The crowning touch of the rough framing at 100 Club Drive has to be the true Douglas Fir timber trusses being set this afternoon. It was reassuring to witness all the months of planning required to get to the point of erection, and seeing it fit together with the structure above designed to house it. These timbers are nothing short of magnificent. The concealed fasteners are two expanding cross pins called Timberlinx which are stronger than traditional mortise and tenon joints. Spaced at 8′-0″ centers, spanning over 40′-0″, these timbers are showcase quality adding sophistication and authenticity to the home. The wall panels have parallam columns to support the massive amount of weight generated by their girth. Openings in precise locations of the doubled, three piece roof trusses above were coordinated with the timber engineering to assure accuracy. The dining area and kitchen utilized shorter span timbers, shadowing the larger, great room timber shape. Qualifying as a Fortified Home, the load paths are evaluated by an independent structural engineer working in conjunction with the local engineer of record. The use of component technology, with the added twist of working a plan around the giant timbers, made this project as gratifying as it was memorable.
Posts Tagged ‘component construction’
Tucked away off 6th Ave S and Waterway Drive in North Myrtle Beach is Babb Custom Homes latest component construction home. Consisting of three levels, this piling house has a beautiful view of the Intercoastal Waterway and has been under construction for a little over one week. All of the walls past the first level have been set in place with a crane and shuffled to their respective positions Much of the anchorage hardware, necessary bracing and blocking is handle on the level as they move upwards. The use of wall panels aids in the completion of these items as the level is already basically framed and the permanent fastening requirements can be addressed earlier in the construction process. The second level floor system was to be set and sheathed before the third level wall system arrived to be craned into position. The roof system is scheduled to be delivered on Wednesday the 23rd to allow for several days of deck assemblies. As in most large multi-leveled coastal homes, a combination of steel I beams with deep LVL’s are integral in transference of the load paths generated through both point and uniformed loads. Structural sealed drawings are adhered to in the design of the wall panels and trusses, allowing for the proper strapping as required by code. Babb Custom Homes realizes the benefits yielded by component construction’s review process prior to problems occurring in the field.
The progress on setting the roof system on the 100 Club Drive job site is nothing less than remarkable in my humble opinion. IG Construction crew members, shown here, have a right to be proud of their achievements up to this point. The main roof trusses along with the garage trusses are erected, as the “piggy-back” upper roofs are being swung into place atop the purlins prepared for them. To handle and brace these large span trusses is difficult and dangerous. Their experience was clearly evident as they moved nearly effortless on the top plates, each conducting their individual roles. The left side hip was being nailed as the sunset sunk into the ocean across the street, taking with it all ambient lighting for the work site. The form and the shape of the building is defined by the intricate roof pieces being assembled into place. Nestled between the great room, sitting and kitchen areas walls are columns designed to carry the timber trusses observable from below making this home unique in more ways than one.
Hit hard by the flu bug and relegated to bed for the last two days, I still managed to get to the Dunes Club to handle issues, at least Monday morning that is. The opportunity to go into the structure and take some photos yielded these pictures of the variety of plate heights present on the job. Ranging from 10′-0″ to 18′-0″ tall, the angled walls on either side of the great room were the most striking. This afternoon, the general contractor sent me the one where trusses were set over the same area, a “little house he was building in the Dunes Club” he called it. Thought it was fitting showing the massive great room walls capped with the vaulted ceiling that will house the exposed timber trusses below them. Actually, as mentioned in the previous post, nearly the same amount of trusses started shipping today to occupy the same area vacated by what was set. The wall panels using the Framers Series lumber were erected without much of a hitch. Not the same result for the roof trusses though, as three problems arose leading to creative problem solving. I am fortunate to have a design staff and an insightful general contractor to review the situation and choose the correct course of action to solve them. One of them involved the 4 ply girder bearing height. You can imagine the amount of materials and labor it takes to screw, bolt and arrange the hangers prior to setting it. Being able to use it and stay on schedule, finding the most advantageous solution, was probably the most significant single decision of the whole project thus far.
Any question I had regarding breaking the main roof trusses into two orders was cast aside upon arriving at the job site for 100 Club Drive this morning. What is shown here is “Part 1″ consisting of four individual truckloads. After the rain subsides, the crane is due to begin setting this massive amount of trusses, creating room for “Part 2″ scheduled for Wednesday of next week. The interior wood wall panels are completely set, of which I didn’t even enter the structure to take pictures as I marveled at roof deliveries in front. “Part 2″ is almost as large of a shipment as what you see here so the framing crew has their work cut out for them preparing for it. Literally there is no room for any materials left until “Part 1″ is set into place. Besides consuming all storage area in the front, there are trusses clear spanning over 66 feet long in these stacks. Special lifting and bracing details are required in handling trusses this large. Of special interest are the trusses over the great room, designed 12″ o/c and doubled. This section envelops the true Douglas Fir timbers below, stubbed around the masonry fireplace as necessary. The wall panels in the great room were engineered to carry the huge point loads via parallam columns. Although the roof trusses above will carry the roof and ceiling loads, these timber trusses spaced 8′-0″ o/c are extremely heavy, generating their own forces needing a load path to the foundation. All these factors were prepared for in advance through the coordination of timber engineering firm working in unison with the truss and wall panel designers to assure success.
