Inspection & clarification of issues

Our private inspector came yesterday and reviewed our slab concerns and checked a few other areas. Not a full inspection this time just a review. Report mentioned the following:

- He wasn't too concerned about most areas despite them not looking too pretty at the moment. The exposed steel part of the slab (reinforced mesh frame) in my basic terminology will be sanded back treated and then sealed before finally being covered pre the remaining render applied to lower part of slab. The issue remains that pre slab pour concreters were told the cracker bars in this section needed to be lifted up and they said it was done. During pour it must have dropped back down as it isn't in the top 1/3 of slab as agreed on the day. Solution, nothing can be done re its position in slab and we've been reassured this bar once corrected sealed treated and properly covered still keeps the slab integrity high.

- Alfresco – the aluminium sliding door frame bottom sill section is showing a bow  downwards of about 10 mm. Supervisor has had a go at his internal chippy once again as this is yet another thing he "forgot" to do. Seriously if the SS wasn't friends with the internal chippy I think he would have been put into line a long time ago. Door to be packed and sealed soon.

- Guest bedroom – the wall outside the ensuite is showing misalignment of about 10 mm. Wall needs re working.

- Fascia & guttering not aligned yet.

- Garage Hebel overhang by 50mm, I was worried this now in neighbours land now but told our slab was 80mm short of boundary line so we still have 30mm. Lucky for that or I might have had a fit. Whether or not the slab was actually on the boundary line or not I will never know as impossible to check as front boundary dot on footpath disappeared when United Energy dug the underground electrical pit.

- Entry door frame completely needs working as margin of 7mm gap in door to frame and also a 7mm out of plum in the whole frame too. Apparently they haven't replaced the hinges which will correct the gap but the frame needs reworking too.

- Various bowed skirtings and plastered walls were marked and should have been picked up pre paint by builders.

- Roof space – the pipe is running through the manhole opening and inhibiting clear access through the manhole. Plumbers will correct this when they come and correct other issues and pipes.

- Lounge – I was able to detect an out of square skirting that exceeded the allowance of 4 mm tolerance over 2.0m.

- Kitchen – the bulkhead is showing out of level from front to rear by about 10mm. This is very evident at the overhead cupboard end panels

- Missing waterproofing to wet areas as per BV which we paid extra to do. Still not done. Tiler now going to be delayed as they now have to come back and do this.

Tiles are all onsite and are correct ones. I just hope they put the correct ones in the correct location! Also I confirmed the tiles we selected are the 15mm grout line. The tiles/grouting needs to be sealed post handover as PD don't do this, must add that to my list of jobs and quotes.

Today we met with site supervisor which was great as many issues can be instantly resolved or noted in person rather via phone or emails etc. Also helps me feel a connection to the process along with supervisor rather than just a painful customer noting or complaining about every tiny issue. 

I felt reassured all issues have been acknowledged and fixes are coming. Others new to SS will be fixed now rather than wait for pre completion inspection. 

Excitingly he think house will be finished by end of June. That's a 7 month build including a large break over Xmas nye period. Wow.
Now I better start with landscapers...

This is where the kitchen piping was altered due to a design fault but luckily the plumbers could correct it so I can still have my corner cupboards.

A quick kitchen shot

My little one already loves going up and down the stairs

Here is some of the waterproofing in master ensuite

Tiles galore. Confirmed we will be given leftovers approx 1 box per tile type. 

Painters will leave approx 2L of paint per colour. 

A biggie I ask SS where our line will be in kitchen bench and he confirmed it won't be near the sink. Also asked if we can have cut outs of bench for chopping boards or hot plates. Super excited if this eventuates, nice bonus. 

SS is a good man and had a leftover plaster sheet and put it under our stairs which wasn't in plasterers plans. Lucky me understairs looks really clean and finished now.  

I believe they are doing their best to make a high quality home for us. There are hiccups along the way but overall standards will be high when complete. Even the paint finishes on doors is really good with a minimum of 3 coats which is great for my kids will test them once they arrive. 

Painting in progress & current issues incl slab

Current issues on our minds:

Slab, slab and slab. The same issues remain, with poor repairs and patch jobs done. All goes back to these images. Oh and the repairs they have done are crumbling already and incomplete. AND we have now exposed steel frame/wire from the slab on one wall that looks rusted already. They have done a grout filler on sections where overhang was but in some areas that is crumbling away too. The rain water tank slab ok but not great workmanship.

