Honing the Skills

Though we completed our entry door frames and slabs [inner structure] near the end of last semester, there is still a great deal of designing and fabricating to be done on them. Additionally, there are two more doors and a cistern enclosure door to be completed. The past few days have been spent getting our drawings, materials, and skills in line.

Because a new team came on-line just last week, it has been important to get everyone on the same page. Because I spent a great deal of time in the wood-shop last semester, I have been showing newbies Justin and Matt how to use specific tools and fabrication processes so that they will be knowledgeable as the semester progresses. We have started with the simplest [crawl space] door in order to hone our skills. In three days we have gone over how to: 1) take a rough-cut and often warped piece of wood through a jointer, planer, and table saw in order to get it perfectly square; 2) biscuit join the inner slab; 3) rout the plywood faces for a perfect edge; 4) dato cut the corners of the door frame for an optimal gluing surface; and 5) assemble the pieces for a square frame.

Aside from showing off our fresh skills, this list begins to show the importance of understanding the process of building component assembly and fabrication when solving design problems both on the site and in the office/lab during the design and drawing process. In order to draw a manufactured object, one must first know how to manufacture that object.

For example: today Matt, Justin and I went to research some Andersen hardware for our doors. Needing all entry hardware to match [between our Andersen french doors and self-fabricated doors] we are required to use a specific hardware which requires us to rout mechanical channels into the edges of our fabricated doors. It was a culminating moment for me to see us work through this multi-faceted problem together. Now that Matt and Justin have a sense of familiarity with the fabrication process, it is easy for us to have intelligent problem-solving conversations about how we can fabricate these doors to work with our complex hardware. It will only get easier as we become more adept in the fabrication process.

Being familiar with how something is built only pushes a design further because it allows us to fix an issue before it becomes one. As we acquire more knowledge about building methods and tools, we bring compounding options on how to solve a single problem. This honing of skills will only help us as we begin to work through even more complex designs of details - such as our hidden-opaque-window-assembly [even the name is complex] due next week.

For some of us graduation is just around the corner, making it easy to think about how these skills apply to an office environment. Throughout this process of designing, testing, redesigning, building, and repeating as necessary, we will be able to pass this knowledge of design and process on to our peers and co-workers, allowing us to improve overall design intent from large to small-scale, and effectively enhance collaborative energy and problem solving in an office environment.

rain, rain, go away.

Unfortunately the weather seems to be getting the best of team Norris. We had another day a rain today which meant that we were unable to continue with the unfinished business on site. Fortunately there was plenty of work to get done in the computer lab and in the woodshop. We also were able to tend to some general housekeeping details that have been piling up while we have been on site.

The windows and doors are coming along slowly but surely. A large group of us spend most of today in the woodshop preparing wood for the blocking and framing portions of the windows. The glass for the windows was delivered yesterday, Tuesday the 2nd, and we all look foreword to the day we can see all the pieces come together in all their beauty. One thing we are nervous about however is getting the glass panels to the site. They are quite large and heavy and, as we all know, glass is…well…glass.

Having spent the entire day in the woodshop I have discovered that although our woodshop in the art and architecture building on campus is more than adequate for most of what the students need, it can sometimes become very cramped and crowded when you are trying to build large scale objects for an actual building rather than a small scale model. I feel that if the university plans for more design-build projects in the future, an investment in a larger workspace dedicated solely to the design-build program is necessary.

While most focused on the windows and doors, a few headed to the computer lab to work on certain details of the Norris House, and to finalize the job site sign that includes the names of all our sponsors. Allie Ross, who has experience with LEED documentation, took today to organize and read over our LEED folders. She believes that she may have found an extra point that we can acquire- great news as we need as many as possible to reach our goal of LEED Platinum.
Although we were able to get a lot done today while in the art and architecture building, we hope that the weather cooperates with us on Friday so we can get out to the site and complete a few things before the weekend. The forecast calls for afternoon showers, so keep your fingers crossed that the weather will shift in our favor.
Peace.Love.Norris….

Happy November!

After a week of rain, it was back to work for Team Norris. Down at the wood shop, the better half of Team Norris was busy priming the siding and putting the last touches on the windows. Out on site, the other half of Team Norris installed insulation under the house and began the cistern enclosure. Here, the gang learned a lesson in one of the downfalls in prefabrication. The cistern was previously build by students last semester, but plans and drawings of the design have changed since them. Although we appreciate prefabrication in all of its glory, much of today was spent taking apart prefabricated panels, re-fabricating them, and then installing them correctly. Because so much time was spent redoing the panels of the cistern, we didn’t get to finish. But that’s ok because we can finish on Wednesday and it is going to look awesome, like always. In other news, the plumber and the electrician were also on site to discuss some details in their line of work. We look forward to finishing up the cistern and installing some siding and windows in the new few weeks!

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!

