generationalhome

Meet Me on the Porch

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.

Mildew, Mil-don’t

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.

Couldn’t do it without a little help from our friends!

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.

A big ol’ stack of purlins

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.

a red pepper and two human-sized cactus cardboard cutouts stand in front of three people

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!

Surface Level Thinking

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.

Steel-Clad Sensibility

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.

On Deck

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!

How To Fill A Wall

The latest is in from the Myers’ Home project site! The team has squared away interior framing and are close to debuting their windows. This means it’s about time for the house to get its nerve center. The Mechanical, Electrical, Plumbing train is leaving the station in Newbern.

Becoming Plumbers…

With Riley offsite in the woodshop working on the custom window units, Madeline and Judith have been at the helm on site for the past few weeks. Madeline is taking the reins on plumbing the whole house, and ducting it too! Judith has got the power alongside her, running electrical wires, installing outlet and switch boxes, sorting circuits, and labeling everything.

The plumbing contains stub-outs to the attic space allowing a bathroom to be built for future generations. These are beside the water heater, also in the attic to save space in the downstairs. Electrical decisions were also based on rooms that could serve different purposes across generations. Dedicated circuits are in place for AC units and the home is treated in zones of use.

Lighting the Way

This also entails a discussion in lighting the house, helped along by a new consultant to the Studio, Thomas Paterson of Lux Populi in Mexico City.

The flexible nature of Myers’ Home doesn’t stop at the plan, section, or material finishes. The team’s been applying their goal of generational expansion and flexibility to the lights in the house too. The home was studied in zones to determine lighting strategies, and tools (fixtures) were chosen to achieve these. The team is working to balance task lighting and spot lighting with the necessary amount of immediate switched light in a space.

The team mirrored lighting and fan locations in each zone for alignment no matter the scheme of flex walls. They then worked to place lights in the core such that it remains a hearth and can be the main source of immediate light in the home.

As these folks press on with electrical work, they’ll begin to test how to optimize the tools they’ve chosen for each flexible space.

It’s Getting Hot in Here…

Drywall looms and Myers’ Home Team must consider all that the wall must hold before it is sealed up. Wires and pipes have been run, the lights are set in their places. It’s time to stuff if full of foam and fiberglass. The insulation line for Myers’ Home is at the roof. This requires five and a half inches of spray-in, open-cell insulation. It’s one of the few jobs that the Studio hires out. Meanwhile, the team put up blocking framing upstairs and left the premises for a day. Upon return, the attic was cool as a cucumber and ready for windows.

The original intention for the home was to install a flash-and-batt insulation system downstairs. However, foam prices are cost-prohibitive and the team moved forward with Rockwool insulation in downstairs walls. Madeline, Riley, and volunteer Bess from Project Horseshoe Farm knocked out the ground floor in just a couple mornings!

Sheetrock City

The team put some quick blocking in place and documented each wall before making the call for sheetrock. The crew arrived first thing and got to it. By lunchtime, the first layer of finishes were all in place. All that remains for drywall is mudding and sanding to smooth everything over.

Neckdown

Much of this happened over the course of Neckdown weekwhere new students knock out work around Hale County using, arguably, everything but their heads. Myers’ Home played host to a few helpers who helped begin more layers of finish materials in and out of the home. Many thanks to new 5th-year students Jackie, Hailey, Davis, Brenton, and Caitlyn, as well as 3rd-years Peter and Laura!

Window units ready to show their faces soon! In the meantime, the home is being battened down with flashing and prepped for siding as the summer slides on by. Check out Myers’ Home team’s brethren over at Rev. Walker’s Home as they also install windows and siding. Or jump to the Thermal Mass and Buoyancy Ventilation crew for some big moves upward! Best to all, over and out.

An Inside Job

With a shady roof finally in place, the team is ready to fit out Myers’ Home on the inside. This includes all interior walls but the “flex walls,” the staircase, and the attic floor. Once these are all set the team can move on to rough mechanical, electrical, and plumbing work.

Taking Shape

Framing interior walls is much the same as exterior walls. In this case none are load-bearing thus headers don’t require the same level of structuring. However, as the core in Myers’ Home interlocks with the staircase, funky framing conditions arise. Before the walls can go up though, the team lays sill plates again, sans gasket and caulk this time around.