  

- Down pipe above garage (outside bedroom2) & one on west side of house are flapping back and forth with the wind constantly; looks like their bracing brackets have detached from the wall and swinging.
- The WIP cabinetry issue. The corner cupboard can't be opened or used because the mini wall containing the plumbing stack has been made too big. The cascading problem is now we can't use that corner cupboard because the wall is 470mm and too long. Taking measurements from the cupboard side of this wall (containing plumbing stack) it should measure 320 but instead onsite it measures 470.  The pipe sits out of the way up until 2000mm then angles at 45 deg pitch towards the right and then up into the ceiling. Plumbers were onsite today fixing this, hopefully the wall will be reduced soon too. 

- Full area waterproofing to all wet areas both levels still not done as per contract (to be done post painting)
- The wall corner entering the lounge is clearly not at 90 degrees on the skirting

- Garage roller door does not close fully to a vertical angle.

- The right side plumbing waste pipe in the guest ensuite was not moved to the right as it was meant to be. Now the cabinets have been installed the pipe now under draws. It still needs to be moved 300-400mm to the right. Plumbers didn't fix this today despite being onsite!

- Cabinetry fine tuning & fixing open/close of a few doors I'm sure this gets reviewed pre handover so wont mention. I know every door and mechanism that doesn't work already and so glad I could review this at my own pace pre front door being replaced and hence now locked. Master Ensuite shelves are not level as they've drilled holes wrong, looks very odd (just like the front door lock). 


- New front door now installed at last and hurray for chippy who put lock and handle in correct location this time.
- Awaiting wardrobe fit outs & new correct robe doors to arrive- Alfresco sliding door frame is bowed
- Excessive concrete removal on neighbours garden.

Painters are in and I think busy doing what they do. I hope they do the 3 layered paint as required, no way to check if they are actually doing this. We have chosen white all over the house as mark up costs to custom do feature walls too much, might to post handover. Haha yeah right, temporary is permanent in our house!

Felt pushed aside by SS lately and know he is really working hard as 3 other supervisors have resigned and he has been looking after over 20 buildings concurrently for a period of time (hopefully no more). Excessive workload is unacceptable and reflects badly on Porter Davis. Luckily they have new guys all starting and hopefully our SS not so strung out and can supervise our job more. I have locked in an site inspection with SS next week and bringing backup so I stop getting wishy washy answers and fixes (husband is better at being direct).

Slab fixes (sort of) & plaster done

Plasterers "fixed" slab issues apparently as per SS, so I went & looked for myself and they must have only just left as it was still wet. As long as it's structurally fine as they assured me and it's just cosmetic I have to accept these repairs that will be covered with render in weeks to come anyway. They put steel at angel under one section and then filled it to satisfy our Inspector they said they normally wouldn't do this. 

The plasterers were meant to start on Friday. We had a sneak peak on Sunday morning and the entire house is done! Apparently they worked until 9pm Saturday night as per my neighbour; love my neighbourhood watch team. Time to deliver some thank you choc brownies again to them. 

Upstairs activity area

Upstairs master bedroom

Kitchen & dining room

I had to submit a building objection to council on Friday because our next door neighbours are developers dividing block next to us. Never done one before and feel bad but don't like the idea they are planting a tree agsinst our backyard fence that could grow to 12m high in their building plans. Hopefully they will move it to other side of their yard. Also they are building 2 town houses and building on boundary line in several areas with an underground car park which means a massive 3.4m deep crater will be dug 1.2m away from our new house. I'm nervous they are going to damage our slab when they dig the piers & excavate their site in the next few months. Will see what council have to say. 

Slab issues still here & carpentry issues getting there.

A few carpentry issues have been done. Yippee. They did our recessed cabinets at last. 

They've fixed some studs and noggins and have gone through shaving and adding things to walls to make them not bow once plaster on. 

My issue over rain was pacified by saying it was the wind that blew it in via windows, I disagreed but accepted I could be wrong. I now can see daylight through roof and know I am right, roof is leaking. 

Plumbing issues mostly fixed with all pipes (gas/water) secure and held in place nicely in roof and walls and siliconed at every entry point in stud or noggin. 

Slab issues remain. Unacceptable overhangs still not filled and gaps and holes need filling. Most issues around garage so there isn't such weight on it but it must be fixed to meet standards codes and hebel covering most of it up now. Hopefully slab supervisor can meet me on site to discuss issues ASAP. We are getting annoyed still not fixed. 

This weeks issues to chase up

- slab issues

- electrician return to wire bathrooms now recessed cabinets insitu

- roof leaking

- front door frame detached and leaning at 80degrees. 

- Front door detached and leaning

-  Sliding doors frame not all frame pockets nailed to abutting wall frame. 

- check why toilet external air vent pipes not installed yet in every toilet. 

-  Stegbar to fix all windows doors and sliding doors

- framer - Lounge Sliding door frame one frame pocket not nailed to abutting wall frame. Study - broken frame above doorway. Upstairs activity area noggin broken.  Bed 3 - west wall bracing has been removed and not reinstalled.  Master suite - entrance gaps near cavity door not closed off on floor/roof where external air flow will come through cavity door area. 

