prefab

Finishing Strong

A photo of the house's windows glowing at night.

Here we are, at that last and most essential push. In all our blog posts, we have tried to communicate some of the major milestones that we have taken throughout the project. We have celebrated the resolution of single details that took months to work through, or simply described the various layers of structure, waterproofing, or insulation that we applied to the house. Much of this work, when everything is said and done, will be covered or buried. There was a lot of thought, effort, and care that went into those forgotten moments, so these last layers of finish need to convey that sentiment.

We have been working this past month on the interior finish of the house, the exterior cladding for the porches, and the flooring.

The interior of the house has been finished with white-washed cedar ship lap boards. Whitewashing the boards meant that the boards were done the moment we put them on that wall and ceiling. It was an effort to reduce the amount of messy or wet work that would have to take place around the cores. It was incredibly rewarding to put the boards on the wall and know it was complete. The whitewashing also preserved the cedar’s natural beauty. This is a wooden house with a warm heart of mass timber in its center, clad on the exterior in a thin skin of corrugated metal. The interior finish should be understood as being wood without clashing or overpowering the Douglas Fir of the Cores.

The porches are clad in cypress tongue-and-groove boards with a clear coat wood finish. It is here that you can read the transition from the thin metal skin of the facades to the warm wood aesthetic of the house. Any internal space is finished with wood, the porches being no exception. The porches are trimmed with 2×8 cypress boards left over from the Bathhouse project.

The flooring is LVT (Luxury Vinyl Tile) from Interface. We chose a neutral birch wood tone with a pattern that would dissolve over the floor area. It is a backdrop to complement the natural wood on the walls, ceiling, and cores. Thank you to Adam Whitley for coming out to teach us how to install the product!

As we have applied the finishes, we have been following behind with the trim, cabinets, HVAC, lights, switches, and outlets. We have the order in for the countertops as well.

We have been working very hard to finish up the house, but we have also made time for more fun things. Recently, we got to have an amazing lighting demonstration at the CLT Core House, courtesy of Thomas Paterson. We also got to do a wonderful drawing and watercolor workshop with Dan Wheeler and Frank Harmon. Lastly, we put on a show at Rural Studio’s Halloween events; dressing up as OSHA inspectors and having the winning pumpkin of pumpkin carve!

A collage of watercolor paintings and hand sketches.
A photo of the teams carved pumpkins.
CLT Core House team dressed as OSHA inspectors

Things are coming together. The next time you read our blog should be the last. Exciting times at the CLT Core House!

Straightening Ducks and Mocking-Up

Students stand proudly on dug trenches for mockup.
Duck Ahead!

In the time since our graduation, the world has kept spinning. The team quickly returned to work on the project with the time for outside work quickly approaching.

After all the labor poured into iteration and preparation, we are ready to make our plans a reality. In Rural Studio fashion that means it’s mock-up time! But let’s not get ahead of ourselves here. We must get all our ducks in a row, or at least some of them into a decently straight line. We worked on transforming the core and house elements to a smaller scale, while also putting the finishing touches on details with the help of Dan Wheeler.

Dan Wheeler sketches over 1 to 1 detail drawings.

We are also double and triple-checking our structural strategy with Joe Burns. On top of this, we met with Thomas Paterson to discuss our general lighting strategies, which, like many other things, needs more iteration. With all this help, everything is looking good enough to get started. So, we have officially broken ground on our mock-up and things are progressing smoothly.

It is fascinating to realize that there is another layer of complexity in construction that we must reckon with beyond the seemingly overwhelming complexity we face with our drawings and design. It is a lot to keep track of and easy to make a mistake, which you then find yourself taking time to fix. One of the incredible opportunities of Rural Studio is that we must work through all these problems as a team and truly understand the repercussions of what we design. No one does it for you; if we find a problem, we must think ourselves out of it.

Groundbreaking News: We Broke Ground

So where are we today? Well, we are busy finishing the foundation trenches and prepping our pieces for the assembly. We have built the core base and the walls. We also have the formwork assembled and rebar cut to size.

Materials and pallet for the project organized on Fab Pav.

Throughout, we have been critiquing and altering our process and design. As soon as we finished the core base, we became aware of how we would build differently and how it would be designed differently. We all know that design has a long way to go and that even as the house itself is built, we will see things we would change if we could do it again. But that’s for future teams to figure out.

For now, we are pleased with our progress and do not want to slow down anytime soon. At the time of writing this, we are hoping to pour our mock-up slab in one week! It has been a welcome change of pace to do some physical work. We’ll see how long that disposition lasts in this heat. But for now, we are happy to swim through the humidity towards our next task.

Here Comes the Leftovers

Students walk across the street
DOO-DOO-DOO-DOO

Since the team’s last blog post, a lot has happened. All of April was spent preparing for Pig Roast and the Executive Reviews that followed. The team focused on refining our thesis to fit our goals. We tried to bring the level of detail of the whole house up to as high a standard as possible. There always seems to be another layer of detail to dive into as we learn more about the project.

One to one detail drawing of whole house section.

