Wednesday, 8 April 2015

Excavation continues

Following the Easter weekend (no work done) and due to some melting from the recent snow we lost a day during muddy conditions, but our excavator was back today loading and hauling dirt. He had stockpiled and prepped enough such that loading could be done just by a skid steer.  This is another advantage of frost free conditions (soft material allows some excavation to be done efficiently via skid steer).  Dumping had been pre arranged at another jobsite fairly closeby, saving a long and wasteful (costly) haul to the landfill.  Tomorrow the wall shoring job begins, this will form the basis of our next blog post.  While we don't view the shoring as necessary on this job, we are obliged to do so anyway to keep the government at bay.  Our post will detail the techniques we have used to attempt to cut cost on the job while still remaining in compliance with our obligations.  Our homemade shoring job will hopefully work out and form the basis of a significant cost reduction to the excavation job vs. using the conventional technique of shotcrete (i.e. the quick and easy way to outsource the job fully and absorb the cost of a $12,000 bill).

just the skid steer and gravel truck on site today.  One operator running both pieces of equipment means  our excavation company incurs less cost

The skid steer can fill the capacity of the truck in just a few minutes longer than the  full size track hoe, but at much lower operating cost

Our building footprint dwarfs the 60 year old neighbour.  This is one of the consequences of rebuilding Calgary from the inside out.  Three new houses will have to take up more space than a quaint cottage footprint.  In a few years (if the economy is good) we expect most of the remaining houses on the block to be removed.




Sunday, 5 April 2015

Name change - Rebuild Calgary

Our old blogger name was building Killarney.  I had planned just to use the blog for the duration of the project to document some construction photos and share it with my friends and associates. The name worked well and the blog proved useful to various parties.  However, our new site is one community to the east of killarney, so the name is now out of date. I selected rebuild Calgary as a new name as this is more generic yet still a specific and appropriate to my operation. I'd like to continue with the same sort of blog posts and possibly some more general commentary on inner city development in Calgary. Stay tuned for lots of posts over the next few months on our threeplex project.

Saturday, 4 April 2015

Schedule management - at the office and on the jobsite

Numerous techniques are available for project managers to manage the job.  While they differ in cost and capability, we think any system is better than no system.  We once were involved with a builder that printed schedules on excel spreadsheets before the job started. There was the expectation the job would follow the printed sheet from beginning to end without deviation.  We felt this was an unrealistic expectation and should have been improved.  Any changes would be a nightmare to manage as the spreadsheet would have to be modified, reprinted, and put back in the schedule binder.  Needless to say this system was awful, and hardly an improvement over having the entire schedule managed inside the brain of the increasingly haggard and burnt out site superintendent.  Now that we run our own jobs, we won't be subject to such as flawed schedule system.

Our townhouse projects can get increasingly unmanageable and disorganized leading to painful mistakes and additional cost if tasks are tackled out of order.  For this reason, and for maintenance of our overall sanity, we use a schedule tool to manage progress and keep everyone on track.  We like to use the Gantt view, and we link dependencies between related tasks such that changing the date of one job will change the schedule for the remaining linked jobs below it. Here is a look at the current schedule system that we use at our home office.

This is the desktop version of our operating schedule
Thanks to the adoption of cell phones, we can shrink this large schedule down to a manageable format to view from the site, and share it with our contractors.  The willingness of our contractors to actually use the application for the schedule hasn't been as smooth as we would like, but we are working on increased adoption of the schedule.  This is a view of the same schedule on our phone

Viewed on the cellphone screen, the schedule is easily navigated

Client use of the schedule will also be possible. Had we pre-sold a unit of our project, we could share the schedule with the buyer, or make another schedule to ensure their changes and selection date deadlines are viewable, in real time.  Hopefully as the project progresses we can find a buyer willing to work with this tool as we think it would lead to greater organization and accountability of  everyone involved to stay on track.

Since the construction season in this part of Canada is compressed due to our winter and the erratic weather in our spring, it is critical to get certain jobs done in the warm weather.  Stucco, concrete flatwork, landscaping and garage building come to mind as some of the most critical to get done before the end of October. While any job can be done in the winter, heating, hoarding and extra labour involved to work when it is cold is very costly.  The consequences of poorly scheduling a job can be huge if the warm season ends, and outdoor work is not done.