Nestled in the foliage of serene Tidewater Plantation in North Myrtle Beach, work to complete dry in continued on lot 227. This houses cantilevered overhangs served several purposes. They run straight across even with plate level which helps define the freeze boards over top windows. The sub fascia is set at a predetermined height, in this case 2×6. They are energy efficient by allowing high rating R value insulation to travel to the perimeters of the exterior wall. Probably the best feature is the easy of installation of the soffit materials. It is a selling point I put this way to interested clients: “not everyone buys cantilevered overhangs from me, but those that do always reorder them”. Kinda a non confrontational way of gentle persuasion. I had a flash of the “Dos Equis” man (stay thirsty my friends..). Foundation strapping required in this 130 mile per hour wind zone was inlayed into the 7/16″ sheathing. Coastal construction differentiates itself from inland construction by the hurricane anchorage and foundation strapping requirements. Wall panel construction can accommodate these necessary connections just as truss designs are the point of reference for uplift values. Load paths are identified and the correctly sized header members, whether it be LSL,Timberstrand or LVL, are used to transfer the load to the foundation. I talked to the general contractor today about the overall performance of the component system. He commented about consistency being the most beneficial byproduct. When the products arrive, they are ready to be installed with the guess work removed.
With the wall panel delivery on Wednesday of last week, walls were standing on my Friday morning arrival. This new component construction home in Tidewater Plantation features 2×6 10′-0″ tall walls. Temporary bracing is evident until the walls are permanently fastened to the foundation. Babb Custom Homes, having the most experience with erecting these packages, has refined the process into predictable construction practices. A good example of this is using impact resistance windows, two studs as opposed to a 2×6 separation makes the fit easiest to work with. By specifying particular kneewall heights for kitchen pass through walls, valuable onsite labor is eliminated. The roof truss system was to arrive later that Friday morning to be set on Monday. Even a jobsite that lacks much open area to place materials can be serviced with component construction. By staging wall components, loose material, and trusses, for their respective appropriate arrivals times allows the job not to be overrun on existing space. The garage door opening was completed less the LVL header which will be in the roof package being delivered. This knowledge and expectations of the sequence of events is the result of pre-construction planning. Implementation of the plan is realized seamlessly through correct, on time deliveries based on their needs.
Work on the foundation is being conducted in the Dunes Club, 100 Club Drive in Myrtle Beach. It is very exciting to be involved in a project of this magnitude. This is a 21,700 square foot home built under fortified home specifications. The 12″ concrete block foundation will be followed by a LVL pier system topped with 16″ deep floor trusses specially designed for 7″ drops in the theater room and 6″ drops in the showers. An ICF wall system will be installed with the interior walls constructed out of Framers Series wall panels of varying plate heights before the massive roof truss system is installed. On my visit to the job site entering from the left side of the structure, I mentioned to Rod Edwards, the general contractor with Innovative Design / Build, that the walk seemed like a football field. He corrected me by saying converting from feet to yards the distance was actually 75 yards. A house of this size takes time to develop especially considering the unique specifications presented. We started in earnest April of 2012 by presenting numberous elevations to the homeowner on the basis of the architectural floor plan. Structural engineering was developed with major considerations given to load transference and hurricane anchorage in this 150 mph (20 mph higher than the code of 130 mph for the fortified home compliance). Approval drawings were submitted and reviewed for months leading up to this stage of construction. It is fulfilling for me to see all this work forming the plan, but not half as thrilling as seeing the components placed into action as the house continues to materialize. I will continue to document the progress in future posts…
The house on the corner has taken form and shape as it rapidly moves through the construction process. Shown on the previous post, lot 135 Sunset Harbour will be ready for roof sheathing tomorrow as the roof is braced on the inside today. The second floor is covered with 3/4″ T+G plywood and covering the roof will be the next order of business. Having gone vertically upwards the crew will sheath the roof using 5/8″ radiant barrier and cover it with 30lb felt paper while working downward, completing the soffits before sheathing the walls with 7/16″ OSB. This experienced crew of component construction understands the advantage and time saving methods of completing each level as they move through them. Starting on the slab, it was important to move upwards first, but having reached the pinnacle they will work their way down consolidating movements and energy focused on doing what is necessary for the current position. The roof sheathing along with the felt will need to be set on top with a boom truck to maximize efficiency. When they reach the lower level, the house will be in the “dried in” stage awaiting plumbing, electrical wiring and installation of the HVAC units and ducts. All these trades have been considered and planned as to their location and interplay with one another. The result is an organized process, minimizing labor, using engineered products to reach the desired goal.
Babb Custom Homes began this morning to set walls on a new structure in Sunset Harbour, North Myrtle Beach. I arrived onsite at 10:30 am so you can see the progress accomplished in that brief period of time. We have been dodging rainstorms locally as Tropical Storm Isaac blows up the coast of the Atlantic. Putting together consecutive productive days has been more than a challenge for area builders, but the brief respite allow this component construction home to come together nicely. With limited space on the lot, tightly scheduling wall components, building materials, and trusses is essential. The wall panels and bracing lumber arrived yesterday, with the floor trusses and 3/4″ T+G floor plywood slated for this afternoon. Both sets of panels, first and second floors, both exterior and interior walls are stacked and prepared to be erected. This crew is full time employed by Babb Custom Homes understanding the required speed and possessing the experience to benefit from what prefabricated components can add to the construction process. Interesting to note is the center bearing post of the garage being shipped loose so the LVL garage door headers can be set in the notched openings on either side. What transpires onsite is the cultimation of hours of planning and design, with approval modifications, integrating structural and architectural specifications into a cohesive component unit. All that is left is to fit the puzzle pieces together.