December 29 - It Is the Holiday Season

It's A Wonderful Time of the Year -
The Christmas season is such a wonderful, joyous season. A time for the Sunday school Christmas program, Christmas services, Christmas parties, family gatherings, entertaining visiting guests, traveling to visit family in far off locations, and other enjoyable events. Throw in a wedding or two, since family will be in town for the holidays, and you have a pretty slow season for making progress on building a church with volunteer labor. So, without much building activity there has not been a lot for the chronicler to report, which makes for a great time for the chronicler to take in the Sunday school Christmas program, attend Christmas services, take in a Christmas party or two and entertain family visiting from afar. In all, a very pleasant and enjoyable couple of weeks, even if I did not attend any weddings.
Some Progress - 
Despite the labor shortage, there was still some progress. On a very cold evening before Christmas a few hearty souls worked outside attaching firring strips, on which the siding panels will be hung and putting on window trim. Paul and Eric are in the lower unit while Bob and an Brandon (?) are in the upper unit. Neither the picture nor my memory is good enough to provide definite identification of the other worker.



Some windows got trimmed out that cold evening also.





















Septic System -
One other significant event occurred before Christmas. The high tech septic system was installed. I got the scoop on this system from Sam. There are four septic tanks, each with a capacity of 2,500 gallons, that run in series. Down stream from there are three pump tanks, each with a capacity of 2,000 gallons. These tanks are connected in parallel. By my math that is total of 16,000 gallons of tank capacity. That is a lot of room even for a bunch of coffee drinking Finnlanders. This picture shows the top of the last septic tank in the foreground and the top of two of the holding tanks in the rear. The gray box houses the brains that control the pumps that move the discharge from the pump tanks into the leech fields, formerly known as drain fields. I am not sure when the name was changed but this is the first time I have encountered the term 'leech field', which sounds to me more like a place to raise fishing bait. The leech fields, of which there are two, can handle 2,900 gallons per day. There are two pumps, one for each field. The pumps can cycle up to 8 times per day, discharging 362.5 gallons per cycle. I am impressed by all these numbers.  I am certain that there is still a lot of arithmetic that can be done with these numbers, but I leave that as an exercise for the reader. I learned about all this sewage stuff just so I could pass it on.

This digging machine was just making its escape when I arrived on the scene that evening. I did not get a chance to see it in action. I was surprised that they could plant the tanks in such cold weather.







Digging Inside -
As nice as it is to have a septic system and leech fields, they are rather unnecessary unless there is also plumbing inside and a way to feed the outside system. The plans in the picture depict where the trenches need to be dug that will handle the under-floor heat ducts and plumbing pipes. But it is never so simple as to just start up the digger and make trenches. First the dirt need to be leveled. The magic laser beam machine throws a level line around the walls. Since there is a chalk line already on the walls indicating floor level, just set the laser machine in comfortable spot and measure the distance between the floor level chalk line and the laser line. Knowing this distance, just walk all around the building with a tape measure and check the distance between the dirt in that spot and the laser line.

Here is the laser machine resting on the tripod.

















Bob is wandering around checking the current grade at various spots. The red line can be seen on the distant wall and on Bob's leg. Using this technique it is possible to chart all the measured points and make a topographical map of the church floor in its current state. Of course this is a useless exercise so it will not be done.

















Instead, the inside digger machine will be used to move the dirt around so there will be level base on which the concrete floor will be poured. Greg Wuollet is the designated machine operator, shown here pushing some refuse out of the way so the serious leveling process can begin.

Watching this size pretty-big machine gently nuzzle the dirt up next to the wall is impressive. Obviously some skill is required to maneuver this equipment without smashing the walls, ceiling and/or windows.

While Greg drives the big machine, Bob demonstrates his skill with a manually powered excavator. Watching this scene develop made me think of the legend of John Henry's race with the steam powered drill.





Happy New Year - 
Well, the new year is arriving and next week will bring a return to a more regular work schedule at the church.

December 25 - Christmas Greetings

Merry Christmas

December 19 - The Weather Turned Cold

Twenty Below Zero -
Saturday morning I got the following text from Bob saying, "Don't know if you've gotten the memo but no work at the church today". I think the high temp for the day was minus 10. Well, I was hoping to get out to the job site Saturday, but with the weather so cold I was not sad to stay home by the fireplace. I did hear later that both Bob and Sam were there, and Sam told me on Sunday that a few more hearty souls also ventured out. By Monday it was in the twenties above zero. So I made the trek Monday evening.
We also received a fresh snow job before the sub-zero temps moved in so the building actually looks quite pretty. Maybe we should hang a wreath on the door for Christmas. I took the above photo when we first arrived. I took the one at left just before I left. Note the photographers shadow stretching all the way to the door. The shadow is caused by the car approaching the photographer from behind. Needless to say I hastened my exit.


New Heat - 
On arrival at the site I learned that we now have permanent temporary heat, as if I am not confused easily enough already. There is a new, size large fire breathing dragon plumbed into the propane tank. The picture on the right shows the beast with his (it must be a 'he') black feeder hose and his large exhaust pipe. The picture below show the view looking right down his flaming throat. I am feeling the heat as I take this picture.