Friday, 3 April 2015

Excavation underway

With survey work complete site excavation is now well underway.  Once footing depth was reached, we were able to arrange a site visit by the geotechnical engineer.  His inspection of the soil horizon led to the conclusion that the silty clay layer at depth was more than adequate for the wood shoring design he had submitted to the city at the building permit stage.  Our original shoring plan was overly conservative so we are adjusting it to account for actual conditions observed.  Our initial fears of a $12,000 shotcrete (a spray on concrete used to stabilize a cut slope) shoring job are now alleviated in favour of a much more economical wood post style system.  Given the soil conditions at site, a collapse appears less likely than at many sites around the city where no preventative shoring system has been deployed.  We will provide an update once actual shoring begins.

the changes in soil are investigated as the cut has reached the final elevation of the basement footing.  The bottommost layer is a 'silty clay' thus a good base not just for the shoring piles but also for our house

The machine is ready to begin excavating again following the geotechnical engineer's visit

At the end of day the basement is approximately half dugout.  With the easter long weekend now underway work will likely slow

Tuesday, 24 March 2015

Building permit issued

The building permit for our Richmond location in SW Calgary has been issued.  This completes a lengthy and costly permitting process, that, start to finish, took over one year.  The building permit component was much quicker than the development permit component, as we were fortunate enough to be assigned to a plans examiner that offers quick turn-around on most items.

The outcome of the building review was as follows:

a) requirement to install shoring to protect the sides of the excavation hole from collapse.  The final additional cost of complying with this request will be between $10-20k, depending on how the soil investigations go and our install technique.  The actual merit of this work is debatable, on our last site we had zero issues with soil stability.  On the site previous, in an area renowned for poor soil conditions, we had no issues with soil stability, but we did have to install some foundation protection at a cost of less than $10k.  In my view, that was a total loss of $10k of construction budget.

b) requirement to install metal truss tails and non combustible truss details on side yard.  We are not yet sure the cost to comply with this item, as it largely depends on how long it takes the framers to work on it.  We expect, like any change involving new and uncommonly used material, this will end up costing 'a couple thousand'.

c) garage wall fire details such as non wood construction on the side yard wall and extra fire protection for the wall facing the building.  The incremental materials here are likely to add up to another 'couple thousand' including the labour for installation.  We are pretty sure our stucco crew will charge us a few extra dollars for stucco preparation, as they dislike working on metal studded walls as well.

Overall it appears we escaped the permitting process with our plans and vision for the site intact, and that is a major victory.  Permission to build the size and arrangement of our upscale units on the site is what makes the project economically possible and able to absorb the high cost of meeting all of the City requirements for engineering, storm and sewer management, and fire protection.  By the time we get to the framing of the roof of the house and garage, we will have had to sink an additional unplanned $20k into the project however....

This site use is approved without change at the BP stage

City permit is granted so construction can begin

Sunday, 15 March 2015

Kitchen design


The importance of kitchen design can't be overstated.  The kitchen is the most expensive room in the house and it makes a major impact on the decision of any buyer.  At our townhouse project, we understand the expectation of our buyer is extremely high.  In fact, the expectation is often higher than the budget can allow.  Regardless, we believe our upcoming project will deliver a stunningly stylish yet practical design.  In this instance, we think our buyer expectation may actually be exceeded. Here are some concepts and materials involved in the kitchen based on our nearly final draft.


The concept involves a floor-ceiling height component adjacent to a row of vertically opening upper cabinets (yes this is some of the nicest cabinetry hardware available in modern kitchen design today)
This plan view provides an exceptional look at how the kitchen will function - note the wrap around seating at the island instead of a more conventional four across bar arrangement.  We find this much nicer for entertaining

The palette here is modern, luxurious and warm.  Countertop - background, upper cabinet (white), floor (brown),  wood grain cabinetry (grey)

Why does it cost so much?


We often encounter questions related to the cost to build an inner city house, the construction cost per sq. ft, or  other similar inquiries.  The reality of building in the inner city in Calgary right now is that new homes are a relatively poor value versus other jurisdictions (particularly across the border in the USA); to smaller cities in Canada; to the rents possible to achieve on the finished properties; and in terms of the likely allocation of wages of the buyers to housing.  Why is this?

The largest reason is the increasing proportion of the cost of a new build that is allocated to non-construction related cost, not including land.  The high cost of building in Calgary are explained mainly by the 'system' that builders must operate under, and have no cost control over.  Keep in the mind the builders do not control much of the process except their own internal company costs such as wages and use of capital.  For all else they are at the mercy of the labour and wholesale supplier market.

Many of the non-construction costs are linked to the municipal government, the primary regulator.  While it is easy to 'blame city hall' for all sins against small business, Calgary is notorious for planning bureaucracy, delays and costly processes to overcome just to get a new project development application approved.  Despite some efforts at cutting red tape through a Mayors Office program, little to no benefit has reached the level of an individual project applicant.  Instead, the city authority, with scarce knowledge or understanding of the building industry simply adds process and associated fees to deal with any issue it deems necessary for regulation.  The provincial authority also has a role here and it has a similar approach to layer on additional process that it creates and administers, and uses to collect revenue.

