Garage Construction Project

Initial Build

13 min read

🎉 INITIAL BUILD COMPLETE — January 21, 2026

Hershberger’s construction contract complete. All contracted work finished:

  • ✅ 24’×40’×10’ stick-built garage shell with loft
  • ✅ Metal roof, vinyl siding, Versetta Ledgestone accents
  • ✅ All 8 windows and entry door installed
  • ✅ Three 8’×9’ insulated garage doors with Genie 6170H-B openers (battery backup)
  • ⏳ Dumpster cleanup pending — Hershberger’s returning soon

Reference: Jan 21 Photos | Timeline

Contract status (as of 2025-10-25)

  • Total: $68,400 with Hershberger’s Amish Builders for the full 24’x40’x10’ stick-built garage shell.
  • Payments: 20,000 paid 2025-10-25 (contract signing); 21,800 at completion.
  • Scope highlights: 8”x42” rat wall, 4” slab over 2” Creatherm with 1/2” PEX radiant loops (pressure test), embedded sleeves for sewer/water/electric/fiber, Burnished Slate metal roof (snow guard front), Dutch Lap Herringbone siding, white aluminum soffit/fascia, Genie 6170 jackshaft openers on (2) 9’x8’ insulated OHDs, Versetta Ledgestone (Plum Creek) between doors, enclosed stair to loft with OSB floor/wainscot and mechanical closet.
  • Excavation/dig slated to start Thursday 2025-10-16; verify lift bay PEX-free pads before pour (not yet in contract language).
  • See also: Products Used for complete product specifications and links

Open coordination items

  • Ask about pouring small slab for mini-split heat pump (still needed outside contract scope).
  • Confirm insurance carrier notified prior to dig.
  • Coordinate utility trenching budget (still estimate 10k); consider tackling basement rear wall repair while yard is open.
  • Confirm driveway allowance remains 15k placeholder outside current contract.

Related: Utilities & Conduits

Sequencing Notes

  • Pour radiant slab and install subslab rigid insulation before wall framing where possible.
  • Coordinate PEX layout photos/sketches prior to pour; keep lift column pads PEX-free.

Construction Progress (Updated 2025-10-30)

