Dropping the house

Thanks to our fine friends at Clayton, the house has officially dropped. To this point, it had been precariously supported by a combination of temporary CMU spacers and a steel substructure, hovering approximately 16 inches above the sill plate of the foundation walls. This rather unique construction process allowed the masonry team ample room to lay the second half of the foundation and the interior piers once the two modules had been delivered.

The actual "dropping" of the house was more of an oscillating settling than a sudden fall, thanks to the coordination of the Clayton team underneath the house. Three installation experts used a set of 6 hydraulic jacks, 3 at the North end and 3 at the South end, to "see-saw" the entire structure down to the sill plate, approximately 4 inches at a time. While it was great to see the house finally settle onto our laboriously constructed foundations, I would be remiss if I didn't admit an overriding sentiment of trepidation concerning the ultimate fate of the CMU walls underneath the full weight of the house. Fortunately, everything seems to be holding!

This process of prefabrication and coordinated delivery has resulted in some interesting conversations about the potential for this particular method of construction. While I won't get into the many trajectories we've discussed, one pertinent issue that we've all had to grapple with is the scale of coordination within this project. In typical construction, various phases are more flexible in the overall timeline of the project, yet in the New Norris House we are constantly investigating logistical issues of phasing in order to ensure that every bolt, block, and beam are delivered and installed in an efficient order that (1) won't bog down the construction schedule (2) won't clutter the site with an "on-deck circle" of prefabricated components waiting to be installed and (3) takes advantage of the rapidity of assembly to ensure an exacting standard of quality that is hopefully reflected in the final efficiency of the home.

Time Lapse: Clayton Onsite Installation

A short time-lapse film condensing the two day installation process by Clayton Homes on-site in Norrs, Tennessee.

...GO!

It was a fantastic day in Norrisland. The weather was almost as beautiful as our freshly delivered house. The day started off with a little bump in the road (literally). The transportation of the dormer was rough, but after a quick pit stop and a very slow climb to Norris, we finally delivered the beast. When we first arrived, the Clayton men were hard at work. After a morning of prepping, it was the moment of truth for Team Dormer. Wall-by-wall and nail-by-nail, the dormer was guided into place. Placing the dormer might have been an extremely long and tedious task, but seeing that sucker hanging from the crane is a moment to be held dear in all of our hearts forever. It was great to finally see everything falling into place (not literally...it was more of a slow glide). It has been a very productive week and we all look forward to continuing this progress!

Ready.. Set..

Today was the last day of preparation before THE BIG DAY OF HOUSE DELIVERY (Clayton will be delivering the house on Thursday).

The dormer team has done it! After a lot of hard work and endurance through some small glitches in the system, the dormer is complete and ready for transplantation. Tomorrow evening, this group of fine craftsmen/women will deliver their masterpiece to its new resting place in Norris.

The masonry team has also arrived at its goal. 2 1/2 walls have been laid, and today the bond beam was reinforced and poured. Highlight of our day: because of our efficiency, we had some time before the concrete truck arrived, so we took the opportunity to visit the nearby Norris Dam. The weather was great, and the dam and its natural surroundings are incredibly beautiful! Everyone should go see it! In the visitors center, Andy Pittman and I had the opportunity to talk with a very nice lady that worked there. Turns out, she and her husband live in the Town of Norris, and he served as Mayor for several years. It was clear that they really love the way of life there when she told us that "Norris really is the best kept secret in all America!" We were also happy to hear that she and her husband are looking forward to coming to see the house.

Once the house is delivered to the site, our work continues. Next steps: the other two foundation walls will be laid, and the dormer will be placed onto the roof. I think we're all really looking forward to see all of this coming together.

Rain, rain go away...

Originally, the house was supposed to arrive from the Clayton factory today to be pieced together onsite. However, weather delays have slowed down on-site production, holding off delivery, and today was no different. We have been waiting for fall to show up around here, and it has- in true Knoxville fashion- with a 68 degree high, gray storm clouds and rainy drizzle.

A little chill and rain could not hold us back though! A few members of the masonry team trekked out to Norris once the rain died down and tied off rebar in preparation for the pouring of the bond beam. This was initially to be done today, but drying cement and rain do not mix. Instead, it has been moved to Wednesday, which should give adequate drying time before the house is placed on-site on Friday.

Back at the woodshop, production on the dormer, windows, and skylight continued.