In our three years of operating in the inner city, we have already experienced considerable cost and process creep at city hall related to builder requirements and fees.  It is safe to estimate that just since we have started building small condos in calgary that an additional few thousand dollars of fees per unit is now layered on to already expensive new homes.  The effort needed to comply with increasingly complex and burdensome process must be internalized by the builder in the form of lost time, and this can be hard to quantify.  These building fees are of course, at odds with providing affordable housing and contradict policy at the highest political level at city hall to increase urban density, reduce the cost of servicing new communities, enhance the green credibility of the city, make transit more viable, create healthier walkable communities..., etc.  It often appears that despite the policy of the city to promote inner city development, the reality is the development is just seen as a way to generate fees for the many 'parasitic' elements that stand between the builder and a saleable product.  The bottom line here is the City claims it wants multifamily infill development, yet it acts in such a manner to handicap the builders by putting many costly and frustrating roadblocks in the way of such development.

Another broad category of fees and cost is what we would classify as 'white collar fees'.  These fees are significant and enjoyed by the type of professionals that are now increasingly needed to satisfy the regulators and the consistently scope-creeping complexity of regulations.  Unlike the contractors,  such as a roofer, where you would expect to pay a given amount of dollars for an amount of shingling, the 'white collar' fees are less linked to the effort or value of the service, and more linked to a pay scale or formula where a significant minimum fee is needed to retain the professional.  Often these fees don't relate directly to building but are more peripheral to the actual construction, yet just as necessary.  These fees are also the least likely to be negotiable  or avoidable since the professional doing the work has a guild, body, profession, certification, or some other essential service or speciality that has no work around.  In Calgary, these providers enjoy their essential status and charge accordingly, particularly for specialized 'paperwork.'  In the case of engineers, it is a very inefficient process as hiring of three or four different firms means unique fee structures and the overhead, office space, administration and high wages for the each of the professionals.  These fees tend to be good only for a single use, and must be levied for each project as if it is a distinctly different job.  This means the foundation engineering, for example, (picking on the structural engineer here), must be done for each job, even if the foundation is identical between two, or two hundred foundations, or even two identical foundations built next door to each other at the same time.  As essential as these fees may be, they offer little to the end user of the home except added cost.  Due to the policy of the city to avoid any liability for construction mistakes it inspects and approves, a large part of the fee going to the professional class is simply to compensate them for the risk they accept by 'signing off' on the paperwork.  This can also lead to overbuilding, since the entity accepting some share of the risk in exchange for a stamp tends to 'over spec' its design work.  It may do this to create a larger margin of safety should 'something go wrong', because the designers don't bear the cost of executing the additional site work, there is little incentive for 'leaner' specification.  Picking again on the structural engineer, it is far easier to add a few thousand dollars of rebar to a concrete wall than it is to carefully consider if that additional support work is truly needed, or if twenty years ago that rebar pattern would have been deemed 'overkill', and not warranted.  

Below is a list of some of the fees needed to be paid well in advance of starting a project, both recurring, and one time costs.  Bear in mind that these costs often don't relate to actual building of the project, they are mainly fees.  These fees go to groups and individuals that have been able to insert themselves into the industry for the primary purpose of extracting money from the builders, and they add up to a significant amount.  The fees are often paid well before the project begins, so this adds upfront cost to the builder and reduces the construction budget, likely necessitation the builder take on more project financing funds.  Here is a brief list:

name of fee              amount       notes
water shutoff           $4250         this fee is refundable if certain conditions are met at project finish
asbestos sample       $500           test of old house for asbestos, hope there is none, or get ready to pay!
demo permit            $                 time consuming process with a least six site visits,      
                                                    inspections and meetings with the various authorities and utilities
warranty security    $10,000      cash or bond paid to warranty company
warranty fee            $1500         per unit fee to warranty company
development app     $1000         city fee, no guarantee here your project will be viable or approved    
                                                   and may take a year or more to get the permit
design fee                $15,000      this cost varies depending on the size and complexity of the building
building permit        $12,000     expect to pay a large sum for city inspectors to conduct a very small 
                                                   amount of inspections of the site and to accept little to no liability for
                                                    any situation where you might  expect the city to have responsibility 
road rehabilitation    $1900        a new fee so the city can increase its road repair budget to account for 
                                                   damage during sewer install
property tax              $2500       this varies, but expect to pay a year or two of tax because the permits 
                                                   take so long to acquire on inner city property                                                   
engineering               varies        Structural, civil, geotechnical and soon to be building envelope   
                                                   engineer needed.  Expect this to add up to about $10,000 or more
storm water fee        $1500        cost here is per meter of frontage, such as $50/m of street frontage                                                  
dssp fee                    $1500        this cost is for the city to review civil engineering/storm water plans
legal                         $1-6000     this cost varies based on sales fees plus many other possible legal
                                                   services such as sales documents and bank requirements
insurance                 $7000+       Contractor general liability and course of construction per year or
                                                    project.
condo plan               $6000         Survey company does the project work and the condo registry work

and finally, the two 'big ones'

GST                          $25k per    This federal tax on new housing has never been indexed to inflation.
Commissions             'large'        The current industry standard pay for realtors is well out of line with
                                                    the work involved in selling houses. This may be the fee builders
                                                    enjoy paying least.

