The Wollochet Bay Project "Carriage House" in the Cromwell neighborhood of Gig Harbor took two years from initial groundbreaking to hardscaping. Lystad Construction was there from the start, working with the site superintendent, architect, designer, and owner.
The contractor worked on a concrete storm drainage system and structural slabs in the beginning. This consisted of 12,000 square feet of interior concrete floors complete with indoor carwash. The concrete walls in the car wash were skimcoated with two coats of Ardex Tilt Wall Patch and then mechanically ground to give a swirl finish. After grinding, the contractor stained the walls with Mirastain 2 with an HVLP gun and then sealed the work. This gave the owner smooth, easy-to-clean walls that look great too.
Another interior feature included a 5000-square-foot ground and polished showroom floor. Initially the floor was cut to large 3/8-inch aggregate and polished to a 3000-grit finish. Dye and seal Midnight Black was used to stain the floor and a sodium densifier with polish guard finished the polishing system.
Throughout the entirety of the project, the crew installed precast veneer and stone veneer to the house, outbuildings, fences, and retaining walls. This theme is continued on the inside of the house as well.
When the sitework began, the contractor first poured a retaining wall in some places 20 feet high with four different radius points. The largest of these was 43 feet high, which swept into two other radius points. The difficult part came when the surveyor left and the points given went right through a very large maple tree the owner would not part with. After a day and a half of moving every single survey stake, the contractor was able to make the walls fit with the design and save the tree. The top of the retaining wall set the elevation for the driving area concrete flatwork that was to come later. The retaining wall elevation was crucial because 13,000 square feet of surface water had to flow to one drain in the courtyard area.
The contractor poured a driving wall on top of the retaining wall, which also had tight tolerances because the precast cap had to be made to fit precisely. The final wall was surveyed upon completion and was within 3/16 inch.
In total the contractor poured more than 30,000 square feet of stamped concrete made possible with Geotech fabric with crushed rock for the base, rebar grids to hold it all together, and five catch basins to make the driveway and walkways last generations. More than 2,600 cubic yards of concrete was poured on this project.
The Brickform Small Ashlar pattern was used as well as their Roman Slate texture skins for the borders and field. Brickform's color hardeners and release agents also were used with the stamping process.
The very last portion of work to be completed were the three circle center pieces. The contractor had to wait until the following spring to complete this work because of a very Washington winter. When it finally warmed up, the contractor ordered stencils from Modello designs with the owner's "double S" logo.
Just before the stencil application in the circles was to begin, the contractor was informed that the integral color originally poured in the fall wouldn't be compatible. Two weeks remained to complete the work per the contract and after a phone call to a Brickform sales representative, several sleepless nights, and a site visit, the contractor found a solution, which was to use Brickform Cemcoat.
The contractor completed the job on the final day of his contract and completed a one-of-a-kind, successful two-year project!