Week Six in Review

What a week it's been. At the A+A, Monday and Wednesday consisted of cutting down the stationary windows' Atlantic white cedar to size, sheathing the dormer walls, and mastering the bolt connections for the dormer. Wednesday's excitement included the first [and second] window assembly after the corner dado/rebate joints were cut [pictures and videos to come]. Also, the dormer team's diligent efforts brought them close to completion, and Friday morning Arya, Michelle, and Patrick made final preparations for its site delivery next week.

Believe it or not, even despite all of the mile markers passed at the A+A the most progress this week was made on site. Thursday and Friday blended together, consisting of a stellar performance by the masonry crew in laying two walls in two days, and exemplary brawn by the rest of the class in moving blocks, mortar, gravel, and pouring perlite CMU insulation. It was a physical workout for sure, though shown by Allie-Ross and Katharine's new 'gravel shoveling ab workout routine', everyone made the best of it.

Thursday morning at 7:45 AM, we started with four wall footings and three pallets of cinder blocks. By 4:45 PM Friday, the foundation of a house was more than 50% completed. It was fitting that we finished the day with the whole team on site. Though it was easy to become distracted by each of our individual tasks, upon stepping back and looking at the class working as a whole, it became apparent that bigger things than construction were happening in Norris. Our class has become quite the well-oiled machine.

In a short amount of time, large amounts of preparation and anticipation [weeks for some and years for others] have come to culmination. In just a matter of days, the house will be on site, foundation work will conclude, and the house will drop. This is an incredibly exciting time for the Norris class. But to quote the 'Carpenters' duo, "We've Only Just Begun."

The Mason's Challenge

The rain over the weekend presented some unique obstacles for the rough grading of the site, pushing back the schedule a few days. While the masonry team eagerly awaits our debut laying block in Norris, we have continued training under the close supervision of JC Neumann sharpening our skills day after day. We have come a long way since our first day, struggling to spread mortar using a trowel which fit awkwardly in our hands as some foreign object. As time passed, the trowel became as an extension of our bodies, spreading mortar quickly and evenly.

Day after day, we build up a new wall and dismantle it, improving its aesthetics each and every time. While we gained confidence in the appearance of our work, Mr. Neumann had another lesson in mind for us today. The delays in the schedule have put us in a tight spot, crunching the time that the masonry group has to lay up the first two walls of the foundation. In order to help improve our speed, Mr. Neumann presented us with this challenge: He would single handedly lay one course of block in the same amount of time that it took all six of us students to lay the same amount of block. We quickly accepted the challenge.
The clock began ticking as we feverishly began laying block after block, making sure that it was plumb and true, cutting the mortar, and continuing to the next block. As we laid the closer block, Mr. Neumann announced our time: 15 minutes - shaving ten minutes off of our normal speed. Mr. Neumann realized that he had his work cut out for him in order to beat our time. He, however, had 50 years of masonry experience on his side that made him ready for the challenge. As he started, all of us students simply watched in utter amazement as each block that he laid seemed to magically just fall into place with no effort. Even his glasses were slowing him down, so he laid them aside - going completely by touch. His final time was 16 minutes and 38 seconds. We were astonished that he could lay almost the same amount of block by himself as we did with six people. He taught us a very valuable lesson in speed and it will be put to the test this Thursday (9/23), as we begin to lay the foundation.

Save the Mortar!

Excavation of the site starts tomorrow, and the masonry team will be ready to begin laying the foundation next week. The team includes Maxi, Derek, Andy, Chris, Matt, and myself. Over the past few weeks we have been practicing laying CMU block walls at the Lincoln Park Trade School, under the teachings of JC Neumann. The first few days were hard, knowing it would be our responsibility to build something that supports an entire house. As each week has passed, our masonry abilities have improved and the reality of building a house has set in. Luckily Mr. Neumann will be on site with us to make sure all our walls are true and plumb.

It has been difficult working outside the building, as so much has been happening with the other teams. It will be good when the house arrives and we will all be working on the site in unison. There will be a lot of mixing of groups to help out and make sure everything gets finished on time. It will be nice to be able to participate in all aspects of the house, rather than just the foundation. Time is of the essence, and it will be important to budget it wisely (including a time between 2-4 for Sonic’s happy hour!).

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.

Busy Builders

Today was a big day for the Norris house. It seemed like a lot of things that we have been working towards in the past couple of weeks have progressed into the construction stage. Downstairs in the wood shop Jimmy started assembling the first window frame for the house. The dormer team (Arya, Michele, and Samuel) made their first cuts for the dormer’s construction after a couple weeks of building study models and revising drawings. It will be so neat to see both of these things become real in the next week or so! Upstairs, Chris and Patrick were busy getting together a rendering of the exterior of the Norris House so we can show off its design as we move toward on-site construction.

I think all of the students involved with the Norris House are beginning to realize how important the scheduling and organization of the different construction-related tasks are. There are always so many different duties at hand- materials deliveries, drawing completions, as well as communication with involved outside parties. It definitely takes a bit of juggling and a serious commitment for things to run smoothly!

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.