Storm Shelter build

[3Ts]

My wife and I contracted to build a house to our specs and finally found a builder that was willing to build it. It's around 2100 sqft, not especially challenging, but we're out at the limits where he normally builds. We have several unique things we wanted and as it was built we challenged him on some of the things he (meaning his subs) were doing. For example, his sub used a sanitary tee to tie 2 horizontal drain lines together (not allowed by code). There are other things y'all helped with (specifically a multi-wire branch circuit) that I ended up making him open up the wall and doing it right. The electrician was not happy with me and has not been back - of course, I told the builder I didn't want him back on my property as well. This is to let you know the house is done. One of the things y'all wanted to see was the storm room that we built. So, - -

First, We tried to use the FEMA construction drawings located here:
https://www.fema.gov/media-library-data/1418837502817-920f09bb8187ee15436712a3e82ce709/FEMA_P-320_2014-ConstructionPlans_508.pdf

found out that the builder couldn't figure them out. And had never done a storm room before.

We also selected a storm door from here:
Tornado Doors

They have a really nice door, but it is a long lead time. I told the builder that it was a long lead, but - - you guessed it! It wasn't ordered until just before it was needed.

The builder originally estimated 4 months to build, we figured 6, with 9 at the most. It took 1 year.

I have a series of pictures that I will be posting, but I have a really slow internet so it may take a few days to get them put up. So be patient, I'll get them there eventually.

 

[3Ts]

Here's the beginning of the storm room. It serves as the master closet. You're looking thru the master bath into the master closet.

Something just doesn't look right here, but I'm not sure what it is.

 

[3Ts]

I went back to the house plans. They put the door opening in the wrong spot! This is a custom design, not one of the builder's stock plans - for that matter he does not have stock plans. Every house he builds is different, so one would expect the subs to refer to the blueprints when placing walls, doors, and windows. But, there are some things we did not catch until it was to late. (Yes, we could have forced it, but did not think it was worth the conflict.) This door, however, was a big impact on what we planned to do with the closet, so we had him move the door to the correct position. You can see the new blocks added to the right side. There is supposed to be rebar in the 2 cores on each side of the door. Now there is only one core with rebar on the left and 3 cores on the right.

 

[3Ts]

Now that the wall is up. Let's take a look at it. 1st, that's a 6" knife between the motar and the block. There are a few places where you can see light thru the wall.



2nd, The cores at the top of the wall are not supposed to be filled in - there's supposed to be at least 1" to tie the different courses together. And the rebar is supposed to be bent over into the ceiling pour to tie them together. There's a minimum spec and this isn't it.



3rd, The ceiling is supposed to be 6" thick minimum. That is a 2x6 form board so the concrete is less than 5". I could understand if the concrete was at the top of the form board, but it isn't.

 

[3Ts]

Here's how they supported the ceiling while they poured the concrete. They used a 4x8 hardie panel with the wood grain up for the form. (The room is supposed to be 8'10" feet wide inside to inside of the block) turned out to be 8'2". Like I said earlier, not all the walls were put in the right place. An inch or two I understand, but 8"?

Now, the ceiling looks beautiful with the wood grain embossing. There are no cracks in it. This will come up in decisions later as well.

 

[3Ts]

View attachment 563196

Now to install the door. - - OOps! The door was damaged by a fork lift and they tried to patch it. A close up of the patch follows. This is a custom house, one would think they'd read the blue prints. The door doesn't fit the opening. The opening is to wide and the door that was ordered is for a thinner wall.

View attachment 563197

 

[3Ts]

I'm NOT accepting that!

It's a long lead time item, but back to the factory for repairs/replacement.

Finally gets back and now how to get it embedded in a concrete wall that's already up? Take out some blocks that are in the way of the anchor pins and try to squeeze concrete between the blocks and the steel frame.

 

[3Ts]

Yes, that is a finished counter top, plumbing fixtures, and cabinetry. (unprotected)

 

[Lelandwelds]

I feel your pain. My builder just stalled and made excuses and promises. Convincing promises. When he was mostly paid, he slowed the work rate until he just quit showing up and answering calls.

Make certain you have enough retain age to guarantee he finishes correctly. Or just finishes. I wish you success.

 

[Paddy]

3Ts,

Everything about this is crazy. How complex can laying concrete block to make a "box" with a poured concrete ceiling??
We have a poured concrete home, 450 cubic yards. We call it our "safe house".

ICF's make it quite easy, but I have the feeling your contractor could messed that up too!