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Index and About

  1. Workshop Positioning
  2. Version History
  3. Design
    1. Foundation Detail
    2. Roof
    3. Hydronics
    4. Floor
  4. Work Flow
  5. Bill of Materials
  6. Instructionals
  7. Work Structure
  8. Learning Outcomes
  9. Collaborative Partners

This is a 5 day workshop intended for individuals who are interested in exploring the limits to the swarm-build efficiency of environmentally friendly housing. We will blend Compressed Earth Block construction with modular panels to allow for a rapid build of a complete home. Our goal is to demonstrate that high quality housing can be built on time scales compressed by a factor of about 20 compared to industry standard construction, while achieving a cost 1/3 thhttps://www.google.com/images/branding/googlelogo/2x/googlelogo_color_150x54dp.pnglast 3 workshops to produce the most ambitious - in level of completion - build of a 762 sf house using our open source equipment. This workshop is intended for those people who are interested in building a natural home, but who also want to do so with state-of-art efficiency. This is an experimental workshop where we will do a proof of concept that our swarm building techniques allow for complete house builds on the time scale of 4 days, including hands-on training throughout the process, and a full day at the end for review, discussion, and exploration of open source entrepreneurship ideas consistent with economically-significant social production. The process up to the day of the workshop will include daily design sprints where we perfect our documentation of the build steps to eliminate potential bottlenecks in the build and to plan for contingencies. Collaborative planning leading up to the event via the open source community is intended to provide a rapid development process for open source blueprints and enterprise. We intend to make this a showcase of OSE’s Extreme Manufacturing techniques

This is a 5 day MicroHouse Extreme Manufacturing (XM) workshop intended for innovators and entrepreneurs who are interested in exploring the limits of XM for rapid manufacturing of environmentally friendly homes. Blending Compressed Earth Block construction with modular roof panels as our contract-first design, our goal is to demonstrate that quality housing can be built with multi-purpose flexibility using module-based designs and parallel building for optimizing changes. Our goal is reducing the time of construction by a factor of 20 compared to industry standards, at ⅓ the cost of conventional housing. Our XM design process involves a rapid parallel swarm workflow with 48 people using simple-to-follow documentation created with Agile and Waterfall methods prior to build. The MicroHouse XM 4 design is built on the experience of the last 3 iterations to produce the most ambitious - level of completion - build of a 762 sf home using test-driven open source techniques and equipment. If you are interested in natural home building or extreme efficiency of effort towards manufacturing, you will learn first hand how to take your home or project to the next level of ownership. Workshop includes 4 days of hands-on immersive team building, and a full day for review, discussion, and exploration of entrepreneurship opportunities. Our concept is consistent with open source economics and social production.

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Design Sprint Plan and Burndown

Roof panel 1

Plumbing Diagram

Hydronic

Radiator

Design Sprint Invitation - link. Note: any filled in bubble on this page means that work has been started. If the fill color is the same color as border, it means task is done.

Electrical Diagram

Hydronic Circuit Diagram

Roof Section

French Door

Door

Stucco Section

Flashing Detail

Bond Beam

2” Wall Insulation

Foundation Forms and Pour

Aug 26 Marker 1

Door

Install into Frame

Door Frame

Install into Wall

Foundation Pour

Chimney Install

Concept Diagram/ Drawing Detail

Bond Beam

Window

Requirement

2” Ground Insulation

2” Ground Insulation

Process Review

Technical Drawing Detail (DXF or...)

