This Spring has been busy for our 3rd-year team! Scroll down to see what we’ve been up to with Rosie’s Home, Woodshop, and History!
First off, our team has begun our study of Rosie’s current home with interviews and a series of empathetic drawings that we will continue to work on throughout the semester. Each of us has chosen an element of the home to study that will help us to make informed choices about the design of the new home.
We are using our findings from these drawings to begin the process of adapting the floor plan of 20K Turner’s Home to Rosie’s needs.
As we continue to create iterations of these plans, the team has also begun our foray into creating full-scale wall section details.
Recently, construction began on our post-frame structure. Our team helped bolt together the truss system while the sub-contractors implanted the posts and lifted the trusses into place. Afterwards, they attached the purlins to the truss system in preparation for the metal roofing to come.
My First Woodshop
For our first adventure in carpentry, each member of our team was tasked with designing and making a cutting board from a set amount of wood. In the span of a couple weeks, we learned a lot about woodworking, sanding, and staining, and ended up with a striking variety of cutting boards.
Our next goal is to begin the process of testing ways to build our chair precedents. For the next few weeks, we’ll be testing out different methods for the construction of their components.
History and Watercolor
We have visited several historic homes in the past month, such as the (pictured below) Carlisle Hall, Bluff Hall, Lyon Hall, and Tasso House. It is so interesting to learn about the details of these buildings and the reasoning behind their construction, along with developing our sketching skills on site.
We also just completed our first watercolor assignment, a study of light and shadow in a monochromatic painting.
Check back soon to see how we’re makings strides on floor plans and post-frame home details!
The start of 2022 brings six new 3rd-year students to Hale County, Alabama! Get to know the students who will be continuing the work on Rosie’s Home this Spring!
Anna Leach is from Gadsden, AL
Grant Schurman hails from Mount Carroll, IL
Jon Hunt Ficken is homegrown from Auburn, AL
Julia Whitt is from Abbeville, AL
Sarah Recht calls Atlanta, GA, home
Will Robinson comes to Rural Studio from Madison, AL
What’s happening in Hale?
These six 3rd-year students are following up on the work from the Fall 2021 semester for clients Rosie and Frankie. Rosie’s Home is planned as a continuation of Rural Studio’s residential post-frame research. This spring, students will see the post-frame structure, or “pole barn,” raised by a locally contracted team.
With this investment in labor and a covered site early on in the building process, site work can continue through weather delays and should lead to an overall cost reduction in the project. Following the construction of the roof, the 3rd-years will work to design the interior scheme based on 20K Turner’s Home plan, which was originally built by another group of Rural Studio students in 2012. Additionally, they will be charged with much of the exterior detailing of the home beneath the roof.
But wait, there’s more!
In addition to their studio work, the group will be taking two classes. First, there’s Woodshop with instructor Steve Long, where the infamous “chair project” is making a return! Students are assigned a famous wooden chair and must research the dimensions and production. Then, they will design a process for constructing it in Rural Studio’s very own shop.
The students will also study with local architect Dick Hudgens in the long-standing History and Watercolor class. The students will visit historic homes, churches, and agricultural buildings in the Black Belt each Monday afternoon. They’ll learn the history of how these structures were built and used, as well as the context in which this history happened. The students will also complete watercolor assignments along the way to document what they are learning and build representation skills.
With all this happening, it’s going to be a busy Spring! But that’s certainly not a new phenomenon out here. Keep an eye out to see what hands-on assignments have kicked off the year for these folks.
It’s curtain call on the Myers’ Home, construction that is. The team wrapped up just in time for the holiday season and towed away the trailer and all. The keys have been given to the clients. The team can’t wait to hear how the house functions in action. But how about a dive into those last few weeks on site in Newbern?
Flex Walls, Finally
One of the primary aims of the Myers’ Home was to provide a formwork for varying generation needs. The team explored this concept by building the “shell” house with no spatial divisions outside of the “core” volume. With this method, a client could hypothetically walk through the full-scale model of the home. With full experience of the space, they can decide where they’d like bedroom divisions from several schemes.
These “flex walls” are stud walls constructed in place, rather than tilt up, and anchored with a few masonry screws. They are paneled with sanded and primed plywood and fasteners are entirely visible. These details allow the walls to be more easily altered or removed years down the road. If the family is in need of a new room configuration, these walls can handle it.
Bits and Bobs
Of course, at the end of every building project there is what’s called a “punch list.” It’s a list of the remaining tasks to ready the house for turnover. On this list for the Myers’ Home was a few coats of finish to the butcher-block countertops, making the stair handrail, caulking the last of corners, tightening up door hardware, and sealing the interior and exterior slabs.
Another final task was to complete the lower row of siding on the front exterior face of the home. A quick task that certainly visually completes the house quickly!
With all bents in place and secured, we begin raising and securing purlins. Then, we welded the purlin mats at the same time as the bents and installed them as single units by bay. Riley took the reins and began welding up a storm while the others clamp and shimmy the pieces to level.
