Category: Basement Digout

Basement Floor Pour

We have a basement floor! Mario and his crew came out early yesterday morning and by 8:30 the concrete truck had arrived. In no time they’d poured the entire pad and screeded (leveled it out).At that point the rest of Mario’s crew left, but he stayed for the rest of the day carefully hand troweling the surface to a burnished finish. The pressure gauge on the radiant PEX tubing never wavered, so we’re confident that nothing was damaged during the pour.

Initial screed

Initial screed

There was one minor issue, in that Mario didn’t want to leave the J bolts I’d carefully positioned during the pour because he couldn’t smooth the finish with them in the way. I explained that I didn’t want to drill or nail into the finished concrete for fear of hitting the PEX tubing. Ultimately we left some of the J bolts in position and pulled some of the others. I took a bunch of measurements and photos to help me position new anchor bolts in the finished slab, but I’m not thrilled about the nerve-wracking possibility of hitting a tube and losing a whole loop of the radiant heat.

Finished floor

Finished floor

This weekend I plan to install the last of the basement windows and the back door. I’ve installed the window buck this past weekend to ensure I wasn’t going to be making any more dust. The next project is to stain and seal the concrete once it’s cured. I’ve been doing research on the specific products and techniques we’ll be using for that. I think with the finish that Mario put on the floor, it’s going to look really nice with the stain and seal.

Troweled finish

Troweled finish

This feels like a really important milestone. We started breaking up the concrete of the old floor over a year ago and never imagined it would take so long to get one back. We’ve gained close to a foot of headroom in the basement, a critical difference that makes it a much more usable space. In addition we’ve got the rough drainage in place for our basement bathroom and utility sink, our new water main and sewer, and an interior weeping system that at this point really needs to be hooked up, since the sump basin has almost completely filled with water! With the new windows, the new back steps, the painted ceiling and beam, the tuckpointed brick walls and the all new electrical outlets and lights, it’s a night and day difference from where it was. While I really expected to be at this point in October, I’m happy that we’re finally here now and looking forward to the steps ahead.

Basement Floor Prep – Plastic, Mesh, and PEX

As planned, Mario (our concrete mason) came out on Monday of last week and put in the plastic vapor barrier and the wire mesh on top of the foam insulation. Over the weekend I installed “J” bolts (they’re shaped like J’s) where our interior walls will go, so we don’t have to drill or nail the new concrete slab. I cut short pieces of steel rod and stuck them into the foam and then wire-tied the J bolts to them to keep them positioned and upright.

Basement PEX tubing

Basement PEX tubing

Today Lester, our radiant heating contractor, came out and installed the PEX tubing that will eventually allow hot water from the boiler to keep our concrete slab nice and warm and heat the whole basement. Once the tubing loops were run and zip tied to the mesh, he pumped compressed air in to 70 psi as a pressure test to ensure the loops are air (and water) tight. They’ll stay pressurized during the concrete pour and cure to make sure they don’t get squeezed anywhere. He gave me a list of warnings to pass on to Mario and his guys when they’re pouring the concrete: when they’re using a concrete spreader, don’t hit the tubing! When they tip up a wheel barrow, don’t hit the tubing! When they’re running wheel barrows back and forth, lay down some half-inch plywood so they don’t hit the tubing! I sensed a trend.

Also basement PEX tubing

Also basement PEX tubing

Mario is planning to pour the floor on Thursday, and I’ll be there making sure that Lester’s instructions are followed. If anything happens to the tubing during the pour and it leaks, our whole radiant-heating plans will crumble. The only choice would be to tear up the whole brand new concrete slab and start over, or switch to hot water forced air in the basement, and with the lack of head room I don’t want to run ducting!

Basement Floor Prep – Stone and Insulation

Mario, our concrete mason, came out on Saturday and put down the stone that makes up the bottom layer of our new basement floor. I had hoped that he would also install the layer of rigid foam insulation that makes up the next layer, but apparently that’s not in his menu of services, so I was on the hook to do it myself. More than that, he wanted to come back on Monday to put down the plastic and the mesh, so I needed to get it all installed on Sunday. My friend Dean and his dad, Hector, once again offered to help.

Insulation delivery

Insulation delivery

The first challenge was getting the insulation. We’re using 4′ x 8′ panels of 2″ thick XPS (extruded polystyrene) foam, which are commonly sold in different densities. The higher density foam is better for under concrete because it doesn’t compress as much. Unfortunately it’s not stocked in as many places and I was buying 30 panels. I placed an order Saturday morning at a Home Depot that had “99+” in stock. By late Saturday afternoon the order still wasn’t ready, so I called them. After being on hold for 15 minutes I was told they “couldn’t find it” and apparently had zero in stock. There was only one other Home Depot near me that had enough in stock, so I switched the order to them. They had it ready by 6:30. Unfortunately they didn’t have a truck available, so I wound up renting a truck from a Menards that was nearby (they didn’t carry the foam). I went to Menards and got the truck, drove to Home Depot, manhandled the five-foot-tall stack of foam onto the truck, drove the truck home and dropped off the foam in the back yard, drove back to Menards to return the truck, and finally drove back home.

