Footing #10

From start to finish, in cold and hot weather, with gentle breezes and gale force winds, with and without help from friends, the final footing was poured yesterday.  Who-hoo, ten footings!

Can you believe on this monumental moment only one single picture was taken! ONE!  Oh sure, there was a camera running to capture the whole process but only one still image.  No close ups, no steps of the process, no moment in time.  And, to make matters worse, the only picture was of me attempting to run the skill saw.  Really!

Yesterday was the second time I have tried to run the saw.  The first time was on footing #1 and it was a disastrous experience.  Board was cut wonky and eyes were watery.  To make matters worse, the board being cut didn't have to be cut straight.  If the 2x4 were cut on an angle it didn't affect the final results. They were just formboards.  Later, I tried again on the plastic boards used to create the chairs for the re-bar mats.  If the chairs were not exactly square it would not affect the structure and integrity of the footing and would not be seen by anyone once concrete was poured on top.  So why did I freak out?  Because, because, because.....I have issues, okay.  "Hello, my name is OCD".  It just HAS to be perfect.  I can tell the Kid "practice makes perfect" but then I expect to run the saw perfectly the first time.  Or even by the second time.  Practice what you preach.  Oh, OCD, why?  Why???

Not including prep time, but from the moment the mixer was turned ON to when it was turned OFF, a footing could be poured in a little over an hour.  Not bad for amateurs.  At what point are you no longer amateurs?  Does having poured 10 footing make you practiced?  Of course, we are not skilled or professional by any means, but can be at least be past beginner? Novice.  Is that the next level of skills?

In order to complete a pour this quickly meant the Planner and the Kid had to have all materials ready and waiting for my arrival.  And let me tell you, with winter daylight hours, it was a mad dash from the office at 4 pm to pour a footing and clean up before dark.  There were a few days when headlamps were being used.

The sheer amount of materials used to pour footings was amazing.  It was not more than the Planner calculated but it was too close for comfort for my taste.  When sand and rocks are being raked together to fill in the last buckets, it just TOO close.  Why add that layer of stress?  Just by an extra 100lbs or so.  Jesh.

Steps for pouring concrete never changed.  Not even tweaked.  Even with the Sailor helping, the process still took the same amount of time.  Having his help allowed duties to rotate.  This meant I didn't have to tamp and fill buckets of rock, the Planner didn't have to fill cement and pour all materials into the mixer, and yes, it allowed the Kid a break from shoveling sand and getting water on hot days.

Yes, having friends help allowed the Kid to play a little more. The kid was a trooper, though.  He hung in with his duties without squawking until footing #8. Then all deals were off.

But hey, he got to put his mark on the deal on footing #8.  Look how big his foot is.  Didn't think it was gonna fit on the footing.  By the end of clean up of footing #8, he was done.

By footing #9, there was the need for constant reminders and the promise of rewards to finish out the footing.  Rewards had to be of high value. Promises of an extra desert... only those of little will power would agree to that.  The Kid, he went for the big guns. "Yes please, I will drive the tractor all by my onesies."  What were we to say, no?  Please, we are not that mean.  Just sometimes.  By the end footing #9, he was nowhere to be found.  His sand would be shoveled (sometimes) and poof he was gone, vanished, nowhere to be seen or heard.

 From footing #1 on Jan 14 to footing #10 on Jan 30, there were cloud cover cool days (perfect),

followed by extremely hot days (wear your sombreros and long sleeve, thin cotton shirts, shorts and boots, and sunscreen.  Lots and lots of ice cold water refills were needed on those days!),

to down right, cold blistery days (and no, not just cold for me either.  Just cold.  Yes, in case you are wondering at the picture, I have on four layers of clothing: tank top, t-shirt, and two thermals.)  This winter has held true to form.  "Welcome to Texas ya'll, today it's 85 and sunny, tomorrow it will be 45 and cloudy."

After ten footings worth of tamping, and tamping, and more freaking tamping, my body was showing some signs of usage. When working, I would have thought my hands would be the first thing to cramp up with the constant rubbing of the re-bar against my palms.  But it wasn't.  It was in my back and arms.  Muscles were tight in places I didn't know there were muscles.  Just look what tamping did to the end of the re-bar.  Once rusty and rough with texture is now shiny and smooth.  That's friction baby!

All in all, it was a fine experience.  Am I ready to pour footings for the house tomorrow?  Hell no!  I might not even be ready in a month.  Will I be willing to pour footings for the house eventually?  Yes.  Just make it two or three months down the road.  No, wait, that won't work because it will be the middle of the summer.  So make it eight or nine months down the road and I will be ready to pour footings again.  Sure, no problem.