Plumbing Diagram

Electrical Diagram

Hydronic Circuit Diagram

Electrical Diagram

Sept 2 Marker 2

Sept 9 Marker 3

Sept 23 Marker 5

Process Concept

Sept 16 Marker 4

Exterior Insulation

Interior Stucco

Framed Straight wall sections build

Exploded Diagram

Wall Section with Outside and Inside Insulation

Roof Layers

Framed Door

Framed Window

French Door

Toilet Detail

Shower/Bath Detail

Sink Detail

Breaker Box

Overall Water Circuit Diagram

Year Round Water Hydrant for Garden

Brick Floor Layers

Interior Framed Wall Section

Hydronic Radiator Hanging

Framed Slanted wall sections build

Hydronic Stove

Bond Beam/Wal/Apertures

CEB Floor Workflow

Outdoor Stucco + Apertures

Roof panels

Bond Beam Prep and Install

Stucco Exterior

Stucco Interior

Roof panel 2

Foundation Certification - Engineering

Hydronic System Engineering

Wall Build

Exterior Wall Finish

Floor Install

Roof Panel Build

Interior Wall Finish

Apertures Install

Hydronic Install

Bathroom Install

Electrical Install

Rough

Plumbing Install

Interior + Exterior Plaster

Triangular Exterior Wall Ends

Hydronic Balance of System

Bond Beam

Overall Process

1

1

Exterior Wall Finish

Bathroom

Floor Plan DXF

Bond Beam

Roof Section

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Design Sprints for Instructionals

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Design Prioritization

Day One

Foundation-

Bricklaying

  • Floors -
    • detailed instructions - A to Z
    • Electrical - detailed plan
    • Plumbing - detailed plan
  • Walls - Details A to Z
    • Structure
    • Apertures
    • Electrical -Outlets

Day Four

Exteriors Apertures

  • Apertures Door One - select a desirable replicable door and provide detailed instructionals
  • Apertures French Door - detailed instructionals

Window Frames Sizes

  • Window 1-3 Main room - find one similar in Menards
  • Window Four
  • Window Five
  • Window Six

Bond Beam

  • Hurricane Straps

Day Two

Roof Panels and Side Slanted Walls

  • Bottom 18
  • Top 18
  • Chimney stove pipe detail
  • Hot water full detail

Day Three

  • Exterior Insulation
  • Hydronic Radiators Installation

Roof Insulation

  • Use sketch

Stucco

  • Interior
  • Exterior
    • Insulation
    • Stucco
  • Stabilized Block Patio

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MicroHouse 4 Extreme Manufacturing Workshop

September 25-30, 2014

Factor e Farm

Maysville, Missouri

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Scope

The scope of the MicroHouse project is to develop the most replicated sustainable construction set in the world over the next 2 decades. For MicroHouse 4, our iteration cycle is 1 month of planning - with iterations on future modules on a monthly time scale. That's a general strategy, where we will integrate modular panels, CEB walls, natural material biomass panels, charcoal gasifier gas, solar concentrator electric, CNC furniture, 3D printed useful objects, renewable energy systems, year-round in ground heat storage, and many other elements. As a Construction Set, the design is for optimizing for change and flexibility, along the lines of Extreme Manufacturing.

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Test-Driven Collaboration Requirement

  • Develop a Library of usable components for designing MicroHouses using proven techniques.
    • Generate Libraries of parts through Design Sprints
  • Recruit 6 people from workshop participant list to lead sections of workshop by preparing instructionals
    • Prepare a massive Design Sprint for generating workflow instructionals - 9 AM on Friday, Sep. 12 - 2 weeks prior to build, including workshop participants
    • Recruiting:
  • Post for review on Open Architecture Network
  • Draw up a list of natural Sustainable Building, MicroHouse, and Ecohome groups, forums, and venues for inviting Collaboration, Design Library, and Review
    • Identify and collaborate with a thought leaders in Micro Houses to attract a larger audience
  • Do a press release and have media show up to the event.
  • Agroinnovations Podcast
  • Leverage Collaborations such as New Town Builders - air quality, moisture control, heating and cooling, panelized construction, Jonathan Kocurek - build process design, Dan Silent - CEB construction techniques, Colby Thomson - Enterprise Development, James Wise - Sketchup Support, Marc Zorn - Press Support, Emily Aiken - Social Media

Feedback

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Orientation Links

Platforms

OSE Wiki - General Info

OSE Dozuki - Instructions

OSE Trovebox - Photo Albums

Sketchup - Tutorial

Sweet Home 3D -

Current Needs --

People who are interested in helping, please do not hesitate to email, Facebook, and or comment. We need your help with building, designing, Sketchup , step by step instructions, and more. If you need help getting started with these platforms, contact us.

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Construction Set Requirement

  • Develop a Library of usable components for designing MicroHouses using proven techniques.
    • Generate Libraries of parts through Design Sprints
  • For the library components, document how a novice without knowledge of Sketchup - can take existing assets and:
    • Combine module files into a document by copying and pasting the module into a new working file
      • To do this, do not do File-New in Sketchup, but just open up a new instance of Sketchup all together
    • Go from, say cubic foot - to a wall section 7 feet.
      • Triple click to select the part. Do not make into a component at this point. But do group the object.