Finally, we wrapped up the roofing, a quicker job than expected. After just a day and a half the team completed the final line of siding and the porch roof. The panels went on with slightly more precision than the main roof. The tapping screws needed to catch the 1-1/4″ purlins, so measuring and pre-drilling of the sheets and purlins were required.
With a final coat of sealant to the interior slab and porch pavers, the house was ready for move-in!
That’s a Wrap
Madeline, Judith, and Riley are on to new endeavors, though questionably bigger and better than this one.
Start spreadin’ the news! Riley is kicking it in the Big Apple, starting work at MADE Design/Build in Brooklyn, NY. With an in-house woodshop and IKEA next door he’s sure to be up to his ears in miters and meatballs.
Judith is sticking around Newbern and joining the teaching team as 3rd-Year Instructor/Coordinator. She’ll be working on Rosie’s Home with Emily McGlohn and the new batch of 3rd-year students. Hale County just can’t seem to shake her off!
Madeline has hit the road to Bozeman, MT, where she’ll be working at Minarik Architecture. She’s pleased with her new snowboarding opportunities and excited to get into conscious and contextual residential work. Stay thawed up there!
The team could not be more grateful for the support of Rural Studio faculty and staff, student colleagues, consultants, donors, and friends. It’s not goodbye, it’s see you later. This is the Myers’ Home team signing off.
The Myers’ Home team has been busy preparing the porch structure on the Western face of the home. This porch is unique among previous Rural Studio projects for a few reasons: It’s fabricated from steel, has its own slab, and barely touches the rest of Myers’ Home.
Looking back, the home was designed for longevity and flexibility through generations. In previous Rural Studio homes with front porches, the space is most often subtractive. This means that the open porch is carved from the main volume of the house and its structural system. In doing so, the rafters are exposed and gaps between trusses are exposed. These must be filled in some way, usually bird blocking. The other solution is a soffit under the eaves.
In both cases, the exposed undersides of the rafters or soffit are nearly always in shade and tend to mildew. Over time the uncovered portion of the truss or rafter can degrade faster than the interiorized segment. In these cases the whole member is still compromised.
The team addresses this problem by eliminating the condition entirely. Myers’ Home has no true eaves, only a slight overhang of the corrugated roofing material. Flashing details are tight and the long Western porch is entirely removed from the structure of the house.
Finding Your Footing
But how’s that little gap mitigated? A separate foundation for the porch is planned. Ideally, this job could be completed with just the team and some extra hands in one morning. This settled into five separate pavers, with two inches of gravel between and roughly a foot of separation from the main house slab.
Before the pavers can be placed though, footings for the metal columns of the porch must be set. This system shook out to be a trench footing, with ten-inch-deep reinforced footings at the columns and a six-inch-deep trench spanning each bay.
With the help of a handful of 5th-year students and professors Andrew Freear and Steve Long, the pour was complete in just about an hour with all levels squared away. The team can look on to the next pour the following week of the pavers.
Prep for the latter involves formwork once again, this time with removable dividers between eight by eight-foot segments. These folks took a leaf out of Horseshoe Courtyard‘s book and used a system of stakes and plywood strips for this maneuver. They then mound backfill dirt around to keep concrete from spilling out beneath the forms. The last step before the concrete arrives is reinforcement with metal mesh and grade pins. The mesh strengthens the concrete as it settles over time and grade pins are fluorescent marked stakes driven to signal the correct level of concrete in the forms.
Finally, the team can tackle their third and last concrete pour of the project. The truck arrived and they were soon in the groove of a process with aid of Patrice’s Home team and Steve. Riley manned the chute; Judith, Daniel, Adam, and Lauren shoveled and screeded; Madeline and Lauren troweled and floated away; and Steve edged each one.
These pavers, being on the porch, are also exposed aggregate which necessitates an additional step after the concrete is finished but still wet. Following a half hour’s wait, Judith misted a specialized concrete retarder atop the fresh pavers, bright ectoplasm green. This allows the majority of the concrete to cure normally while the topmost layer of cement is kept a slurry.
After roughly eight hours, Madeline and Judith return in the evening to hose and scrub the surface of the pavers and wash away the cement. This reveals a texture of the aggregate, in this case pea gravel specially ordered for this type of slab. The team is aiming for a change in surface material between the concrete of the porch and that of the interior as well as a more rugged finish for the home’s entrance.
Weld, Weld, Weld
These three can now focus on the porch structure itself, made entirely of metal with a corrugated roof to match that of the main home. Thanks to the generosity of Studio friend, Jim Turnipseed, the team was able to spend about a week in Columbiana, Alabama at Turnipseed International’s metal shop. There they built jigs, practiced welds, fabricated purlins, and built bents.
With the oversight of teachers Flo and Luis, they quickly learn the equipment, cut pieces to length, and weld up a storm.