Future fee growth are likely related to fire code, site safety and hiring an additional 'consultant' to navigate the large body of pre-existing regulations plus any changes that are brought in by the regulators.  To coordinate the 3-4 engineers and the design team, navigate the bylaw and code changes, manage document versions and revisions with the design team, and to deal unique elements of a new project such as community engagement and appeals is a formidable task. This work, and the many strategic decisions related to launching a project is currently within the realm of responsibility of the builder. In the foreseeable future it is quite likely the task will become too time consuming or overly technical for the builder to tackle 'in house.'    Keep in mind the builder has to supervise the daily operations at the job site and manage the business, so time spent dealing with process is time spent away from building a quality house.  The reality is the builder must already invest a year or more to get the permits for building a small condo (if all goes well), and this timeline is only getting longer, along with the builders' cost of tied up capital in the land.

Particularly challenging is the relationship between warranty requirement and fire code.  For example the requirement for fire resistance creates a scenario where attic mold becomes a more likely outcome due to inadequate ventilation, given the material and technique commonly applied today.  Warranty providers will likely require enhanced attic ventilation and this will most likely contradict the fire code that significantly reduces attic ventilation options.  Caught between the inflexible code/bureaucracy and warranty provider criteria, the builder may be left to hire more professionals and throw more money at the problem until a resolution can be negotiated.  
                                                
One final note, the city can justify any fee in deems necessary, since it controls the budget for programs like road building and planning, and its internal cost for salaries, pensions, benefits, etc, is massive.  What the city neglects to mention is how much its tax base permanently increases from year to year due to inner city building.  The city often enjoys a factor four increase in tax base upon completion of a project.  This means a $2500 property is now a $10,000 annual revenue source, permanently, but the cost to the city of inner city building are only absorbed once (road repair as an example).  Take any fourplex project in an inner city location.  The number of occupants of the property increase from one or two to eight or nine on existing serviced infrastructure, and an extra $7500 is collected each year, escalating with tax increase and inflation of property value.  So while the city pleads poverty and creates a new fee, one thousand inner city homes may be built every single year and the tax base expands accordingly.  While inner city infrastructure is old and can decay, at leas the schools, bus routes, police stations and roads are already available, unlike in greenfield development in the far reaches of Calgary suburban sprawl.  

Simply put, based on our experience building inner city, expect higher building cost every year in Calgary, regardless of the market or economy.  With the increasing 'professionalization' of building in Calgary, it would appear that less builders may even be capable of entering the inner city market (of course we would see this as potential benefit of these fees!).  When selecting a builder, ensure that individual is experienced in dealing with the myriad of fees and requirements as it can't simply be outsourced effectively, unless of course you are willing to pay that monumental fee to have qualified people take care of it for you (we don't, this is simply too cost prohibitive to expect to outsource all the preliminary work).

It would be an interesting exercise to estimate how many hours/cost we have already absorbed on this project prior to starting real site work beyond the demolition phase.  At this point, dollar value paid in fees is approaching $50k on the preliminary work, plus perhaps 300 'staff hours'.  This doesn't include the stressful moments where the project was nearly killed due to community opposition at the design stage, and a full revision would have been needed (luckily we avoided that nightmare, nor were we subject to an appeal).  Fortunately those staff hours are 'free', we do them for our buyers and out of necessity to get the project going.  Another side benefit, our company owner charges the lowest  hourly fee of any of the professionals in the process (current wage, 0$/hr all fees/parking/overhead/insurance included).   

Demolition - threeplex site

Upon completion of the lengthy regulatory process that allows for inner-city demolition, we ordered the safety fencing and started with the demolition of the awful old house that was slowly rotting on site.  By the time we took ownership of the property, it had already been vacant for a year, but was in significant disrepair for many years previous.  In fact, we later discovered after chatting with a long time neighbour that the water had been cut off during the last owners' occupancy, and he had been using the 'honey bucket' system, with customized system of disposal of the waste (stockpiled in the basement).  Even after two years of composting in the cellar, it made a nasty mess when being demolished and some of the sticky material found its way into the cat-tracks of Jason's loader, giving him ample justification to complain about the odour.   Otherwise the demo proceeded nicely in almost summer like weather of early March.

The neighbours we met seemed pleased to see the house go, including an original occupant across the street who has lived there since the 50's, and purchased her house for $12,000 (oddly enough the cost of doing the demolition in 2015 equals the cost of purchasing a new house in 1950 in Calgary).

The hideous bathroom - kitchen was possibly worse