Feedback

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Design Sprinters OPEN

Roles

Product Owner and Scrum Master- Concept Requirements & Design Drawing Detail Specifications

Marcin

Design Sprint Development Team

Marketing & Outreach

Open -- Marcin Scrum Master

Team Annie -

Sketchup Designers

Marshall Vaughan (In progress)

Carl Kagy (Needs Update)

Jean-Baptiste Vervaeck (Standing By) (Floor requirements/specifications in progress)

OPEN

Instructionals Dozuki

OPEN

Technical Designers Detailed Exploded Diagram

OPEN

Process Review

OPEN

CR Peterson

Steven Twigge

Jeff Adams

Jonathan

Bill of Materials

OPEN

Design Sprints daily, if you cannot make the 10 am call, contact us through FB or comment.

sweet home 3D - Jesse + Jenna

Marcin - hydronics concept design

Jonathan - brick floor

James Wise - Interior Wall Sections CAD

Marshall - wall brick animation

Carl Kagy - Window/Door

Module

Philip - CNC Furniture

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MicroHouse 4 Workshop Critical Path

August 16 23 29 Sep 5 12 19 26

Start

Start

Actual Duration

Duration

Construction Manual

2 wk

MicroHouse 4 Workshop

Sept 26

Sept 30

5 days

Concept Design

Feedback

  • Criteria for selecting Solar panels established - Ben, Local Dave
  • Hydronic stove validated
  • Bricklaying validated
  • Roof detail validated
  • Floor validated
  • Foundation Designed + Calculations Verified
  • General Workflow design completed
  • Backup controller

1 wk

Brick Pressing

Foundation Excavation and Pour

  • Excavation Plan
  • Excavation
  • Forms laid
  • Cement Truck ordered (pour can be later)

New Wheel Units for Tractor

16 Aug

3 Days

  • Design Completed for wheel hubs - OK
  • Instructional Prepared for Wheel Unit Fabrication - partial on Dozuki
  • Wheel Unit fabrication

Brick Moving and Site Organization

  • Detailed workflow based on General Workflow

  • Create Template
  • Instructionals
  • Design Sprint Methodology for Construction Instructional
  • Hold Documentation Sprint to create Build and Process instructionals

Eventbrite Announcement

16 Aug

10 days

23 Aug

2 Days

2 wk

  • Integrate Wordpress with Eventbrite
  • Video shoot
  • Video cut
  • Invite media
  • Press release
  • Event description
  • Rent bobcat
  • Fix CEB seal
  • machine refurbished for higher fluid flow (8 blocks per minute)
  • 300+ PSI for block validated.

  • Marc
  • Danielle
  • Ben
  • Jean-Baptiste
  • Jonathan Kocurek
  • Catarina

Build Process Integration

1 wk

Sep 15

8-foundation forms

9-pour

9-roof section prototype

10-wall section proottype

11-window prototype

12-exterior door prototype

12-interior door prototype

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Design Sprint Invitation

Dear Design Sprinters,

As part of our MicroHouse 4 Workshop - we are pushing the limits of global collaborative design. We are calling all builders, architects, designers, sketchup users, and technical writers to participate in a 4 week flurry of Design Sprints.

We are preparing for a seamless build of MicroHouse 4 - our most ambitious build yet. See announcement.

To deliver on the radical efficiency key to OSE’s values - we are calling for a global design sprint where we invite you to participate in the production of the instructionals and teaching material so clear and complete that we deliver on our promise of a civilization starter kit - a set of blueprints to critical infrastructure technologies - build in the most simple and efficient way.

The MicroHouse is one part of it.

This time around - we will be optimizing 2 things: the CEB wall build, and roof build. The wall is a general wall system that can be applied to many structures. The roofing system consists of modular, 3’x16’ panels that can be built quickly, and light enough that they can be installed in minutes. To do this, we are paying special attention to interfaces such that panels can be joined in a few minutes, while closing air gaps tightly. This system is intended to provide a generalized wall-floor-window-door-roof system that can be applied to any construction.