Oh, wait I just remembered, there were two pictures taken on the last day of pouring footings. The second picture had nothing to do with the footing process.  But, haha, it has everything to do with a celebratory dinner.  And where else would we celebrate?  Whataburger!!!! It was the Kid's idea.  Honestly.  Ask him.  On a side note, I live with clowns.  They are available for usage anytime and they come cheep.

Water Management System Update

It has been a while since I've posted about the Water Management System.  Went on and on about not having any water and now that I do, not a drop.  Figures, really.  It is easy to rant and rave.  It takes time and effort to report.

Let us recap the water debacle. I guess one could say it all started when the land was still under the 30 day option period way back in Nov 2015.  The Request for Utilities came back stating not only was water not available, it would cost over $60K to have it brought to the house.  That is almost what the land was purchased for and the land does not come with a monthly maintenance and usage fee.  Ok, well, that is not true either.  It comes with yearly taxes.  Anyhoo, I digress.  Being there was no way $60K was being paid, several well drillers were called with the same result.  Yes, a well could be dug and produce drinkable water at our location because there are live oak trees available.  Apparently, the local farmer's lore states: "live oak trees don't like to get their feet wet".  Meaning, there should not be salt water, just fresh water. With that settled, a well was dug at an approximate cost of $6K.

Knowing ahead of time city water was not available, a well was installed by a local company in September 2016.  These people were and are the nicest folks around.  They were prompt, courteous, and friendly.  From start to finish, the well was installed in less than a week.  What came out of the ground was just beautiful, crystal clear, non-smelling saltwater.  Yup paid good hard earned money for saltwater.

Undeterred, the water was sent to an unbiased, third party lab several cities away at the end of September.  The results that came back three weeks later were staggering and proved the saying "more than meets the eye".  This water had everything in it, including all three minerals for salt.  Ugh.

While waiting for the results of the lab we were still optimistic.  A quote on an RO system was obtained and prices came back anywhere between $15K - $25K.  Of course, this is just the cost of the filtration system and pumps, not the yearly maintenance or filters.  By the end of the first week in October 2016 and after many phone calls to various water witchers, drillers, and local authorities it was decided to let the well runs for several days to see if the water would clear out.  A hole was dug to contain the water so it did not make such a mess.  And guess what?  Remember the farmer's saying about wet feet? Ha!  Little do they know.  Geneticists should come study these trees because salt water is found just three feet below ground surface.   I could become a tree-billionaire.  Hmmm, need to give that some thought.  Three feet.  The hole was collecting water faster than the dirt could be removed safely. This picture above shows the amount of saltwater collected after one night, less than 12 hours.

But the hole was already dug, so the water was pumped out.  Gallons and gallons at a time for hours on end.  Gallons and gallons of saltwater.  After the saltwater seeped back into the ground, the hole was filled in while a new plan was in the works.

IBC totes.  Until a better plan, more reliable, and completely independent solution could be worked out our water was going to be begged, borrowed, and pleaded from various friends.  And that is what we did.  Three IBC totes to be exact.  Less than 1000 gallons.

Did I mention how great the well company was?  Feeling bad about our water issue, a comprise was worked out to drill a second well. Thinking he drilled past the fresh water level into the salt water table he wanted to check.  Couldn't live with himself otherwise.  During the middle of November, he did just that.  The well was dug at a much shallower level of 55' deep and then pulled up the pump until it started to sputter at 32'.  All with the same results: saltwater.  Oh well, had to try, right?  It was at this point when all positive notions were lost.  One can only be kicked so many times before they stay down.

At least there were still friends in fresh water places allowing us to obtain drinkable water.  By the end of November, Plan473 had become our permanent home making it easier to monitor water consumption.  Using less than 30g/day, a 330g tote should last about ten days.  This is great news.  It means obtaining water from these sources will be even farther apart.  Then come the first of  December 2016 and a better resource had become available.  While not independent, it allows us free access to more water than we could ever use.

An unnamed source in town has an RO water system.  For every gallon of city water filtered, one to three gallons of "waste" water is expelled.  The water concentrated with minerals after being filtered through the RO system read at 340mg/l of TDS (total dissolved solids). This "waste" water was still less than EPA regulation of 500mg/l of TDS.  The well water at Plan473 read at 6359mg/l TDS.

First, there was no water and then there was free water being "wasted" while a water management system was created for collecting and storing water.  A platform was built, tanks were purchased and water was collected.

Water collects all day, every day in an unobtrusive manner behind the building of its source.

When filled, an external pump is used to drain in into another tote on the back of the truck.

That tote is then emptied into another tote at home and then into the water management system once the platform was built.

Even though the water was collected and used at various locations around the property, the system was still not complete.  The ball valve for needed at the bottom of the tank was on back order for weeks and weeks.  Ordered sometime in early December, the part finally arrived smack dab during the middle of footing preparation.