  • ✓ Excavation completed (Oct 20)
  • ✓ Foundation forms and rat wall perimeter completed (Oct 20)
  • ✓ 2” Creatherm under-slab insulation installed - 110 sheets 9x4 (Oct 22)
  • ✓ PEX radiant heating loops installed with manifold (Oct 22)
  • ✓ Initial utility sleeves positioned (water, sewer, electric, fiber, gas) (Oct 22)
  • ✓ Pressure testing radiant system at 60-70 PSI (Oct 22)
  • ✓ City inspection of PEX in-floor heating - PASSED (Oct 23)
  • ✓ Mechanical permit inspection requirement satisfied (Oct 23)
  • ✓ Notified Marcus (contractor) of inspection approval (Oct 23)
  • ✓ Delivered $20,000 payment to Hershbergers per contract (Oct 25)
  • ✓ Confirmed with Marcus that Terry (cement contractor) will install utility conduits before pouring concrete (Oct 25)
  • ✓ Exterior perimeter insulation installed (Oct 29)
  • ✓ Fiberglass rebar grid installation completed (Oct 29)
  • ✓ All utility conduits installed through slab (Oct 30):
    • Water line (2” PVC conduit)
    • Sewer line (3” PVC conduit)
    • Natural gas line (2” PVC conduit)
    • Electric service (2” PVC conduit)
    • Low voltage/data (2” PVC conduit for fiber optic, coax, network)
  • ✓ Concrete foundation pour completed (Oct 30)
  • ✓ Initial concrete finishing work completed (Oct 30)
  • ✓ ½” PEX conduit for future slab sensor installed (blue PEX tube routed through EZ loop with in-floor heating lines - visible in photos)
  • ✓ Control joint saw cuts completed (Oct 31)
  • ✓ Wooden perimeter forms removed (Oct 31)
  • ✓ Perimeter backfilled with dirt (Oct 31)
  • ✓ Radiant heating system pressure testing completed and passed (Oct 31)
  • ✓ Foundation finishing complete (Oct 31)
  • ✓ Temporary diesel air heaters tested for backup and pre-insulation heat (Nov 1)
  • ✓ Family initials added to slab edge as commemorative milestone (Nov 1)
  • ✓ Final site grading completed by concrete crew (Nov 3)
  • ✓ Concrete cure period complete (Nov 18 - 19 days since pour)
  • ✓ Roof trusses delivered by Letherer Truss Inc. - Job #123907 (Nov 18):
    • 41 engineered trusses (5,359 lbs total)
    • 4x LVL beams (1¾” x 11⅞” 2.0E)
    • 12x structural hardware pieces (hangers/connectors)
    • Complete engineering documentation package received
    • T.P.I. bracing instructions included
    • Trusses staged on cured slab
  • ✓ Framing kickoff (Dec 3): First-floor walls stood with LVL headers, OSB sheathing staged, joist hangers installed
  • ✓ Roof trusses set (Dec 4): All roof trusses installed with Gehl RT215 track loader assist
  • ✓ Dormer framing (Dec 4): Dormer wall panels framed and stood on roof structure
  • ✓ Loft floor system (Dec 4): Joists installed with Simpson hangers and blocking; Titebond construction adhesive applied (glue-and-screw method)
  • ✓ Roof sheathing complete (Dec 8): Main roof planes fully sheathed; sheathing lifted to dormer level via skid steer with forks
  • ✓ Weatherproofing applied (Dec 8): Synthetic underlayment installed on main roof and dormer roofs; Tyvek house wrap on dormer faces; starter course and taped seams at eaves/gables
  • ✓ Metal roof installation in progress (Dec 11): Standing-seam charcoal panels installed on main roof planes and dormer returns; crew working with ladders and roof jacks; panels nearly complete by end of day; ridge vent and remaining trim pending
  • ✓ Windows delivered (Dec 11): 8 windows from ABC Supply (Order #580876):
    • 7x Premium Designer NC DH 35½” × 35½” (fiberglass full screen, double lock)
    • 1x Egress unit 39½” × 59½” (Premium Designer NC DH)
  • ✓ Exterior door delivered (Dec 11): Half-lite exterior door with grids staged for installation
  • ✓ Stone veneer panels delivered (Dec 11): Versetta Ledgestone (Plum Creek) decorative stone panels for base/wainscot between garage doors
  • ✓ Siding prep materials delivered (Dec 11): Tyvek HomeWrap, Dupont flashing tape, coil stock/trim, fasteners all staged inside
  • ✓ EXTERIOR SHELL COMPLETE (Dec 12): Metal roof fully installed on main roof and dormers; all 8 windows installed (7x 35½”×35½” + 1x egress 39½”×59½”); main entry door (half-lite) set at right bay; vented soffits installed along front eave; Tyvek HomeWrap fully covering all wall surfaces. Building is now weathertight and ready for siding installation. See Dec 12 Photos (10 photos).
  • ✓ Christmas break begins (Dec 16): Called Marcus; crew taking break until December 29, 2025 to finish exterior siding work. Building is weathertight so no urgency. See 2025-12-16 - Call - Marcus Christmas Break Schedule.
  • ✓ Electrical trenching attempted (Dec 18): SLS Electric arrived to begin underground power line. Wire successfully buried along house foundation (thawed ground from building heat). Open area has ~10” frozen ground — largest backhoe made only 3 feet in 30 minutes. Trenching postponed to spring 2026. Wire spool stored at terminus. See Dec 18 Photos (6 photos).
  • ✓ Loft interior documentation (Dec 20): Site visit during Christmas break to document loft condition. Photos captured: loft floor, dormer windows, knee walls, stair opening. Loft Flooring Plan created with LVP research. See Dec 20 Photos (8 photos).
  • ✓ Front siding complete & door openings modified (Jan 13): Front wall siding and Versetta Ledgestone installed; garage door openings modified from 7’ to 8’ height to match correctly-ordered doors; snow stops and sewer vent installed. See Jan 13 Photos (3 photos).
  • ✓ Electrical ground thawing (Jan 15): SLS Electric deployed passive curing blankets to thaw frozen ground for trench completion; 2-4 week estimate. See Jan 15 Photos (1 photo).
  • ✓ 🎉 GARAGE DOORS INSTALLED — INITIAL BUILD COMPLETE (Jan 21): All three 8’×9’ insulated white garage doors with window panels installed; three Genie 6170H-B Professional Line openers with battery backup installed and tested (doors operational despite no grid power). Hershberger’s construction contract complete — only dumpster cleanup remaining. See Jan 21 Photos (8 photos).
  • ⧖ Next: Dumpster cleanup (Hershberger’s returning soon), electrical service completion (ground thawing in progress)

Video Documentation

See Construction Videos for time-lapse videos of the construction process.

