product.
What I didn’t add was that this stuff can be cut with some serious precision - allowing specific edge details and surface finishes to be cut into the boards to make them as fit for the job as possible. This isn’t such an issue for us as it a pretty standard long straight wall but it has made our builders happy anyway, easy job is a good job.
And on that, our builders made mention of how quick and easy it was to get up. Line up the sheets, and they’re on in minutes. Our backwall is looking mighty well dressed now. Which is lucky, because with any luck we’re never going to see her again!
Except when she appears in the Living Green Show - Our builders are getting used to a variety of cameras on site - Mike reckons it makes him feel even a little bit famous.

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Keeping the water out

2/23/2015

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Our back wall is up and before it can get backfilled and truly form part of the self-buttressing structure, we need to make damn sure that puppy isn't going to let any water in. Earth and fill are going to get pushed right up to the Climafoam XPS system from Knauf, so everything has to be super watertight now because there is no going back. Not without a digger and some serious cash. 
For that reason we've gone for a Volclay system from Allco again: Swelltite. Like the Voltex we have under the footings, this stuff uses bentonite, a compound that can expand to seal small installation imperfections or punctures in the membrane. To be specific, it's an engineered composite consisting of a white 0.3mm polyethylene geomembrane liner and 2mm of bentonite compound with a clear release film applied over the bentonite compound. 
It works by forming a dense, impervious waterproofing membrane upon hydration with water. But for the bentonite compound to activate, the water has to get through the polyethylene liner component, thus making Swelltite a true dual waterproofing membrane. What's more its easy and super quick to install, can be applied in all weather conditions to green concrete with mechanical fasteners or a water-based adhesive. 
Okay, so I say it's quick and easy to install, but then I wasn't the one crammed into a skinny space, trying to weild adhesive, a hammer and a bunch of rolls of the stuff on yet another super hot day. 

In among all of this too we have put our house on the market, and decided to try and sell ourselves - you can read all about why and how on stuff this week. We live in Auckland and the property market is booming, so says the media. We'll see if they're right. I'll let you know more about our experience shortly. 
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One of the team

2/16/2015

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Sorry there has been a bit of a lull over here of late. If you've been following the journey on stuff (and you can see this weeks installment here) you'll know that there have been delays. And delays means that while I could talk at length at what we're going to do, what we're actually doing is waiting for blocks, gravel and concrete to fit together before we can move on to the next stage.
With the return of the sun, and our builders and their diggers, we're starting to get going again, and I have to say it's a relief to Adam - Our Man of Diggers, and Mike - Our Man of Hammers, back on site. These guys really know how to crack up the pace. There will be other bits and pieces to share soon too, as we start filming for the Living Green Show today with the external XPS insulation from Knauf going in. I'll give you the full low down on that when I've got the photographs. In the mean time I thought I'd introduce you to Bella. Cos every building site needs a good guard...puppy.

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