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Basement Interior Wall Framing

Since we’re not framing the exterior walls of the basement yet, we went straight to the interior walls, specifically the permanent walls for the bathroom and mechanical room. After Mario put in the mesh for the concrete, I went around and carefully measured locations for the walls and placed J-bolts to secure the sill plates, so that once the slab was poured we wouldn’t have to drill into it. The main reason for this was the radiant tubing in the slab: if you drill into the concrete and hit a tube, that loop is basically useless, and our floor only has three loops. Unfortunately, Mario informed me the day of the pour that because of the way they were screeding and finishing the floor, the J-bolts sticking up all over would get knocked over and interfere, so he pulled almost all of them out.

First wall section

First wall section

I framed the wall in sections, pressure-treated sill plate and standard 2x4s, sill gasket under the pressure treated sill to prevent moisture wicking, coated screws for anything touching the pressure-treated lumber and regular screws and 8D nails for the rest. The uneven floor joists above required some shimming and I had to add blocking to a couple of sections where the wall was parallel to joists. I watched all my inside corners for drywall nailing edges and followed the tub instructions for framing around it. For the curb at the outside walls I built L-shaped pieces and attached them after the fact rather than try to build it with the section. I came back and installed an additional exterior half-wall for the utility sink and washing machine hookup, though in retrospect I might as well have just framed a full wall. I may reconfigure that, but I need to pick up some additional lumber since my original estimates proved low.

Bathroom framing

Bathroom framing

While the wall framing was pretty straightforward, we did run into some snags. For starters, the plumbers had put the toilet too close to the tub, something I could have had them fix if I’d noticed it before the floor was poured, say, back in October when they installed it. Because the toilet can’t move, I shifted the tub a few inches away, so the tub will have to use an offset drain and one of the few remaining J-bolts no longer aligned with the wall. They also managed to place a vent completely outside of the wall it was supposed to go through, but at least it’s inside the mechanical room where it won’t cause too much of an issue. I had to frame the wet wall of the bathroom with 2x6s because the plumbing alignment with the steel column wasn’t quite right, and I had to make some provisions for the steel beam that runs through the bathroom. In general, framing around all of the pipes sticking out of the floor was challenging.

Bathroom framing done

Bathroom framing done

With all the walls up and framed and a few J-bolts secured, I spent a lot of time poring over the photos I took of the floor after Lester installed the PEX tubing, determining where exactly I could drill the floor and secure the walls with Tapcon screws without hitting anything. After several nerve-wracking drills, including one gush of concrete dust that I was certain was air escaping from the pressurized tube, I had all the walls secure and the pressure gauge on the PEX lines holding near 70psi assured me I hadn’t hit any. Whew.

Now the plumbers and electrician are working on their respective pieces. Once they’re done and we’ve passed inspection we’ll get to insulation, drywall and putting up the temporary walls. I’ve got a list of smaller items as well, like hooking back up the water filter, moving the water heater, running venting for the bathroom exhaust fan, and ordering the other fixtures: vanity, toilet, faucets, and utility sink.

Basement Floor Acid Staining

Our basement floor is radiant heated and the ceiling isn’t all that high, which meant we wanted a flooring surface that didn’t interfere with the heat and didn’t consume any height. Staining and sealing the concrete slab was the perfect solution, and not terribly expensive to boot. There’s a number of tints, color seals, paints, and other options for finishing concrete, but we liked the texture and look of acid staining. After some browsing, research, and shopping, I ordered four gallons of acid stain and two gallons of lithium silicate densifier/hardener.

Washing the floor

Washing the floor

The first step was to wash the floor, and we made it a family affair with Sarah and I and the kids mopping and scrubbing. We’d been careful to keep the floor clean after the pour, and done things like painting before hand, but cleaning was still a necessary step. With that done we let it dry overnight, though the first step in staining was re-moistening the floor. I used a pump sprayer for most of the process, and the only issue we ran into was a couple of spots where water pooled and the stain didn’t take. I’d recommend mopping up any puddles first so you don’t have to reapply stain like we did. We let the stain set for about four hours; the longer you leave it the darker the color. Then we neutralized the acid by spraying an ammonia/water mixture and mopping and washing again. We weren’t quite satisfied with the color, so at that point we did another four hour stain on the lighter spots before neutralizing and washing again. One source said to wash until the water runs clear or the sealer wouldn’t take, but after several washes the water was still brown. Another site said we’d wind up taking the stain off if we over washed, so we finally called it “good enough”.