Once installed, a flexible water line water attached to buried PVC piping connected the water management system and after months and months of dealing with the Great Water Debacle, Plan473 has a completed water management system.

While this system is not designed for the long term because it still relies SOLELY on the generosity of this source, it has worked very well.  Using around 30 gallons of water a day (50 on days where footing clean up is required) has allowed Plan473 to collect, store, and fill one 3000 gallon water storage tank and 1/2 of another.  The long-term plan is to collect water from every roof source.  At this point, the water management system is still not completely finished.  It needs to be closed in to keep the algae at bay and to help with salt corrosion.  However, that step cannot be completed until the shop is built.  The housing will be built from remaining materials from the combination of conex boxes.  So until then, extra bleach will be used.  Nothing like using chemicals to keep one healthy!

Footing #1

Can you believe it?  The day has finally come.  Footing #1 was poured,  Oh, wait, what's that you say?  Footing #2 was poured too.  Hot damn!!!  It was a very busy weekend but major progress was made at Plan473.

With all the excitement on Saturday, yet another picture of the water collected in the holes was not taken.   You just have to believe me when I say five wet/dry vacuum cleaner buckets were collected at a four-gallon capacity.  It is just too bad the water was salty.  Oh so salty.  Crystal clear salt water.  Ugh.  But wait I am past that remember.

Collecting water was simple.  Stick the hose in, turn on the vac, turn off when the pump cycles changes, empty bucket, repeat as needed.  The only difficult step was making sure not to let the hose suck in dirt or rocks from the bottom.  Easy enough until the lid was removed from the first fill up and this is what greeted me.  A bloated, drowned tree frog.  Boo-hoo-hoo. There is nothing sadder than drowned animals.  Once way back in college, when I was a lifeguard at a summer camp, I found a tiny bunny swimming laps in the pool.  The bunny was so worn out when removed it just stayed on my palm where it's little heart could be felt going pitter patter at super sonic speeds.  Every morning afterward I was always prepared for drowned critters.  Fortunately, the only thing ever discovered were beetles, scorpions, and spiders. Being the frog was already dead lessened the stress but it was still sad all the same.  I mean maybe later in the day the stress could have been handled better but at this hour of the morning, it was just too much. Yes, a tear or two was shed for the loss.

Once the water was removed, a formboard was created to secure the concrete cardboard tube, or more professionally known as Sonotube.  This keeps the tube from knocked off center while concrete is poured around the inner re-bar cage.

Spreading the distance of the hole and secured in place with pickets and screws, it also allows the tamper something to stand on since the hole is 3'x3' in diameter.

Next, in the process was attaching chairs to the re-bar mat.  Chairs are used to place the mat a certain distance from the bottom of the hole and help to ensure the mat is level.  If one side of the mat is not high enough, add more rocks.  Too high, remove rocks.  Available in several heights, these chairs are 3" in length.

Each mat received 6-8 chairs each.  The chairs are made of plastic and are designed to pop in place.
Yup, they are easy to snap in place all right.  They are also easy to snap broken too. The second chair attached to the mat broke.  Snap.

Once chairs were snapped in place, the mat was laid into the hole to level.  ***On a side note, see the water in the hole?  This water seeped in less than an hour.  Before concrete was poured, water was vacuumed out again.***   Snap-snap.  Two more chairs broke.

So uh-huh, two more chairs broke.  Chairs had to be re-designed.  There was no way the chairs were gonna be able to handle concrete being poured much less handling the arrangement and attachment of the re-bar tubing without more breakage.  After some quick research, thank you Google, it was decided to use the recycled, pressed, plastic decking.  Yeah, our first use from the trash collected way back in June.

Cutting was easy with the use of the skill saw guard.  Never having used the guard before, I am amazed at how well it works.  Each chair block is 3"x3" and is three blocks tall.  That is a lot of squares to cut but since the material was free and easy to cut, the process went quickly.  Then because there were all these blocks to play with, I did. One is never too old to play with blocks.  Seriously!  If you don't believe me, Google it.   Study and study has been conducted by both physcologists and teachers alike.

Pilot holes were drilled into two out of three squares.  While the material is soft, it is not easy to screw together.  One square received a hole fit just right for the diameter of the screw.  The second square received a much smaller hole.  Why smaller on the second hole?  The hole was just big enough to allow the tip of the screw to enter easily enough but not be wobbly.  Wanted the blocks to stay snug and not waller out.