These big upcoming reviews naturally meant that we needed to spend more time on how the house feels, inside and out. We are having a good time zooming out of detail land and drawing through how the elevations may look and what kind of interior finishes we want. We have some general criteria for making these decisions, but we are approaching a time when seeing how these things look in real life is becoming ever more important.

We also finally have a site! Due to the nature of our project being non-site-specific, it made sense to spend a certain amount of time designing the house without the bias of knowing where our version would go. We are excited to dive deeper into the site, analyzing every inch. Our site is fairly flat undeveloped land, surrounded by trees. Also, it is located right off the road in downtown Newbern. With the downtown projects so close by, we have a high bar to live up to!

Model of house photoshopped onto site photo

We still have to explore through drawings, models, and research before we can try building. Even so, a mock-up is on the horizon. While the finishes are important, the most critical parts of the building process are what need to be tested with this mock-up. The processes of building, moving, installing, and protecting these cores throughout that duration is the real focus of our thesis, along with how all of that process will impact the house.

Pig Roast!

Enough about the preparations. We had a great Pig Roast Weekend! Both 5th-year teams worked hard, and we all felt our presentations went well. It was a beautiful day, and the wind blew our drawings away only once—nice! We tried to have some fun and act out our building process. A little improv went a long way. In the end, it was great to celebrate with friends and family, and the event at Chantilly was unforgettable.

Did someone say leftovers?!

After all that fun, we had to go to Auburn for the much less fun but equally (in some ways) important Graduation. So that’s it. We are adults now who have all the answers to everything. There is nothing we are unprepared for in the real world because now we have a degree. All jokes aside, it has been a pleasure to spend our final school year at Rural Studio. We are so thankful for our time at Auburn and beyond excited to start our time as leftovers to continue the hard work.

Students pose together at graduation
WAR DAMN EAGLE!

Best Footing Forward

Collage of slab to core connections

Welcome back to the CLT Core House team blog! It has been a busy month filled with details and deliberation. As the title suggests, we have been focused on our footing design, particularly on the connection of our heavy and bulky CLT core to our concrete slab. We wish it were as simple as just “screwin’ er’ down.” However, because the slab will be on grade at ground level, we’ve found it difficult to design the right detail. We have worked through many kinds of solutions, all of which we eventually dropped for either being too complicated or too messy.

While working through footing details, we have identified the need for our core to be a six-sided box that arrives on-site wrapped like a present with a bow: something that you only unwrap once you are finished with the dirty business of finishing a house. Also, we know we want our concrete slab to be finished in one pour to avoid the orchestration of getting a concrete truck and team on site multiple times.

Our latest strategy—single-pour slab and a completed box—may not seem like much, but it eliminates most of our previous hurdles. As we both design the core and develop the process of moving and placing it, we are focusing on making sure others can easily replicate our work in the majority of rural contexts. The footing, our most recent detail, is hitting most if not all of our criteria and we continue to examine and refine it. What’s funny is that the final connection is only screws, so we may just be screwin’ er’ down after all.

Section of bathroom core footing

In Other News,

We have been steadily working in various other areas of the project. We are drawing elevation options, both interior and exterior and considering where our porches should be and what they look like. We are also asking ourselves what the human comfort scheme is, which is the heating and cooling of the house, and what passive strategies we could employ.

We have also been in the business of testing the spatial aspects of the cores and taking field trips to Rural Studio projects and places.

This point in the project is exciting. Hopefully, in the next blog, you will see a mock-up and some details that are finally nailed down, pun intended.

Survey Says

After a restful winter break, the C.H.O.I.C.E. House team—in charge of designing and building an emergency shelter for a nonprofit organization—is back and ready to work! To kick off the new semester, we took a trip to Uniontown, AL, to survey and document everything on our site. This information will help us to create more accurate drawings and make better informed decisions about how the units will relate to the site and its surrounding context.

hailey holding story pole on site

Once the site was surveyed, we had the chance to begin exploring how the prefabricated machine modules will be delivered and placed on site. We explored different foundation types, methods of transportation—such as dragging vs. craning the modules—and extents of site preparation. To help us with this process, guest reviewer John Forney of John Forney Architecture & Planning in Birmingham, AL, paid us a visit. His expertise in turning projects inside out forced us to reflect on our previous decisions, redefine what modulation means for this project, and broaden our views on what methods of transportation are available. 

meeting with reviewer

Currently, our plan is to prefabricate two core modules that will contain the bathing and cooking spaces—aka “The Machine”—underneath the fabrication pavilion, load them onto a truck. The truck will drive them to the site, back into a pre-existing pier foundation, and lower the modules to the foundation (this final step is still a little fuzzy, but we’re getting there).  

Now, we are working on detailing this process out and are starting to think about how we’re going to build the stick frame unit on site, but you’ll have to wait until next time for that! 

Until then: 

The survey has spoken to the conditions of the site, 

Of which the results inspired a way to transport the modules upright. 

Now, how will they provide structure and bring light into the cubes? 

In the future I’m seeing… it may be trusses and solar tubes!