Arya, Michele, Patrick, Maxi, and Allie Ross fastened together the roof of the dormer, and are excited to bolt the three sides to it and each other on Wednesday before it is carried off to Clayton. (Any volunteers on helping us carry those pieces to the loading dock?)

Jimmy headed up the windows team, finishing the last of his meticulously made window frames and starting on the stops with the help of Chris and Katharine. They made sure the part of the window the inhabitant can see is smooth to the touch and beautiful to look at. Thank goodness for the belt sander!

In the computer lab, Tyler prepared for his meeting tomorrow with the roofer, preparing the model of the flashing and coordinating drawings, while Andy put his graphic design skills to work on a job site sign. This sign will serve as an informational tool for the Norris community, describing the goals of the project and listing those who have worked on it.

It was a very productive day for the house. We had thought we might not have enough to do, but not a single person left until the 5:30 bell. Just goes to show what we have all been thinking- there will always be something to do on the Norris House!

Visit to Clayton

After the rain all night Thursday, the excavation on-site was postponed until Monday. Meanwhile, the masonry group spent Friday continuing their work of laying block. They will begin laying the foundation next week after the excavation of the site. The rest of us have been working hard in the Art+Architecture Building's shop fabricating window frames and the framing of the dormer. The west and south walls of the dormer were cut and constructed. Work on that will continue next week and then will be delivered to the site to be connected to the prefabricated shell by Clayton.

After hearing about the masonry group's visit to Clayton in Bean Station, TN on Wednesday afternoon, the rest of us were excited for our visit on Friday. We finally met Brad, our Clayton contact, who has been extremely helpful throughout this process. With out bright green visitor hardhats on, Brad took us on the floor of the factory to see the process of the construction. After working with the AutoCAD drawings of the house, it was incredible to see the framing while it was in the wiring stage of the construction process. In conjunction with that, they were putting in the insulation and gypsum board as well.

We were able to walk around and inside the house to see the different details and were amazed at the efficiency of everyone working at Clayton. We also saw Samuel with a complete set of the drawings running around answering any questions. We were also informed that everyone stayed until 9:30 on Thursday night completing the scheduled work for that day. It was remarkable to see everyone's hard work in person.

Construction Begins

The prefabricated shell of the Norris House, which is being built by Clayton Homes' Norris Plant in Bean Station, TN, started its week long trek on the production line today. The masonry group, as well as Joan, Sam, and Samuel, were fortunate enough to watch some of the fascinating work taking place on the factory floor. Brad, our contact and constant reference at Clayton, took us on a tour through the various stages and processes that were all occurring simultaneously.

Here's a list of everything (including elements we are building ourselves) that are currently being prefabricated for the site installation:

-Floor and decking (including electrical and plumbing)
-Window frames
-Hinged roof joists
-Exterior walls
-Dormer
-Cistern enclosure
-Skylight frames

Seeing the house start down the construction line at Clayton was a truly unique experience, because for most of us it is the first project we have designed that has proceeded to construction.

Clayton will be delivering the house in two halves, to be joined on site, as a result of our unique site condition (too small to get a crane). In order for that installation to be successful, the masonry team (myself included) will have to lay the CMU block foundation in respective halves next week, piecing the house together as it lands. J.C. Newman, the master mason who has taken us under his wing the past few weeks, will be on site to ensure everything goes according to plan (and to show off his expert trowel work when necessary).

Here's a link to a recent press release from UT about the New Norris House, and pictures will be posted as soon as I get the camera back from Samuel.

Final Preperations

The stage has been set and we are making final preparations now for construction to begin. Today Professor French and I delivered the last of our materials to Clayton (structural wood floor, tile, and Simpson joist hangers) and the project will go online at their manufacturing facility next Wednesday. The entire process will only take 4-5 days, before on-site delivery takes place on September the 27th.

Back on campus siding is being primed. Dormer, window, and door details are being resolved. Materials are being ordered and the off-site fabrication in the UT wood-shop is about to begin.

Our masonry team (Andy, Andy, Maxi, Derek, Chris, and Matt) has learned the basics of laying concrete block walls and once footings are poured their skills will be put to the test.

This feels like the calm before the storm, but perhaps it is actually the eye of the storm at this point. Either way, as the next few weeks unfold the project will take an enormous steps towards its final realization.