I came back the following day and applied the sealer. I was originally going to put down two coats of sealer, but it went on fairly thick, to the point that we’ll have to go back over it with a broom and then mop off the yellowed excess. As a result we still have a gallon of the sealer to use later, maybe when we finish the basement into an entertaining space in a couple years. When the other basement work is done I’ll come back and wax the floor to give it a bit of gloss, but we’re happy with the result.

Basement Front Window and Back Door

With the floor in, the first order of business is to close up the basement. I put in most of the new basement windows a few months ago, but we couldn’t put in the door until the slab was in, and we left the front window open so that it could be used as a makeshift door during the work. I installed the buck for the front window first. It was a rare case where I could put the box together first and then put it into place whole, instead of assembling in place. The issue with the front window is the outermost wythe of bricks is a smaller opening than the inner two, leaving a gap to either side of the window.

I got the buck into place and secured it with Tapcon screws. I’ve learned a trick with Tapcons (at least when it comes to brick). I use my rotary hammer to drill the holes using an SDS bit because it’s much faster than my regular drill, but then I circle back with the regular drill and the drill bit that comes with the screws because it does a better job of removing the dust in the holes, so the screws will go all the way in. I’ve actually sheared off screws trying to force them into holes that have brick dust. I also use my cordless drill with a spade bit to drill about a half-inch into the buck so that the head of the screw is counter-sunk, and I use the impact driver to actually put in the screw, so I wind up with four power tools arrayed around me, but it gets the job done.

Footing repair

Footing repair

I rebuilt the bricks around the back doorway when I was working on the side windows, but my masonry skills aren’t so hot and it wasn’t very even. I used the laser level with a vertical line pointing toward the house to cast exactly on the brick that needed to be removed and used an angle grinder with a masonry disc to straighten it out. I did this grinding a few weeks ago before the new floor was poured because the grinder throws a lot of dust that we didn’t want all over our new floor before we’ve stained and sealed it. Once the floor was in I needed to address the footer area below the bricks, because we removed the original stone door sill and the opening was wider at the bottom. I used mortar to fill the gaps at the bottom and let it set up overnight. I used the leftover mortar to fill the gaps on the sides of the front window buck.

With the doorway (mostly) even, I cut pressured treated 2×6 boards to build a buck for the top and sides, with sill gasket behind the sides. I used a router to cut dados from the side pieces at the height of the top of the door frame, since the doorway is a bit taller than the door. The left side fit great, but the right side had some sizable gaps behind the buck. I thought it would still work and screwed everything in place, but when I went to test fit the door I realized I was off by about a quarter-inch. I took the right side buck back off, and rather than grind the brick I planed the back of the buck so that it contoured to the bricks. This achieved the same effect and I was able to get the door installed.

There was still the matter of the rectangle above the door. Our plan is to cover the buck with PVC trim, and have a light fixture above the door. I needed a solid base to attach an electrical box, but it needed to be flush with the buck so that the trim would look right. I screwed some scrap 2x6s into the either side of the buck, recessed to accommodate the plywood. I used leftover pressure treated ¾” plywood from the first floor windows. With a little bit of adjustment I got it attached and screwed into place.

As usual, I still need to go around and seal with backer rod, caulk and spray foam, and I still need to get the deadbolt installed (once I re-key it). We’re planning to replace the satin nickel handle and deadbolt at some point with oil-rubbed bronze, but that can wait. These locks are ultimately destined for the garage (which we don’t have yet). This summer, once the PVC has dried out, I plan to go around and install PVC trim on the bucks of the windows and doors. For the first time since we bought our house, nothing is boarded up and we have proper windows and doors everywhere.

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!