  

-  Insulation - various gaps need filling and needs installation under heating/cooling units in upper foyer area prior to plastering. 

- we want to do a sweep of internal wall areas so mess not hidden by plasterers. 

Pre plaster things continue - a big rant

Hmm, I've been pacified re issues but I will believe it is all fixed when I see it for my own eyes. 

Scaffolding down, this means render complete to upper floors, eaves, gutters complete. 

Windows not yet properly glazed and finished installing all windows/frames. Stegbar due out next week to finish the job and I've been told fix the sagging sliding doors. 

Apparently an apprentice was helping our internal carpenter and didn't do good job, he's no longer employed. So, our frame issues remain. Heard several times already they are coming ##day to fix it...blah blah blah. Plaster delayed again till next Friday. 

 Here's what I've learnt. Every trade is a contractor. They do their job and leave. If they do a bad job then it takes time to get them back because it means they're already on other jobs and it means they loose money by returning to fix issues or jobs. They are all "under the pump" to finish jobs. My thinking is, who cares how many jobs they have. Do a good job the first time like you are being PAID to do and you don't loose money by coming back to a finished job that was done shit. I WILL notice and yes I will continue to remind you it needs fixing despite it only been a minor and non structural issue and not vital in "your" opinion but still set out in Australian standards codes as unacceptable and you say it can be corrected in next stage. Seriously didn't your mother teach you to do it right the first time or yes I will ask you to do it again and again until you get it right. 

Oh just because you said you'd fix it doesn't mean it will be done, & if frame goes up and concreter will come and fill it but doesn't and then hebel guys come and cover up issue so I can't see it anymore; YES I still know it's not done and yes you still have to fix it even if yes they have to take hebel off again. Do it right the first time people. 

Ok rant over. I'm a perfectionist and don't like others not doing it right. I'm tired from stressing over it and lack of sleep. SS says leave the stress to me - as if I can leave you in control, youre so busy with other jobs and I don't trust you to remember it all. 

Ooh I think I need sleep and might have to edit this later!

Getting ready for hebel

Hebel preparation started. Will start one day next week. Apparently if slab ledge not square or adequate they don't worry at all as hebel is screwed to frame and not 100% dependent on slab like bricks. They just add extra brackets; I don't truly understand but it was the Hebel guy who said all this. 

Our slab hasn't been fixed yet but supervisor waiting for steel bracing order to fix overhang of steel beam in alfresco area. He said PD engineers happy to putty it but to satisfy our independent inspector he will steel brace it. I'm very happy we have private inspector to keep them to a high standard. 

I've read many blogs and keep up to date with online chat groups on homeone forum. A great one is this one and I've just read a fantastic blog entry of his and recommend anyone to read it. 

http://bendigowaldorf.blogspot.com.au/2014/12/guide-to-building-home.html?m=1

Plumbing in already. 

Hebel next week will go up over a few days. 

Electrician will start too. 

Unsure when insulation starts but the lockup carpenter has to make all modifications to frame still required. Building coordinator still doesn't have report from 2nd inspection for frame. But I know the frame for our recessed shaving cabinets haven't been done, nor have the noggins we requested been done. Hopefully I am allowed onsite this week to see updated frame. 

Also looking into waterproofing wet areas as just discovered they only waterproof shower bath and sink area, not floors in those areas. Unsure if this is normal or required?

Also our water meter fixed again but our original tap point is covered now by dirt rock hard, under if SS aware, another thing to point out next week. 

Solar hot water pipes insitu. 

Framing stage complete & slab fix ups

Today we had the opportunity to go onsite with our site supervisor and look at the completed frame and were even allowed upstairs via a ladder (not kids). So excited that I didn't even take one photo! Oops. Must have been the fact we had 4 kids with us at 7am that made me forget! 

All walls stable and rooms all correctly laid out. Doors all look like correct type, size, height, direction of slide, opening, and some frames already in situ (didn't take tape measure but seemed fine). Windows appear to be correctly centered and heights, size etc look ok. Window companies should deliver in next week or two, delayed because of Xmas holidays.  Roof cavity looks TINY and I totally understand why it's better to do all wiring with PD and not wait to do post handover. I noted the height of the sliding wardrobes in kids rooms were correctly increased to 2400 and not 2000 which is standard (no point in having a large bulkhead as it's wasted space). 

The frame looks good in my lay opinion. Obvious areas needing touch up and finishing touches (abstract nailing, bracing, remaining window framing), all will be sorted out later today as rain stopped; they had to finish early previous day due to heavy heavy rain. 

A few things that will require fixing that I picked up were:

- they were using plans which were not the final plans we signed off on! However that said they were the 2nd final plans so almost perfect. 