To achieve this, we are producing Sketchup libraries of component details - that allow anyone who can manipulate objects in Sketchup to put together their own house.

With your help, the world will receive clear instructions on how to do this. We aim to make our CEB building technique so streamlined that it’s truly replicable by many people. The modules we are building are relevant to tiny homes of 144 square feet in area - and to larger ones - like the current one - at 750 square feet. This existing structure will become workspace and office space.

The process here revolves around people studying our design concepts and assets, building on prior work, and producing the next iteration of design detail. Much of it is converting concept designs to Sketchup detail. We are welcoming anyone who has a good sense of practical build experience - builders, architects, designers, process designers, industrial engineers, systems designers, technical writers, CAD people, and others.

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Scope of Work - Size and Material Quantities

  • 700 square feet of floor for addition in green = 1400 of 3” bricks required.
  • Patio Door - 6’ wide
  • Starting with cured CEBs and sample stabilized pavers.
  • perimeter of 96 - minus 36’ of windows - about 60 feet of wall - 2520 bricks needed if 7’ high at 42 bricks/foot
  • Hydronic heating fully installed
  • Roof finished including chimney
  • Plumbing complete and leaks checked
  • Hydronic stove tested, hot bath taken from hydronic heat
  • CEB pavers sealed with first coat

MH 4 15’x53’ interior

hydronic stove (3’x4’)

door

wood pile

door

door

bathroom

window

window

washer

office

window

MH 1 12’x12’ interior

MH 2 12’x12’ interior

40’

8’

53’

hot water tank on stove

tub

16‘

Spaces for hydronic radiators in red

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Work Flow - Day 1 Bricklaying

D

D

14

W

Mixing Station

Bricklaying Calculations - 200 per person per day from MicroHouse 1 -> 22 people required. We have 28 allocated here, and 14 for the floor. 42 total + 6 on Quality Control and Documentation. Optional: if we are finished in less than

= tuck point

4 hours

= 8 brick layer

teams of 3

= brick carrier

Requirements:

  • 3 water hoses
  • 4 heavy duty drills, 4 backup
  • Bricks laid out on pallets prior to start
  • Electrical extension cords
  • 200A breaker box will be available
  • Mortar
  • Buckets
  • Wall apertures: hydronic heating hole, outlet placeholders
  • Multiladders as scaffolding

= floor brick layer

note: brick carriers also mix mortar; 2 buckets per brick layer, so once one runs out, a second one is made available.

Refreshment Station

Tools,Safety, & Washing

including cleanup and classroom

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Work Flow - Day 1 - Afternoon Wall Finish

All pallets are stacked neatly and ready to be taken away. Doors and windows are fitted. See Apertures Contingency Plan. Insulation and stucco mesh applied, and everyone stuccos at the end of the day. Optional: If progress is good, a team of 6 breaks off the stucco team to press stabilized cement blocks for the patio option of Day 4.

Top Plate is installed, and hurricane ties wrapped around bond beam with bond beam swarm. Stucco mesh reaches up to bond beam. Exterior trim under soffit is not needed because stucco is used to cover up to bond beam.

D

D

W

4h

= tuck point

= brick layer

bond beam swarm from inside of house. Also finishes the edge of the brick floor - fill in last cracks with mortar, after 2” thick blocks are cut (main floor is 3” blocks). Inside wall painted with white latex paint.

= floor brick layer

2

window/door fitting swarm

insulation/mesh/stucco swarm

including cleanup and classroom

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Work Flow - Day 2 - Roof Sections - Build and Install

Wall sections built in 6” thick layers. Blue Swarm installs the roof supports on the back of the existing microhouse.

Red Swarm builds the roof sections under the dome. Green swarm helps until first roof sections are built.

2 Green Swarms Install the roof sections, starting in middle of house, moving outwards. Doing 2 layers (1 foot thick roof), then moving outwards from midline.

  • 4 people carry, 8 people screw and nail.
  • This is done from 2 opposite sides, meeting in the middle.

D

D

W

4h

= Installers

= Roof Builders

= Roof Supports

3

including cleanup and classroom

= Documentor

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Work Flow - Day 2 - Roof Sections - Finishing

Red Swarm - with roof sections installed, inside ceiling-bond beam trim and insulation is added.

