Our Philippine House Project: Learn from our mistakes

Our Philippine Dwelling Challenge: Master from our faults

Our most important Philippine property developing blunders.  We really do not want to current our project as a paragon of perfection, so in this article we present what went improper during our Philippine dwelling development job and why, in the hope that others can learn from our errors. Most of these images also show up in other sections of the web page.

No room for concrete in this post

No place for concrete in this column

This picture reveals the top rated of a 15cm column making an attempt to accommodate eight 16mm rebar from the roof beams and four 12mm rebar from the column. There is basically no home for concrete.  I ended up welding this tangle of rebar in the hope of attaining some strength from the rebar even if the concrete was nominal.  The put up ought to have been sized by the engineers to be substantial more than enough to properly accommodate the rebar.  I told the engineer I required to demolish this column.  The engineer talked me out of it, nevertheless it should really have been demolished and changed with a larger sized column.

Demolishing just completed work

Demolishing just finished operate

The engineers left out a assist column essential to guidance a beam which they also still left out.  One of the workers looked at the options and saw the challenge early on.  The engineers still left out assist for just one close of a main roof truss.  We could not make in that defect, so we had to demolish a just constructed wall and wall footer (shown above) to make it possible for us to pour a footer for the added column.  The concrete in the demolished footer was satisfyingly strong and resistant to demolition.

A column error corrected.

A column mistake corrected.

Personnel laid block ideal up to rebar cage for columns, leaving inadequate room for the concrete portion of the column.  The block (which was crammed with concrete) had to be lower back again throughout the composition — a massive waste of time.

Splicing error in roof beam rebar

Splicing mistake in roof beam rebar

This demonstrates a rebar cage for the roof beam.  The splicing was done incorrectly.  No splicing prepare was included with our drawings so the employees followed their very own ideas which proved to be mistaken.  See /our-philippine-residence-undertaking-rebar-splicing/ for all the gory facts.  This distinct rebar cage was redone three instances ahead of it was performed effectively.  I really do not blame the staff.  In our feeling, a splicing plan should really have been furnished by the engineers.

bad_column

This column was demolished and replaced.   The concrete was way too stony and dry, possibly because I went much too considerably in insisting that  not also considerably drinking water be included to the concrete.  While pretty much anything one reads about concrete warn that drinking water is the enemy of  concrete strength, as I realized, concrete must be wetter in very hot situations.  See the Portland Cement Association’s “Hot Weather conditions Concreting” at http://www.cement.org/tech/essentials_scorching_weather.asp Lots of of the strategies can only provoke a smile in the provincial Philippine problem, these as making use of liquid nitrogen cooled aggregates or chilly drinking water in mixing concrete, the ideas about the great importance of wetting types and utilizing a to some degree wetter mix make perception.  We also continue to keep concrete beams damp for a handful of times.  It will take concrete 30 days to cure.

The effects of over vibration at the bottom of a column pour.

The effects of about vibration at the base of a column pour.

This defect was induced by my crew more than-utilizing the concrete vibrator.  The h2o and concrete slurry ran out of the base of the kind, leaving guiding the combination.  The crew tried using to conceal this from me by covering it with mortar.  I raked it out right away.

Window openings were all made 10cm too small and had to be chiseled

8 of the window openings were being made 10cm too small and had to be chiseled so the home windows would fit.

The welders have been operating at generating the home windows at the exact time the window openings had been remaining created.  Not terrific conversation or oversight — such as my individual!

One step forward, two steps back

Just one phase ahead, two methods again

This is the aftermath of just one of the more discouraging days.  The options call for 12mm vertical rebar in the inside hollow block partition partitions.  Since our partitions are more than 10 toes large, this is particularly vital.  By the time I noticed (the foreman in no way seen) that the crew experienced switched from utilizing 12mm bars to the weaker 10mm bars, several courses of block had been laid.  I mulled this over and determined that I was not cozy with the use of the 10mm bar and had all the get the job done made up of it demolished.  This amounted to a few or four programs of block during the interior.  I could not get a satisfactory explanation of why the crew switched from 12mm to 10mm.  So we are having to pay for the original labor and materials , the demolition and new labor, block, cement and aggregate.  If I was not on-web site, I never ever would have acknowledged about this challenge.

It was astounding and a little bit depressing to see how uncomplicated it is to demolish these partitions with a hammer.  The 4″ block is weak, the mortar is weak.  If I was ever to make a different dwelling, I would use 6 inch block completely.  Don’t rely on 4″ partitions for shear toughness to resist lateral forces in an earthquake.

Column at edge of footer

Column at edge of footer

This shows a column rebar cage way off the center of the footer. Imagine sitting on the edge of your chair.  It’s tippy.  When this column is loaded, the tendency is for the footer to sag or suggestion.  The column was poured off middle because the crew did not want to enlarge the footer excavation so that the column could be centered on the footer.  This thick concrete footer experienced to be broken up and repoured.

Clear span trusses

Apparent span trusses

The engineers specified roof trusses which could span the house with out supports — but why?   A simpler truss method using inside partitions as mid-span assistance could have price much less.

Rebar Chair

Our staff did not recognize the need to preserve footer rebar positioned perfectly up in the footer concrete instead than laying the rebar on the ground and pouring the footer over it.  We did not have any of the rebar chairs demonstrated over so we used greater stones to increase the footer rebar higher than the floor just before we poured.  Having the rebar on the ground in the base of the footer is a significant defect.

Nicely done footer and rebar cage sitting on the ground rather than raised into the concrete.

Properly completed footer and rebar cage but the footer rebar mat must be raised up so that it is in the center of the footer concrete, not laying close to the bottom.

The carport forms come off showing yet more poor work

The carport forms come off displaying still additional lousy get the job done.

How are this sort of concrete challenges repaired? We considered using epoxy but John Thede Joergensen’s strategies seem to be appropriate:

“I would use a slim plaster of high-quality sand and cement. 1:3 and soaked, slam it on layer by layer slender levels at the time.The slamming is like blowing it on, and depart the sandcorn in the slender plaster, but like its vibrated in. It usually takes time and a great masonry hand to do it, but it is the same procedure made use of when a concrete bridge is ruined by a truck, and the reinforcement is open. Then thin solid concrete is pumped and sprayed on to it layer by layer till its crafted up once more. I never know if you can get the software I think of there. I will uncover a image and hooked up in this article. The floating plaster is balanced on the blade,and with a swing slammed on the surface. Practice on a plate first. Establish it up, and allow it dry in in between until a issue where you can “cut” remains absent with the instrument. Then use a sponge to make the area smooth.”

I would use a slim plaster of high-quality sand and cement. 1:3 and soaked, slam it on layer by layer thin levels at the time.

The slamming is like blowing it on, and depart the sandcorn in the slender plaster, but like its vibrated in. It normally takes time and a very good masonry hand to do it. but it is the very same techniq employed when a concrete bridge is harmed by a truck, and the reinforcement is open. then slim powerful concrete is pumped and sprayed on to it layer by layer until its build up yet again. I dont know if you can get the software i think of there. I will uncover a image and attach right here. The floating plaster is balanced on the blade,and with a swing slammed on the floor. Practice on a plate initially. Build it up, and permit it dry inbetwen till a issue where yuo can “cut” remains absent with the software. Then use a sponge to make the surface easy.

Read through all about our Philippine Dwelling making Job at /developing-our-philippine-residence-index/