It was comfortable inside but as the picture reveals, the ice on the windows had not yet completely melted. I am not sure how long the dragon had been belching out fire but I am confident that it will be very comfortable to work inside now. Unfortunately, the next task on the list is to finish hanging the plywood strips on which the siding will hang, which is clearly outside work. Well, this week promises to be considerably warmer than the end of last week.

More Writing on the Wall - 
Mark is shown here perusing the task list on the wall as he waits for the workers to arrive.

 I am impressed with the quality of the task list and the the accompanying plan pictures. I have noted earlier such communications and these appear to my untrained eye to be an upgrade.


I include some previously observed lists and pictures for comparison purposes.

Pencil on scrap lumber.

Marker on foam block.

Full color illustration on corrugated cardboard.





























The Hay Departs - 
With the coming of the new heater the hay is no longer needed to prevent the footings from being undermined by frost. So it can go.
Eric piles up the loose stuff in the wheel barrow for transport outside.  Spencer shown below moves bales to the forklift basket for subsequent transport in mass.

Loose hay is packed around the door openings to help keep the winter on the outside and toasty comfort on the inside. 

December 10 - Insulating Above the Ceiling

The big event on Saturday was blowing fiberglass above the newly installed ceiling panels. The first target was to pile up twelve inches of the blown in material. Later I understand that fourteen inches was the new goal. This picture shows the fluffy stuff piled up like blown snow, but much warmer and not subject to melting. The red lines are not molten lava coming from a volcano but rather are laser marks delineating the desired depth. I did not stick my nose topside but Eric, who was among two or three others manning the business end of the hose, sent this picture to me.

The raw material comes in plastic wrapped bales. The bales are cut open and the fiberglass insulation is stuffed into a barrel. One guy cuts open bales and adds material to the barrel while another one shoves it down the throat of the hungry auger residing at the bottom, trying to stimulate a gag reflex action. The auger digests the material so fast that it immediately passes out the exit orifice where a cyclone generated by a monster fan carries the hapless fiberglass through a mile long hose well into the upper regions of the building where it is finally disgorged into piles on top of the ceiling panels.  Here Kevin is feeding the machine and Steve is trying to gag the auger.

When I first arrived on site Markus was using a long handled homemade paddle pusher but was not able to overpower the machine.

There were initially six pallets of the raw material on site but when the machine appeared to be devouring the entire first shipment, reinforcements were summoned and another sixty or so bales were retrieved.

 Ken had to use the forklift to maneuver the raw material near the glass eating monster. He was able to successfully deliver this pallet without dumping it all over the floor.
Hot Lunch on a Cold Day -
It is December in Minnesota so naturally it is cold outside. I expected it to be fairly warm inside the building, especially when I saw a vapor stream coming out the exhaust vent from the newly connected space heater. But once I got inside and saw all the workers bundled up with jackets, gloves and hats pulled down over their ears, I realized that winter is not yet defeated, even inside the structure. So the arrival of a steaming pot of stew seemed to be well received by the troops. Judging by the disappearance the guys seemed to be able to compete with the blue fiberglass eater currently residing in the kitchen. Tom leads the charge through the lunch line.

The high temperature on Saturday was in the high teens and inside the building was certainly warmer than that but it was not cozy warm. The guys working upstairs faced much cooler temperatures as they put in the stuff designed to keep the lower level warm. You can see the folks kept the winter weather gear on through lunch.
On Sunday I heard that a thermometer inside the building registered about 48 degrees. The space heater is working, but not very well. For some reason it was cycling often and not staying going. I suppose either some wise person will fix the machine or some additional heat source will be required.

While it was not in use on Saturday, I did see a device on site that was unfamiliar to me. An emergency pizza baker. I am not sure but it looks like it uses infra red to cook the pizza. It looks like a clever device but I am curious if it is really effective and if it makes a nice crispy crust. Thee cheese did seem to be melting, though. The turntable rotates slowly, like a very lazy Susan. If I get a chance to try it out I will do a complete review in a future post.

Septic System -
The weather turning cold did not deter the pyramid-building, septic-tank-interring, sewage-draining folks from doing their duty. I did not witness the burial but I did see the displaced dirt and the orange fence. Unlike the roof, the septic tanks do not require big concrete boots to keep them in place. They just stay where they are of their own accord. The fence is there to keep trucks from driving over the tanks. Or perhaps as a security measure in lieu of additional concrete weights.

Ken, who told me about the pyramids, also told me the pretty green tubes are called risers. Construction jargon baffles me again. I think of risers and imagine people responding to alarm clocks or choirs performing, but do not think of sewage systems. So I am still learning. Apparently the risers connect the concrete tank with the surface caps allowing the tanks to be pumped without digging down to the buried tank. Rather like a reverse filler spout.

The filler activity is provided by the pipe that will come out of the building. This pipe marks the spot where the drainage pipe will exit the building. I hope the pipe shown is only marking the spot and not intended to be a fountain.

