The Good: Robert Guice (President of Better Built) worked directly with us to negotiate the contract and design the pergola. Robert appears to have a grasp of construction techniques and the design he came up with seems sound. During negotiation he was attentive to our requests and responded adequately to email and voice mail.
The Bad:
I was present for much of the construction and asked questions of Robert (when he was present) and the crew foreman. I pointed out anything that didn't look right. As a result I uncovered several issues and brought them to Robert, or the crew foreman. The following items were either a concern, or didn't get corrected.
- 1.) Communication with Robert was good prior to contract signing and it began to suffer thereafter. It became harder to reach him by voice, and his email responses were often incomplete. Example: If I ask about three items in an email I expect a timely response, or at least acknowledgement of each issue or question. Robert's practice of answering only one question (often with a limited and incomplete response) while ignoring the other items is not acceptable. This would irritate any customer.
2.) Better Built did a poor job of selecting some of the cedar wood materials. Natural wood products come in lots of grades and run the gamut relative to quality. After determining the type and quality required the contractor should carefully select individual pieces to achieve the best result. This selection process is called ?culling?. In our project much of the cedar would be visible and have a medium stain. The selected wood should be blemish free and without noticeable defect (aka, "stain-grade") because the final finish will show any damage or other man-caused imperfections.
I was there when the wood arrived at my house and watched as they unloaded. Robert identified several pieces that were splintered and sent them back to the lumbar yard. But, there were other pieces with slight damage from strapping and unfortunate blemishes (I call them mill glazing, but whatever they are they were not natural to the wood). Anyone concerned with producing a high quality product would not want these pieces. Why take them? It costs you nothing to return them. When I pointed these out to Robert he said the painters would try to brush them out with a wire brush. Why resort to that when you can return them for better quality product?
So, now I have two vertical beams supporting the pergola with strap markings that the painters could not remove or hide. The Better Built crew placed these so that the damage faces the interior of the pergola where my guests can enjoy it for years to come. I also have a 20-foot main beam (12"x4") with heavy mill glazing running perpendicular to the grain and facing in the most prominent direction possible. The painters could not hide these even with repeated wire brushing and a stain much darker than we had wanted to use. It would have been so easy to face this beam towards the roof of the house where no one would see the markings. Too late now. -
3.) The foreman made a handyman mistake in how he braced the house roofing under the main pergola beam. Robert himself pointed out the house roof deflection caused by the added weight of the pergola. For added safety a wood brace would be cut and placed between the underside of the roof deck and the load-bearing outer wall of the house. This is the correct way to address the sagging roof and allows any weight from the pergola beam to be transmitted through the brace to the house wall and the slab below. The construction industry refers to this as ?point-load?.
After Robert left, the foreman made a potentially damaging mistake. Instead of putting the brace over the load-bearing wall he put it directly over the outer framing of the kitchen window box. This is improper and not what he was instructed to do. In this configuration the weight of the pergola could be transferred to a single 2x4 stud framing the outer edge of the kitchen window. The window box extends 10-12 inches out from the load bearing wall and its structure cannot support point-load. If enough weight is transferred to the window framing it could damage the window box, the window itself, and perhaps even the roofing due to improper support of the pergola structure.
I came out to inspect progress and pointed out the mistake. The foreman however saw nothing wrong with it. At the speed they were working this was perhaps an hour from being hidden behind the Hardie Board siding. It was, in my opinion, just a matter of time before something bad would come of this. I had to insist that work stop until they spoke with Robert. The incorrect bracing was then removed and placed in the proper location.
How is it that the crew foreman doesn't understand point load? Where was the supervision of the supervisor? Unfortunately that responsibility fell to me; its a good thing I was there.
4.) Another example of poor communication and supervision happened earlier when the crew was framing the pergola. The plan called for two 12?x4? beams with one end of each beam resting on my house roof. The ends of these 2 beams would be the only contact point of the pergola structure with the house structure. Robert gave detailed instructions to the crew foreman, and then left the job site. Within a few short hours the foreman was cutting the cross-beams for the pergola roof with the apparent intention of tying the house roofing directly into the pergola roofing. Out of curiosity I asked him about the approach he was taking and discovered his mistake.
Good thing I was paying attention and ?supervising? the work or we might have a very different pergola today. 5.) My home has a window box that extends out and away from the house above the kitchen sink. This window box is in the
middle of the project area beneath the pergola. This kitchen window was originally framed in the center of the window box for aesthetics. (I have pictures from over the years showing this window?s symmetry - If you have one of these on your house go outside and look at it.) For some reason the foreman decided to add additional 2x4 framing to one side of the box causing the window to be noticeably off center. The Hardie Board siding was already in place before we caught it.
Robert insisted that I had asked for it to be done that way. Really? Why would I do that and then call it out as a mistake? I think the more likely explanation is that Robert doesn't take notes consistently; poorly explains himself; and tends to blame the customer first (put that one under "The Ugly" below).
6.) The Better Built crew added Hardie Board trim around several windows. One of the windows is a half-circle with a
24? radius. Because this window is a half-circle the upper trim needs to be rounded. The Better Built solution is to take a length of Hardie Plank; cut it into three pieces; and shape the inner and outer edges to form a radius (like a three-piece