Two things were observed after drilling the hole.  One: the shavings.  Shavings on the drill were so pretty.  Shavings, when piled up, were soft.  Odd right, it is plastic remember.  Shavings should have been brittle and sharp.  But they were almost papery in texture.  Two: difference in driller personalities.  "Hello, my name is OCD".  Yes, ok.  Chill.  I know that I am OCD.  Fairly sure you should know by that about me by now too.  But in case you have your doubts, let the pictures rest the case.

Picture One: The Planner.  Doesn't this just make you want to run screaming into the hills?  At least it makes you want to pull your hair out a little bit right?  Ok, how about grind your teeth?  Something, please.  It has to do something to you, right?

Picture Two: Me, OCD.  Ahh, doesn't this bring a sense of calm to you?  So orderly and contained.  Let us take a moment to enjoy this zenness.........  What a way to calm the nerves and bring about a sense of completion.

Now, tell me you don't feel refreshed.  More holes were drilled into 1/3 of the blocks allowing bailing wire to be inserted.  This wire then attaches the blocks to the re-bar mat. The result is a mat full of wire ties sticking out all over the place.

But the results were worth it.  The mat sits nicely in the hole, is adjustable, and can withstand human wieght without bending or breaking.

Once mats were in place three inches above the bottom of the hole, four re-bar L bars were attached to the re-bar cages.  The L bars allow the cages to be secured to the mat.

Once in place, cages are centered within the hole and checked for levelness.  It is MOST important that the cage remain centered on the mat and within the hole.  Cages not centered will affect the load bearing capacity of the shop.

Formboards were placed around re-bar cage and secured into place using pickets and screws.  The formboard needs to be secured for two reasons.  One: to help ensure cage remains centered within the hold and Two: to allow the concrete tube to be screwed against.

Concrete cardboard Sonotube was measured to the correct length of 30inches, cut, and sanded to remove sharp burrs.  Burrs are not an issue for concrete pouring but for when creating a smooth finish.

Once again, the tube and cage were centered using string lines.  The string lines also were used to ensure the Sonotube was the correct height from the bottom.

The last step in preparation was the placement of the concrete shoot.

Then it was decided that a break was needed.  Once concrete mixing begins there is no stopping.  Come hell or high water, concrete mixing must be done in one solid time chunk.  The kid used this time to play, play, play.  He moved from free roaming helper to contract labor during the pouring of concrete.  Little did he know how hard he would have to work.  And because he did it, the dog had to do it too.  Of course, there were some enticement cookies in the middle of the tube if she went in as a reward.

With the base plate at the ready, the fun begin.  The mixing of concrete, when using a concrete mixer, was easy.  If steps were followed diligently, produced results were consistent.

Step One: With the mixer on, moisten the inside to help to reduce dust.

Step Two: Add  1/2 bucket of rock.  Hope you have your ear protection on because this step by itself is LOUD!!!!!!!  What did you say, I can't hear.  The mixing is LOUD!!!!!

Step Three:  Add 1/2 bucket of cement

Step Four: Add 1/2 bucket of sand

Step Five: Mix, mix, mix
Step Six: Add 1/2 bucket of rock
Step Seven: Add 1/2 bucket of sand
Step Eight: Add 1/2 bucket of rock
Step Nine: Add water to desired consistency.  Remember thicker is better.

Step Ten: Pour concrete

Step Eleven: Tamp to remove air pockets
Step Twelve: Repeat steps Two-Eleven until Sonotube is filled to desired height

Step Thirteen: Remove excess concrete

Step Fourteen: Reattach string line to ensure the concrete is at the correct height.

Step Fifteen: Insert base plate, reattach string lines ensuring correct height, and trawl concrete to smooth finish.

Step Sixteen: Wash all tools very, very, VERY well.  While the cleaning process is being done, don't forget to sign your handwork.  This process is very much a learned skill.  My print when done with pen/pencil, crayon/marker, finger tip in sawdust is very neat and trendy.  My print in concrete is the work of toddlers.  Oh well, can always fill in lettering later.

Woo, wee what a day.  This first picture was taken at 9:16 am and the last one was at 4:33 pm.  This does not include the time it took to take out or put away the supplies from the storage boxes.  As you can see in the previous picture the tractor is still out.  But as in all jobs, once the hard stuff was over, energy seems to be rejuvenated and the play returns.

In recap, the first footing's total material used was: 12 - ½ buckets of cement, 24 - ½ buckets of sand, and 32 - ½ buckets of rock.  The second footing and all subsequent footing total material used differed because not every hole is exactly the same size.  However, the process was the same.  As the saying goes, practice makes perfect.  Instead of taking all day the second footing only took 1/2 the day.  Who knows how fast a footing will be poured by the end of the number 10.  Fast is good but done right, the first time, is better.

All in all, while very laborious, the end result was very satisfying.  We, at Plan473, created the first two footings. How many people can say that?  Not anyone I know.  Now, just eight more to go.