Available time-lapses:

  • Foundation Dig & Site Prep (Oct 20, 2025)
  • Creatherm & PEX Installation (Oct 22, 2025)

Photo Documentation (Oct 22, 2025)

Drone Aerial Photography (Oct 25, 2025)

Note: Blue PEX line visible in drone photos is the slab temperature sensor conduit installed by owner (see Decisions - Slab Sensor Conduit).

Drone Aerial Photography - Exterior Insulation & Rebar (Oct 29, 2025)

Photo Documentation - Concrete Pour (Oct 30, 2025)

Video Documentation:

Photo Documentation - Post-Pour Finishing (Oct 31, 2025)

Photo Documentation - Final Site Grading (Nov 3, 2025)

Photo Documentation - Truss Delivery (Nov 18, 2025)

Engineering Documents:

  • Complete Truss Engineering Drawings (8-page packet)
    • Layout drawing with truss placement (24’ x 40’)
    • Detailed engineering for all truss types (PLY-1, PLY-2, mono, girders)
    • Load calculations and bearing reactions
    • Connection specifications
  • Loading Ticket & Inventory (Job #123907)
    • 41 WoodTruss components (13 attic, 4 girders, 4 special, 10 common, 4 mono)
    • Total weight: 5,359 lbs
    • Hardware inventory (HGUS48, MUS26, LUS24 connectors)
    • T.P.I. bracing instructions included

Photo Documentation - Framing Kickoff (Dec 3, 2025)

Weather: Overcast, 18-24°F. Snow cover on site from overnight accumulation; cold but workable conditions for framing kickoff.

Photo Documentation - Roof Trusses & Dormer Framing (Dec 4, 2025)

Weather: Overcast clearing to partly sunny, then clear by afternoon. Temperature range 10-21°F, NW winds 5-10 mph. Snow cover on site from Dec 1-3 storms; ideal visibility for photography as skies cleared.

Morning - Equipment & Truss Setting:

Midday - Roof Trusses Complete:

Afternoon - Dormer & Loft Framing:

Photo Documentation - Roof Sheathing & Weatherproofing (Dec 8, 2025)

Weather: Clear winter sun to partly cloudy, 20-26°F; full snow cover on site; excellent conditions for roofing work.

Photo Documentation - Metal Roof & Material Delivery (Dec 11, 2025)

Weather: Cloudy, 26-30°F; cold winter afternoon with snow cover; good conditions for roofing work.

Roofing Progress:

Material Deliveries Staged Inside:

Roofing Materials:

Photo Documentation - Exterior Shell Complete (Dec 12, 2025)

Weather: Partly cloudy to overcast, 30°F (feels like 23°F); snow cover on ground; cold but clear conditions for final exterior work.

Major Milestone: Building is now weathertight — metal roof complete, all windows and door installed, Tyvek wrapped.

Exterior Views:

Photo Documentation - Electrical Trenching Attempt (Dec 18, 2025)

Weather: Cloudy, 50°F — warm day but deep ground frost persisted in open areas (~10” frozen).

Work Attempted: SLS Electric arrived to begin underground electrical trenching from house to garage.

What Was Completed:

  • Wire buried along house foundation (ground thawed from building heat transfer)
  • ~6-8 ft of wire left above ground at house meter for panel connection

What Was Delayed:

Photo Documentation - Loft Interior (Dec 20, 2025)

Weather: Clear to partly cloudy, 28-35°F; good conditions for site documentation.

Purpose: Site visit during Christmas break to document current loft interior condition and support Loft Flooring Plan research.

Related: Loft Flooring Plan — LVP flooring research for home theater and apartment-ready finish

Photo Documentation - Front Siding Complete & Door Opening Modifications (Jan 13, 2026)

Weather: Overcast, 30s°F. Cold winter afternoon with snow cover.

Work Completed:

Photo Documentation - 🎉 Garage Door Installation Complete (Jan 21, 2026)

Weather: Cloudy, 30°F (feels like 21°F with wind chill). Snow cover on ground.

Major Milestone — INITIAL BUILD COMPLETE:

  • All three 8’×9’ insulated white garage doors with window panels installed
  • Three Genie 6170H-B Professional Line openers installed (with battery backup)
  • Doors tested and operational using battery backup (no grid power yet)
  • Hershberger’s construction contract complete

Installation Progress (Morning):

Completed Installation (Afternoon):

Pending: Hershberger’s returning with dumpster for scrap pile cleanup

Graph View

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