Purlins are up first, a good practice run as most welds will be hidden from sight. For east of installation and transport, purlins are designed as mats. These mats are welded in a line and installed as a single unit in each bay. Tables are placed a specified width apart and a simple rectangular jig is made with four ninety-degree angles to catch the mat’s corners.
The bents are pitched with a solid four-inch-wide plate welded atop to catch the purlin mats and provide more tolerance. These take more complex jig-work. The needed angle cannot be achieved in the range of the band saw’s angle. So the extra distance is made up by welding a separate tray to make up the difference.
Following this, the angle for the bents’ top and bottom knee-joint are welded to the tables similarly to the purlin jig. Once the pieces are arranged, baseplates with holes drilled are attached to the bottom of the columns. These baseplates are what will anchor the porch structure to the footings poured earlier.
The final step in fabrication is to prepare the members for galvanization. A series of half-inch holes must be drilled in all pieces to allow them to drain. This is relevant when components are dipped in the zinc bath stage. Results can be…explosive, otherwise.
Let’s Taco ’bout Halloween
The welded component are shipped off to Mississippi for galvanization! The team is on their merry way back to Newbern to continue site work. But several days earlier the team returned to Hale briefly for the annual Halloween Reviews! Those who may have spent a few days in this neck of the woods may recognize the wall murals from Greensboro’s own Mi Tenampa Mexican restaurant. As leftover students from the previous year, these three spend review day listening in on new thesis and 3rd-year work, attending the costume contest, and eating quite a few Reese’s peanut butter cups.
Bringing Down the Hammer(drill)
While waiting on the return of the porch structure, Madeline, Judith, and Riley move back into finishes and porch groundwork.
Judith and Riley borrow the Studio’s hammer drill and a masonry bit and spend a morning drilling four six-inch-deep holes in each footing. Riley has a specialized jig that expedites the process. After snagging only a bit of rebar, they’re ready for the next stage. Threaded rods are anchored into the holes with epoxy, these will catch those baseplates on the porch columns. With a system of threaded rods and nuts, the team can micro-adjust the levels of the bents upon installation.
That’s what’s going on around town, catch the final stages of finishes soon. Myers’ Home is getting fitted out with cabinetry, sinks, stair treads, and more!
The Myers’ Home team has made it to the top layer of finishes. Almost every material and layer they apply at this point is completely visible and the finish surface in the home. So they’re watching their step with the mud and taking some extra care in details.
Painting the Day Away
After sheetrock is complete, the team and their helpers scrub up the drywall mud and prepare to begin painting. While the home’s core, outer walls, and to-be-built flex walls are designed using different materials, they’ll all be painted white to reduce noise. It also provides a clean surface, should the homeowner want to paint it to personal preference.
The sheetrock is the cleanest surface on the outer edges of the home. It contains most electrical for the possible rooms and is more workable for openings like windows and doors. The board surface on the home’s core—the kitchen, bath, and stair—is a durable tongue-and-groove board. These surfaces are interacted with more often and need added durability. The flex walls that partition bed and living space will be plywood, and primed white. These walls will be anchored in only a few points should the home configuration need to change years down the road.
Just a Trim, Please
Once the walls have their first coat, trim can be installed around the whole house. As materials change, so does trim design strategy. The baseboards run along sheetrock surfaces, and where board material begins, the trim moves to the top edge of the ceiling. Windows are trimmed out on their edges.
Last Call on Windows
Speaking of windows, all of the custom window units are installed and Riley is adding the last few components post-install. Each of the operable and fixed windows get their own trim box, also constructed of cypress. These are taped off and kept natural as the last coat of paint is applied to the surrounding wall.
Meanwhile, the exterior of the house is getting the full treatment. Siding is starting to be installed on the two gable ends and back of the house. The lower twelve feet of front face will be clad after construction of the porch slab. This prevents siding from being dinged and damaged during concrete pours and metalwork. The porch structure will then be used as a platform to finish the top few feet of siding.
However, the installation process is straightforward for the other three sides. Panels are pre-drilled with screw holes, openings for windows and vents are cut, if necessary. Then the panels are moved into place, overlap length checked, and screwed in from overlap edge over. This prevents most bubbling in the panel as the lines of screws progress over.
The Thermal Mass & Buoyancy Ventilation team has also kindly lent their rental boom lift. The Myers’ Home team is using this lift to install siding high on the gable ends. It’s certainly a much smoother route than multi-story scaffolding! They also used it to install the last few pieces of flashing around windows. The flashing details on this house are in the same family as those used on the roof. To maintain the tight shell, window openings are designed to be sharp and clean.
The team is now on their last big push for the interior. They’re building flex walls, preparing for stair treads, painting cabinets, and making the rounds on finish electrical and plumbing. Soon, all lights will be on and water will be flowing!
On the outside, these folks are on standby for porch plans. Imminently, they’re headed up the road to Birmingham for some porch fabrication. This means steel cutting, drilling, and welding! Before that they’ll be boots in the mud again digging for the footings and pavers of the porch. More on that soon, thanks for keeping up!