06/03/2026
Episode 5: "First Contact" or "Lions and tigers and bears. Oh my!"
Our GC finally got finished with his current job and it was our turn. Per "THE plan" the first task was to open up the ceiling of the existing porch so we had enough space to run both return and supply air ducting. The GC's workers cut open the ceiling the width of the new planned HVAC closet to reveal the top of the exterior structural wall as well as the "original roof" of that section of the house. It was apparent the original roof (just above the ceiling of the porch) would need to get cut open to have enough clearance for the ducting. Through the original "exploratory hole" we knew there was something else above that original roof and the current "top" roof. When we started opening up the "original" roof we discovered there was another roof "structure" in between the original roof and the "top" roof. The GC said he needed to open up the whole patio ceiling width of the proposed HVAC closet out to the end of the roof. We cleared him then went back to work inside.
Shortly thereafter the GC comes in with the "you need to see this" caveat, so we went out to take a look. Apparently when the additional "wings" of the house were built, the 3 roofs for those wings all extended over the porch and the contractors that added those additions just built new roofs on top of the old ones. To make matters worse, one of the roofs was a flat asphalt and gravel roof and it appears there 10s if not 100+ lbs of gravel up there. It also appeared the "top" ceiling joists had just had tapers cut in the end and screwed into the roof/supports at the far edge of the porch. It was apparent there was probably even more evil hiding above the ceiling of the porch that wasn't just an "esthetic" problem, but was probably a structural issue that HAD to get fixed. We cleared the GC to open up the entire porch so we could get a full picture of the problem. If we had structural problems like we suspected it would need to get fixed NOW, which was bad, as "demolition" and engineering was definitely going to "bust" our original cost estimate. We HAD the funds to do what was needed, but like other followers of Dave Ramsey's school of financial thought, those funds were already assigned to a different upgrade (namely completing al the shelves in the "library" so the "Borg Cube" of books could finally disappear from the middle of the library floor.) However, seeing as how one of our "visions" had been for a "sun porch" for Leigh out there, this might be the time to accelerate that project.
After discussion between us, Leigh and I decided the "farther down the road" "sun porch" improvement was now a higher priority. With the GC already on site with workers and having to tear the porch roof up as part of the Radon mitigation (a MUST DO), the porch upgrade would be cheaper and easier to do now.
The porch "ceilingectomy" was very revealing in a not so good way. Yay verily we did have 3 roofs over the porch and there was rotten wood in up there on the "2nd" roof. The "top" roof was not appropriately tied into the beams at the outer end of the house the full length of the porch roof and there were structural trusses protruding beyond the house exterior walls over much of the porch area which would severely limit our ability to raise the ceiling of the porch. Lions and tigers were bad enough, but our final assessment was that the beams holding up the existing "roofs" had never been stressed for that. So, the whole supporting structure needed to be re-engineered and a new structural wall for the roof needed to be installed. On the good side, when we had finally cut away the two lower roofs over the new utility closet area, we had enough space to install the ducting recommended by our HVAC contractor.
While we pondered the implications of how to "restructure" the roof supports and give us clearance to raise the ceiling outside of the utility closet, our GC was able to frame up that closet and install power and condensate drains. With those two things done we gave the HVAC contractor the OK to install new return vents in the 3 wings of the house, route ducting to the closet and move the HVAC heat exchanger. It was going to be a couple days before the HVAC guys could get to our job which allowed our GC to work on the other problems of the porch. Fortunately, the weather was looking pretty mild for the next week plus and we wouldn't need the HVAC. While waiting for the HVAC guys to get there, we continued with the demolition into the exterior wall adjacent the bathroom of the original house to access power, water and sewer lines which would be needed for the wet bar, refrigerator niches and cabinets. The GC also came into the house to start sealing off the old floor air return vents leading into the slab.
A few days later the HVAC guys showed up. The split into 2 teams, one team crawled into the ceiling to locate places to cut the new return ducts and run new ducting and the second team to relocate the HVAC heat exchanger from the kitchen utility closet to the new cabinet my GC had constructed on the porch. While there always interfacing issues when moving existing equipment to a new location, the "joint" meeting I'd had with the "leads" on the GC team and HVAC team before we got started kept the problems small. The biggest disconnects appeared to be a the "finished" passage for the air returns appeared to be too small and a coolant pipe that looked like it was going to interfere with the doors. In both cases everything was built to the agreed upon size but the "fitting" and "final installation" of adjacent structure had to done separately by the different contractors. (Basically the "finished" dimensions were adequate for the finished installation but the finished dimension didn't allow you to install the other parts, so we had to pull stuff apart, finish the HVAC installation then put the pieces back in.) After 2 days, we were able to power up the HVAC and had heating and cooling again. This was a critical Radon mitigation milestone as we were no longer pulling air into the house from under the slabs but there was still an open hole in the kitchen closet floor that needed to be sealed and we still needed to install the Radon venting pipe to the existing sub-slab air return ducts. Work commenced on the porch again and we began the "reconfiguration" of the kitchen utility closet into a pantry. With the closet empty the GC's team cast a concrete "cap" for the air return plenum and sealed that plenum up and we started looking at how/where to run the Radon vent piping from the only access to the old return ducts.
Routing the Radon out of the slab and up through the roof for a passive vent looked like it would be easy but with the new ceiling we were concerned that if we would need to install a Radon pump to keep a vacuum on that vent, that there wouldn't be room. I'd been keeping our Radon Mitigation Contractor in the "coordination" loop for the previous several months so we pulled him back into the discussion with "requirements" for access, space needed and power for the pump so if the "passive" vent was inadequate, we wouldn't have to start tearing stuff out. With that information in hand our GC ran the appropriate size pipe up from the floor vent, along the back wall (where it would be hidden behind the cabinets), up into the attic and over to the apex of the roof and through the roof. We now had a passively vented 60+ year old slab twice as large as the slab for most houses of our size with "conventional" attic ducting. If we were ONLY dealing with Radon incursion from the return vents we should be home free. How much any cracks, seam incursion or/and our floor vent closures that were not absolutely sealed would impact our Radon problem was still unknown. Could one simple modification (sealing the vents) make a problem that was intrinsic to the very ground the house was built on disappear? Time for another test.
Next Episode: "The Shelbyville Experiment?"