2 Green Swarms - install the East and West framed-in triangular sections of roof above bond beam.

Blue Swarm screws off the roof, seals roof, installs flashing, and installs gutter?.

D

D

W

4h

= Installers

= Ceiling to Bond-beam trim

= Roof Support

4

including cleanup and classroom

= Documentor

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Work Flow - Day 3 - Interior Work

Red Swarm - Hydronic Stove installation. Needs careful step-by-step procedures

Green Swarms - install the hydronic baseboard radiators, including fittings and drilling back through MicroHouse 1 to extend heat around entire perimeter.

Purple Swarm frames installs the wall partition to utility room and bathroom and office. After finishing, installs storage shelves.

Blue Swarm works on the bathroom sink, toilet, and bathtub. After this is done, tile is laid.

D

W

4h

= Installers for baseboard

= Hydronic Stove Installers

= Utilities

5

including cleanup and classroom

= Walls

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Work Flow - Day 4 - Exterior Work - Morning

Red Swarm - Outdoor patio if bricks are pressed - and if not - we will do experimental brick pressing for biomass insulation bricks, concrete blocks, etc. 6 people paint outdoor stucco.

Green Swarms - Buries insulation skirt for shallow insulated footer all around the house.

Blue Swarm - 4 people do blown-cellulose insulation for roof of MicroHouse 1. Finishing work on any outstanding items from previous days.

Afternoon: finishing and cleanup.

D

W

4h

= Perimeter bury

= Bricks

= Insulation

5

including cleanup and classroom

= Walls

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Day 5

  • Morning rest
    • or if not finished, finishing work
    • Optional if finished: Design Session with Sketchup MicroHouse library parts
  • Afternoon: 1-5
    • Review and lessons learned
    • Documentation session - filling in pictures
    • Video capture of participants’ experiences
      • Photo shoot of team
    • Replicability and Global Collaboration discussion
    • Enterprise Discussion
      • How do we scale the project?
  • Dinner and farewell

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User Story Example

Child Stories- MicroHouse 1, 2, 3, 4

Product owners

Rationale

As a workshop participant(who), I want to successfully learn how to install a door (what), because I want to put a new door at home and I don’t know how.

(Acceptance Criteria)

If I had a sketchup design, bill of materials, tools, and a step by step instructions. I believe I could do it with the help of others. (Confirmation)

Epic Story- OSE Global Village Construction Set

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Rowlock Corner

Requirement: (1) break the Corner Cubic Foot seam created in last layer

(2) Use Rowlock for bulk of wall outside of corners (3) Mortaring is brick dipped in mortar

1

vs

1

2

vs

2

deprecated route:

Doing bonding strips on corner - 1-2 strips at 2’ long each - each strip gets you ~250lb tensile strength - so for 14 layers - that is over 3000 lb of extra tensile reinforcement for the corner.

deprecated route:

Doing bonding strips on corner - 1-2 strips at 2’ long each - each strip gets you ~250lb tensile strength - so for 14 layers - that is over 3000 lb of extra tensile reinforcement for the corner.

1

2

Good Route:

Test-Driven Design - (1) can the strip be flat - tested last production run. (2)

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Brick Course Layout - Sketchup Demo Wall Section

Sketchup File demonstration:

  • All walls are patterned
  • The NW corner is rendered brick-by-brick
  • ‘Scene’ tabs show CEB breakdown

(see next slides for screenshots thereof)

~4” side

Bricks on-edge

6” side

12” into page

12” long side

Rowlock

30-second overview http://youtu.be/EBXIGfXV65M

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Wall Concept drawing

MH 4 15’x53’ interior

utility room

door

door

bathroom

MH 1 12’x12’ interior

MH 2 12’x12’ interior

40’

tub

4’ wide apertures spanning from floor to bond beam at 7’ of height

8’ wide gap, double window

Wall starts there - 1’ wide footer

Door Frame starts at 2’ from corner

4’ wide aperture, 3’ from corner

Note that this wall is an extension of N wall of MH2 - corner to corner is 13’ for 12’ inner space if we assume that E wall of MH2 is the W wall of MH4 Utility Room

N

distance from E wall corner to broken line is 13’