- At this stage that meant the recessed bathroom cabinet mirrors were not addressed in framing for master ensuite and kids bathroom. Will check other things missed later tonight. 

Slab Supervisor also reviewed site with concreter today:

- The overhang of steel frame in alfresco area will be fixed with and re enforced with a steel plate/screw or something like it & not just builders grout stuff. 

- friable edges will be fixed prior to Hebel installation next week. 

- rain water tank slab area which has snapped will be completely fixed and redone in a few months. Not doing it now so it won't get damaged again while exposed by trades/equipment/future scaffolding etc. 

The PD inspector also reviewed frame today after our visit so all his issues should be fixed before our independent private inspector comes on Monday to review framing stage. 

Overall we are really happy with how well they've done everything. All staff have been lovely to deal with and seem very happy to work with us and our questions. They have great phone manner and communication. Really considerate with neighbours and a temporary fencing issue crushing plants and reducing access to side path. They did say there are always a few things to fix with a slab and frame stages and I believe we are getting a very well built home as each thing is identified and fixed, no patch jobs or pacifying at all now all Trades have finished Xmas holidays. 

Next is roof tiling, and I believe while scaffolding up they put on solar hot water panels, evaporative cooling unit and guttering.  Once roof insitu i think hebel might be next. For those that are wondering what hebel is it replaces the need for bricks and has better sound, hear/cooling properties, cheaper and faster to build; read for yourself http://hebel.com.au

Will get a better picture soon. 

Framing Day 4 - ground floor

Only 4 days since framing started this is where we are at.

View from front door, stairway to paradise yet to come. 

View of back area - kitchen left, lounge fireplace right, back area are dining room left & alfresco right (yet to be framed). 

View if standing at oven area cooking, sort of see pool area to check no kids opening gate without me there.

Kitchen window view, ideas anyone?

View from back corner of garden.

Water tank slab waiting for concreters summer Xmas holidays to end next week. Two areas of frame overhang that I can see so far. All the rest looked good and still very much a work in progress. 

Slab issues & framing started

Porter Davis have started work again now after Xmas NYE break. During this break we sent a letter to them regarding slab concerns. A few bits from letter are:

The two main issues are:

1.      Poorly finished and friable edges/ corners

2.      Integrity of the hot water pad

 There several slab edges and corners that are unacceptable.  They appear quite friable and out of square.  There appears either to have been a problem with the formwork and/or poor compaction.  Either way the workmanship is poor.  It appears that the formwork has been removed before the concrete has reached the required strength before removal (15MPa as per AS3600 Table 4.4).

In particular, I am concerned that later construction work may need to accommodate these defects, possibly leading to other issues or complications.  

The hot water pad appears to be defective. It is a major concern that it is in such bad shape so soon after placement.  In particular, the edges and corners are friable and it is not square to the main slab.  There does not seem to be any expansion or isolation joints between the pad and the slab and there  appear to be some structural defects. I doubt this can be repaired without issues later.  It is not clear how it could possibly be fit for the purpose, nor how it is expected to last a reasonable timeframe. 

Photos at bottom of post. 

Response so far was a pacifying phone call from a slab supervisor that neither dealt with our slab nor seen it in person. He assures me the concreter will rectify my concerns when he returns from holidays next week. Meanwhile the frame starts going up. I speak to frame supervisor onsite and ask him his opinion of slab edges and he gives me a realistic yet not reassuring opinion that it does need fixing before frame complete. The site supervisor calls me after I ask when concreter fixing slab and I want to know how it will be fixed not just when. He seems to think its no drama and frame can be wedged for now and next week concreter can fill in gaps if needed. Hmm, I called our independent inspector for help but he's away this week and returns next week and can review it then. 

So for now I'm pacified briefly there's nothing I can do but next week I will start jumping up & down for solutions not just patch jobs. 

In the mean time they've started our frame and in just 2 days they've done heaps and should be putting roof trusses on next Monday. Hebel planned for 3 weeks time. Amazing how fast this stage feels. 

Slab

Slab done. So glad we had our private inspector visit the site the night before the pour as he picked up lots of things that had to be corrected prior to concrete pour. All things were corrected and weather was good so now the site will settle for a few weeks and work should start again in a month, aka Xmas holidays. The slab looks good apart from the rain water tank platform a bit shitty, no water pooling except in alfresco area of slab just like it should for drainage. The height of slab shocked me a bit, I guess house stands higher than I thought but no dramas, will just add a bit of cost to landscaping as soil will need to be brought into the backyard now. 

Unsure what these drains/holes are for?

Water tank base a bit cracked and shitty looking 

Hope these cracks are normal?

Wow, it's up hill to drive which surprised me as we have flat land.