Monday, 29 June 2015

A yard full of holes. Gophers!

Gopher holes? No, it's not Caddyshack, but I do have to mention my favourite line from Bill Murray though: "I got to get into this dude's pelt and crawl around for a few days. Who's the gopher's ally? His friends. The harmless squirrel and the friendly rabbit"!

The holes are to be made by going nuts in the back yard with a post hole digger, not a gopher. Forty three posts are required to be dug to a depth of 600 mm and a diameter of 300 mm to hold up the eight bearers that will support the back deck.

That's a whole lotta holes!

There were way too many holes for my poor old Bunning's Chinese made post hole digger to dig, and my arms wouldn't have been able to handle it, so I called in Stefan to do the ground work for me. He hired an auger to fit on the back of his Dingo digger and set to digging. There's quite a large tree in the yard as has been previously detailed, so we were really worried about hitting tree roots, of which he found not one. However what he did run into was storm-water pipes! Lot's of them!

Below the RED line shows the storm-water pipes we discovered (and destroyed) with the auger.

Who knew there were so many pipes?

This was a nightmare on two fronts.

  1. The storm-water pipe that ran across the yard aligned right where the post holes for the first bearer needed to go
  2. That busted pipe intersected with another pipe coming from the front yard, which was right next to where the holes went in on the northern edge of the deck. The auger nicked the pipe four times meaning it would have to be dug out and replaced
Funnily enough that pipe was one that Stefan already hit when he was laying the circular paved area, so he was familiar with it already!

Tackling the first issue, it was off the to hire shop to get a trencher. Stefan then cut a new trench for the pipe between the first two rows of holes, and laid down a new section of pipe, connecting it in with the pipe coming in from the left of the yard. He then finished off the holes per below, where you can see all the broken pieces of pipe now littering the yard!

Three rows of holes and a new pipe laid.

Next fix was a little trickier. The smashed pipe coming down from the front yard needed to be replaced, but it also ran right along side where the row of holes were, leaving BIGGER holes and not enough depth to hold the footing without concreting in the pipe as well. Too much concrete and probably not a good idea to concrete in the pipe.


The solution was a product called Formatube, which luckily was sold at a place about 5 mins drive away called The Tubeworks in West Heidelberg. It did the trick! The pipe was repaired, the form tubes dropped in, and then the lot was backfilled over.

Holes dug, pipe fixed, forms dropped in. Problem fixed!

Next stop was the council inspection, however the rain gods decided to drop a ton of rain the night before the inspection, filling the bottom of the holes with water and slop (a technical term for sticky, sloppy, smelly wet mud). You all know the trouble I've had with the council on this project, and there's no way they'd pass inspection on this, so there was nothing else but to get horizontal in the mud and reach down and scoop it all out with a small bucket.

Two weeks later after digging the holes out another 10 cm deeper to get rid of the slop, and a lot of praying for no more rain, the council gave the holes the tick and we could start laying in the posts. 100 mm x 100 mm 'wet' treated pine.

Plopping in the posts

I left it to Stefan to set the posts as he had the truck, concrete mixer and other equipment needed. Like Dirty Harry says, "a man's gotta know his limitations". I'm happy to admit it would have taken me a month of Sundays to lay each post. He had it done in two days.

Panorama. All the posts are in!

Next up I start in on the frame.

Monday, 15 June 2015

Sizing up the next project and laying the ground work

Well this is the big one, the back deck. When we built the house I had always envisaged a deck hanging off the back in the grand plan, and it's going to be probably the biggest construction I have ever undertaken on my own. So let's build a deck!

As you can see from the plan below it's going to be quite substantial at 14 metres long by 5 metres wide. The deck also has two sets of steps, one large one to take the level down to the lawn area, and another smaller set of 3 steps to come up from the deck level to the rear entrance of the house.


The biggest thing I ever built was...

Below shows the pegged outline of the deck to be built. Towards the far end the deck will run around the edge of the house to meet up with the existing side gate, and the stair will run down to the right to the lawn area. I'll run a ledger board along the edge of the house and run the joists 90 degrees out from there.

Adding some string lines makes it real

The first issue I have to deal with is the the over-pour from when the house slab was laid. Slab construction (as opposed to foundation and stumps) is extremely popular in Melbourne, and where we live was no exception, however it's not an exact science. If they've ordered more concrete than fits in the forms for the slab, they tend to just let it slop over the edge, leaving an over-pour, which becomes a nightmare for us deck builders.

As you can see from the photo below I have at least 50 cm of concrete hell to get through (that's 20 inches in the old scale) and I have no idea how deep it goes.

20 inches of concrete over-pour with an unknown depth

The whole over-pour has to go, as the council regulations won't let me lay a ledger board into the brickwork if there is a window present, and as can be seen in the top picture, I have a window present! Because of this I am regulated to attach the ledger board to the concrete slab. To achieve this I need to have a clean edge on the slab that I can bolt into, and the only way I can think to achieve that is with a concrete saw.

The engineer who did the engineering assessment of the design for me luckily had some contacts in the cutting industry and I arranged to have the edge of the slab cut with a diamond wet saw. When the guy came he had a number of tools to choose from, but owing to the overhang of the window sill (see the right picture below) he opted for the hand-held, petrol powered one. Damn noisy it was too!


It did make quick work of the edge though, and he took the cut down as deep as the blade would allow. The closest he could get to the wall without damaging the render left about 100 mm of concrete edge sticking out from the wall with a hopefully clean cut down. From memory it cost around $300 to get complete.

Once the edge was cut it was up to yours truly with the trusty electric jack-hammer to remove the actual concrete.


I love heavy machinery

After it was all cleaned up, I had an edge wide enough to take the ledger board (90 x 45 MGP 10 treated pine) and have it bolted straight into the concrete slab

The jack-hammer makes light work of a hard job

Marvellous (and heavy) though the jack-hammer is, I still had cause to get the mallet and cold-chisel out on occasion to help break the concrete away. The end result though was a lovely smooth surface across the entire back of the house.

Conquered Concrete

Next up I need to dig some holes. In fact I need to dig 45 of them, not a job for the feint hearted.