Archive for November, 2012

100 Club Drive

November 23rd, 2012

Floor installation continues at the 100 Club Drive jobsite combining steel support and LVL’s to form the girder system. Eric Dunn with Dunn Metalworks was chosen to weld and drill the steel beams for appropriate wood facing to receive the floor trusses. Craned into position, both the 3 ply LVL’s and steel with hangers premounted, floor truss placement begins. As shown in the illustration, flat roof trusses oriented in the 1 1/2″ direction allow for the 7″ drop in the theatre room and in the bathrooms 6″ drops for the showers. The mechanical “basement” is large enough for accessing HVAC and plumbing / wiring issues that may present themselves in the future. Once the floor trusses are decked, progress can be realized on the ICF exterior walls which has already begun in the rear garage area. The process of confirming the interior wooden wall panels and subsequently the roof system will have 4 to 6 weeks to develop prior to their need onsite. The douglas fir heavy timber trusses which will adorn the great room, dining and sitting room are being engineered to meet schedule once the ICF walls are in place and delivered with the roof trusses. Custom home building requires special attention to details. It can be somewhat of a moving target with changes occuring in the different phases of construction as plan meet reality. A perfect example is the impact of the chandeliers on changing the plate heights of this structure. Rod Edwards, the general contractor on this project, has great perception of the requirements of his client, making these changes seamless in their execution.

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November 7th, 2012

The poignant aroma of seasoned wood greeted anyone entering our shop for the last few days. Reclaimed heart pine is the species of the lastest First Flight Stairs creation, which makes for a difficult choice of which I enjoy the most; the smell or the beauty of the lumber. Using reclaimed lumber is an ecologically sound decision by recycling and reusing lumber that would have been burnt or scrapped into a landfill. Heart pine can have areas that are very dense due to heavy concentrations of sap. It is more dense in comparison to new lumber, being fully seasoned makes in stronger and stable as well. It adds a special charm to any home it graces with the knowledge it was around in another form as far back as the eighteenth century. Reminants of it’s previous life are shared through nail holes and grain pattern variations. The rustic apperance is milled and planed into a product, such as these stair treads, prove this timber still has plenty of life left.

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Preparing Girder System

November 3rd, 2012

The next step for 100 Club Drive is preparing for sitting the girders into place. The inside of the 12″ CMU walls will have single ply (1 3/4″) LVL’s attached for perimeter bearing conditions. Meanwhile, the main support system which are 3 ply (5 1/4″) 20″ deep LVL’s are to be connected in place before being positioned by crane onto the piers. Floor truss hangers (over 1000) will be applied to the assembled LVL’s prespaced 19.2″ o/c making the process of setting the floor trusses as effortless as possible. These composite beams are very heavy and using the crane to set them is a huge timesaver preventing backbreaking manual handling. There are a number of steel beams which are to arrive next week so having the wood framing portions ready in advance takes advantage of the crane being needed for setting steel. With the exterior walls being ICF, the drawings and approvals for the interior wall panels is my next step for staying ahead of the construction schedule. ICF wall construction will take approximately 3 to 4 weeks once the wooden girder system is in place. This will allow enough time to prepare for the interior wall panels to be closely reviewed and manufactured. Coordination of the massive roof truss system already designed will be scrutinized in conjunction with load transference through the walls to the foundation. Varying plate heights, even lighting fixtures selected, are all part of the approval process upcoming next week to assure the premanufactured wall panels are correctly sized and ready to be built.

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