Sunday morning came earlier than expected (due to the Daylight Savings time change) and Dean and Hector showed up. We started at the front of the basement and worked toward the back, using the hand tamper and a rake to even out the stone base in places. The concrete curb around the footing and the column footings have rough edges that we couldn’t get the foam completely flush with, but we worked around them as well as we could. The bigger challenge was the plumbing. Because the plumbing in the basement drains to an ejector pit, the pipes aren’t particularly deep. That meant in addition to cutting holes for the pipes themselves, we had to allow for horizontal pipes and fittings as well, not to mention the sump basin and ejector pit. Overall the process went smoothly and after several hours we had everything installed. I did some foam sculpting to cover up the bathroom plumbing group and I’m pretty pleased with the end result. We were frugal enough with the foam panels that I have seven left over to return. Since they cost me $32.50 each, I’m happy about that.

Insulation installed

Insulation installed

Mario is back today to put down the plastic and mesh, and then Lester (our radiant contractor) will be out next week to attach the PEX tubing. Mario should be able to pour shortly thereafter. We’re still working on the painting and prep for the front window and back door. I hope to have posts about those projects shortly. A big thanks go out to Dean and Hector for all their help!

Basement Retaining Wall and Footing Curb

We’re still waiting on our plumbers to do the re-lining of the sewer and the new water supply line. They in turn are waiting on approval from the City, which is being difficult. Apparently the connection between our sewer line and the sewer main under the street is damaged, and City is determining whether we need to repair it to do the re-lining.

Interior footing curb forming

Interior footing curb forming

In the mean time Mario, our concrete guy, is going like gangbusters to move things along. We can’t pour the basement floor until the plumbers finish their work, but we can work on the back stairs. After I removed the back steps down from the first floor, he re-dug out the hole we had filled behind the house and knocked out the existing retaining walls. For a rare change, rapid progress was being made without me being directly involved.

Nighttime concrete

Nighttime concrete

Within a couple days, Mario got the forms in for the new retaining wall as well as for a curb around the inside perimeter of the basement, since the existing stone block footings were exposed from the digout. Then, unexpectedly, Tuesday afternoon the concrete truck arrived a day ahead of schedule and Mario and his assistant wound up working until 10pm to get everything poured, smoothed, and cleaned up. Anything ahead of schedule is rare indeed with our project!

Retaining wall, formed, braced, and poured

Retaining wall, formed, braced, and poured

The forms came off the retaining wall yesterday and soon the stairs can be formed. I need to get the drain for the landing outside the back door roughed in and then Mario can get that and the stairs poured.

Completed retaining wall

Completed retaining wall

The forms are still on the footing curb, but you can definitely get a feel for the difference it makes in the basement. It’s really starting to feel like we can get a floor poured and start putting up walls, if the city would just sign off and let the plumbers get to it.

Basement Updates

I haven’t posted in a while because I’ve been trying to complete something before making a post about it, but I haven’t finished anything other than leveling the subsoil, which I already made a post about when I was a third of the way done with it. I didn’t want to write another post just to say I’d finished, especially since flattening dirt isn’t particularly interesting, even if it is a lot of work. Instead there are about five different things in progress, all basement related, so I’ll give a run down on where we are and what we’re trying to get done.

First off: the plumbers. We’ve signed our contract, paid the deposit, permits are being pulled and/or updated, and once that’s done they can get started. Rather than dig up the existing clay sewer pipe they are going to re-line it, a process where they run a scope, clean out the pipe with water jets, then shove an inflatable sock down it all the way to the city sewer main. They inflate it and then squeeze an epoxy resin around the sock, which not only creates a whole new pipe within the existing one, it fills any cracks or holes at the same time. The result is a brand new sewer line without any digging, plus it will actually be a larger 6″ diameter pipe than it would be if it had been if we had redone it in cast iron. The sewer line will be an “overhead system” meaning it will go up to collect the drains from the first and second floor, but the basement drains will go to an ejector pit which then pumps up to the level of the first floor before entering the drain. That prevents sewer backups from flooding the basement.

Next, the plumbers will need to dig a hole in the basement and a couple pits out at the street so they can horizontally bore a new copper supply line and disconnect the old lead line. Once that enters the basement at the front there will be a new water meter and an overhead copper line running along the beam back to the mechanical room. Finally, they will be canceling our old catch basin in the back yard and running the rough plumbing for the basement bathroom. The process should take about four or five weeks, depending on permits and inspections.

While that’s going on I’ve been working on the interior weeping system (aka drain tile). I’ve dug a trench around most of the basement that will connect to a sump basin. I picked up a large 24″ x 36″ crock that’s about twice what’s required by code. I’m still researching sump pumps to put into it. For now that will tie into our sewer system, as Chicago code allows combined storm and sewer, but once we’ve redone the back yard I plan to route this into a rain garden along with the downspouts and the drainage for the walkway along the side of the house.

I’ve talked to our concrete guy about getting the back steps redone while it’s still warm enough out. Our plans call for the exterior basement steps to go to the South rather than straight out or to the North as they do now, so we need them to knock out the existing retaining walls and put in a new one. The plumbers will install  an area drain at the bottom landing that connects to the weeping system. Hopefully he’ll be out this week so we can get that process rolling. We unfortunately had to fill in the pit we had dug for the steps with all the excess dirt from leveling the basement and digging the trench.

Lastly, I tried replacing the rest of the basement windows yesterday but discovered the brick around the windows and the sills are in worse shape than I had hoped, so I called our tuckpointers. We’ll have them replace the sills and clean up the window and door openings so we can get the rest of the new windows installed. I also ordered our new back door, since it will take a few weeks to get it in.

So despite not being good about updating the blog, we are keeping busy with the house. As we finish any of these projects I’ll write posts about them individually. The weather is getting much cooler as Fall sets in, so we need to get a lot done in the next several weeks!