Water Table Revisited-
I think I have this water table thing figured out. A strip of aluminum is run around the building at ground level. Just above it and covering the top edge of the strip is a band of green-treated plywood. Resting on top of the plywood is a bent aluminum flange that is also tucked under any window frames encountered. The siding will come down to the horizontal member of the flange. I think this whole assembly is called the water table, or it may be I am just revealing my ignorance.

 Bob figured that the aluminum strip was not quite up to snuff in this spot so he said it needed a patch.

 Andy is shown here fabricating the patch. Bob says Andy is a good fix-it guy. I have already seen this in action earlier when he made the bucks fit the openings and then made an opening for the buck. I agree. A good fix-it guy.

 Green Treated Lumber -
Chemically treated lumber, most, but not all, of which is green, is treated to help preserve the wood and keep it from rotting. The chemicals in the wood do not play well with all metals. On the water table, where the treated lumber is in contact with aluminum, there is apparently no problem with undesirable chemical reaction. The laminated posts in the firewall, however, were joined together with about 1,475 regular old nails. The posts seemed to tolerate the punctures well. However, the framing inspector said the chemicals in the lumber will cause the nails to deteriorate over time so reinforcements were called in.












Jacob Byman (I hope I have the name right) is driving in long galvanized screws to help out the nails. It is hoped that between the decomposing nails and the screws that the posts will remain happily joined together for a long time.

December 8 - Winter Arrives

Heat -
We who live in Minnesota can be pretty certain that winter will come and bring in some rather cool weather. This fall has been amazingly mild which allowed the roof to be completed and the windows installed before the cold stuff rolled in. All of which is very good.  Not quite so good was snow followed by very warm days which caused a very muddy approach to the church. Now winter is flexing its muscles and Canada has been very generously exporting brisk refreshing breezes this way. Which is good because now the 'driveway' from the road to the church is again solid. As in frozen solid. Now it is easy to drive on.
Foam was added above the sheeting on the ceiling. Randy blew foam over the flat ceiling and the south half of the sanctuary ceiling. I think the building would be nice and cozy if it had some heat added.





I asked Bob on couple of occasions recently when will the heater would be connected and working. He replied, "It is in negotiation." Well, apparently the negotiations were replaced by actions. I saw a propane tank resting along side of the building. Not only that, a fuel line is connected to a regulator hanging on the outside wall. I am not sure who was negotiating with whom, but whatever issues caused the delay have obviously been resolved. Energy so close you can almost feel the heat.

I said almost. Brian and Mark are working to connect the line from the regulator to the space heater hanging from the ceiling. Brian is stringing up the ducts for the exhaust. Maybe I will finally get got see some real duct tape action. I have my fingers crossed.

 Apparently running gas lines is fussy work. Mark says the joints can't be soldered like water pipes. The joint materials must be heated to red hot and then the brazing rod applied. It is probably important that the gas line does not leak, so take your time, Mark, and do it right.

But even the last step in getting heat inside is not straight forward. The heater was previously used with natural gas and propane burns hotter than natural gas so some modifications must be made to the heat exchanger.

I am rather proud of this write up. I think it makes me sound like I might know what I am talking about. With any luck at all I remembered Mark's comments and reported them accurately. If not, no worry. Like one man has often told me, don't let the facts get in the way of a good story.
Building a Water Table -
Andy was crouched down outside a window, looking like he would rather be working inside. When I asked what he was doing he replied. "Making a water table." I could visualize a unicorn story coming. I admit that it turned cold enough to do some ice sculpting. But the only reference I have for a water table is the ground water level relative the to the ground surface - that is how far down beneath the surface is there water hanging around in the pores and fractures. But Andy has not been one to deal in unicorns so I waited for further explanation but it was cold out there and all I remember was something about a skirt board and this bent aluminum needing to tuck in behind the window. The point of this is to keep water outside the building and not creeping in from under the windows. If I get smarter about this I will add the info to a later post. At any rate, making a water table seems to me like it might be better done on some sunny afternoon rather than a winter evening. Fortunately Andy is a rather hearty soul who is willing and able to work out in the weather.

Rocking the Ceiling -
The area of exposed trusses is greatly diminished. Sam, Markus and Dan work from the platform on the mobile forklift to hang one of the few remaining sheets. The hope was to have the last of the ceiling rocked by the end of Thursday evening.
While one crew did the hanging using only the minimum number of screws, Tom and Joe were flying around in the quidditch machine filling in the remaining area with the requisite number of additional screws.

Joe also operated the mobile forklift. When I inquired about his forklift operator training he pointed to the patch on his jacket that read US Air Force. Joe is earning his living these days as a computer programmer but he is using his previous military training, as a fork lift operator, to build the church.

 It will be good to get the high altitude work done. The gasoline and diesel engines do not make good air fresheners. A strip along the peak of the sanctuary ceiling has been left uncovered to allow the ridge vent in the roof to serve as a chimney to carry the exhaust out of the building but the air does get a little thick at times.

Inspectors - 
I have commented already about the mechanical rooms tucked up in the trusses being possibly used at Brent's private retreat. Thursday evening he brought  several family members to

inspect the space. Shown at left is the inspection team assembled in the kitchen area.

Ascending the ladder.



















Looking out at ceiling level.


No inspection report had been received by the time of this posting.