Once sill plates were secured, Madeline and Judith framed the ground floor interior walls. The north bedroom was the first to rise, followed by its southern counterpart, the two bathroom walls, and the stair landing.

A Step Up

Judith and Madeline took the first stab at building the staircase. It’s been a while since the Studio has built a staircase! After a day of figuring up from down, they were off to the races. Once Riley returned from the woodshop — he’s been hard at work on some special windows — they really started moving. The platform for the landing is framed first and joists are placed atop before OSB flooring. Stringer angles are measured from marked distances and pulled string with an angle finder.

Once measured and scribed, they cut the stringers from 2×10 boards and leveled them across each step, from bottom to top. This became a touch more difficult on the second run when the stringers were fourteen feet long. Madeline stands on the newly moved scaffold between trusses to level the attic end. Judith pushes the lower ends in place and checks to ensure each step is level across stringers.

Floor It

After these three completed the stairs they moved on up to installing the attic floor. The 3/4″ tongue and groove OSB is hauled up through remaining space between trusses, interlocked, and tacked in.

The attic will soon be partially divided by the enclosed volume of the stair. These folks are in the process of framing those small but tricky little walls. Judith and Madeline will be getting into electrical, mechanical, and plumbing next while Riley returns to the shop for that mysterious window fabrication. All will be revealed before too long. So long for now.

Gimme Shelter

Myers’ Home team is flying high as they install the roof on this generational home. Goodbye errant raindrops, so long harsh sunbeams. Say hello to a cool and shady workspace!

After nailing the sheathing and taping the seams, the team can’t get straight into roof metal installation. The edges of the corrugated metal sheets must be finessed. This is all accomplished with honed and tight flashing details. Way back when this team reviewed such details with Jake Labarre and Dan Wheeler. They tested them in a mockup and it’s finally time for the real deal.

Sneak peek of that roof on a shady morn!

Done in a flash

The flashing is ordered custom and is produced from sheet metal with folds and smash joints as specified. It provides a clean edge for roofing and siding panels to run into and weatherproofs by serving as a drip edge from openings. Later down the line door and window flashing will also be applied before siding to protect the home’s openings.

The team also installed what’s called a “vapor diffusion port.” This consists of a strip of Tyvek paper taped across the gap in the peak of the sheathed roof. Once open-cell spray-in insulation is installed it will serve to diffuse moisture from the home through the attic space.

Up and at ’em

With flashing up, it’s about time to start slinging metal up of Myers’ Home’s 10/12 pitch roof. The team went with a larger corrugation width, 1-1/4″, than that of the siding, 3/4″. This creates distinct planes with similar textures.

Thanks to extra hands Andrew, Steve, and Chelsea, the process was about as smooth as can be. The roofing began with Andrew at the peak and Judith on the roofing ladder at the eave manned with drivers and screws, Madeline and Steve manning the scaffold positions, and Riley and Chelsea pre-drilling and hoisting sheets up.

The front slope of the roof, shortened because of the heeled truss, was completed with just one row of 12′ panels. The back of the house however has a slope length of nearly 20ft. To roof this with a single run of panels is slightly more unwieldy to install with the small crew on this project. The team split the back into two portions; an upper 8′ run and a lower 11′ 6″ segment.

In the home stretch!

The final upper portion proved trickier to maneuver with a lower row already installed. The previously designed rope system continued to prove its worth in this area. Down on the scaffold, a string is pulled across the bottom edge to mark where the roof overhang ends. The scaffold hands push the panel into place and align corrugation to the sheet adjacent before those further up secure the metal.

These folks completed the whole job in two mornings of sunrise starts. All that remains is installing the ridge cap once the team gets their hands on the elusive closure strips. These corrugated foam strips seal large gaps in between the roof and ridge cap across the house’s peak. A complete roof is well in sight!

The Great Indoors

With the roof and sheathing complete, Myers’ Home team finally has that shaded interior workspace. They’re jumping into the first steps of interior wall framing, which will be the core unit of the bathroom, laundry, and staircase. The team has also hit the shop with the first pre-fabricated cypress window unit well underway.

Soon to be released, the woodshop tell-all and the beginnings of plumbing and electrical!