South Door is 4’ from corner

2’ from broken line

4’ space

Marshall: Sketchup

basic render MH 1+2, wall render MH4

4’ gap

4’ wide aperture, 2’ from corner

4’ space, 2’ from W corner

16’ long edge - or 15’ of interior space

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Beginning of Technical Design

2352 Bricks

center this on wall

remove window

16’ width, add 2’

add 2’ of space

center 2 doors in wall

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Beginning of Technical Design

2352 Bricks

TODO: extend 12” north (see slide 50)

Render brick-by-brick NW corner

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Workshop Messaging/Positioning

First Position Statement, then Message

What? We are hosting an Experimental Extreme Manufacturing workshop by building on the experience of 3 previous MicroHouse Builds. Our Goal is to build a 765 square foot addition to our first MicroHouse - in just 4 days - starting with foundation in place - complete to interior and exterior finishing.

How? We are doing this by invoking a most ambitious parallel build strategy yet. Goal: nearly 100 feet of wall laid with CEBs - in under 4 hours with 42 people. Goal: roof to cover 750 square feet of

Why is this unique? This is modern-day barnraising + open design + enterprise development by a global collaborative community

Learnings:

  • MicroHouse 1 - First demonstration that the Open Source Soil Pulverizer, Brick Press, and Tractor worked together seamlessly - with skilled operators to produce a beautiful, affordable home - the MicroHouse.
  • MicroHouse 2 - We learned that complete instructionals are a critical prerequisite to house completion - without them, completion cannot occur. Because the workshop grew to 24 participants - this led to the learnings on the dynamics of a swarm build.
  • MicroHouse 3 - 50 people total participated in the build. We learned that increasing the number of participants does not lead to a more complete build if build techniques are not optimized to take advantage of the swarm. Further, we allowed unskilled people to operate machines, and found out that frequent tractor breakage is an issue that needs to be addressed in future builds.
  • MicroHouse 4 - We aim to learn what it takes to harness 48 people effectively in a fun and productive build, and what critical improvements in our process need to be made for this to be highly replicable - and if our techniques can be extended to be competitive with standard house construction

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CNC Furniture

  • CNC Furniture Make issue has design files
  • Recruiting Hackerspace collaborators to come 3 days early
  • Announcement on Facebook:

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Hydronics

  • See DESIGN DOCUMENT
  • Use Buderus radiators
  • Glenwood 7020 stove -
    • System design - documentation
    • Greenwood 100 - Seton boiler, was discontinued
    • Tech support -wildfirefighters.com, woody@woodstoves.net, crazyfirefighters.com
    • Uses thermostatic relief valve
  • Drake’s Landing Alberta - year-round in-ground heat storage - will aim to integrate in-ground heat with summer solar concentrators in later phases

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Hydronic Wood Stove

other options, deprecated

  • Use Buderus radiators
  • Glenwood 7020 stove - not shippable by Sep 25 - so shipped directly with rush by Sept. 19
    • System design - documentation
    • Greenwood 100 - Seton boiler, was discontinued
    • Tech support -wildfirefighters.com, woody@woodstoves.net, crazyfirefighters.com
    • Uses thermostatic relief valve
  • Drake’s Landing Alberta - year-round in-ground heat storage - will aim to integrate in-ground heat with summer solar concentrators in later phases
  • Other Stoves
    • Biasi - 802-583-2726 - online requirements -http://www.houseneeds.com/customer-info/contact-us-admin
    • Harman Stove Company - www.harmanstoves.com - dealer in Jamesport - montanaloghearth@gmail.com 660-684-6331 - LM
    • Charmaster Corp. $7.8k, 218-326-6786 , www.charmaster.com
    • HeatmasterToll Free: 1-877-325-9792 -Email: info@heatmasterss.com -- Phone: (204) 325-9792
      • MO dealers - - 600 Main St - Atlanta, MO, 63530US 660-239-4385 LM. Another in Harriburg, MO - 573-881-3305 - Heatmaster G100 $280 heat ext., stove is $7995. Gasifier type.
    • Aquatherm - online email form -+ phone http://aqua-therm.com/?page_id=66
    • Aquagem - from Obadiah -
    • Woodmaster - (816) 364-6540 - Woodmaster 3300 - outdoor - greg.kerns@woodmasterdealer.com - See more at http://www.woodmaster.com/- 660) 562-2234, allenwenzl@hotmail.com
    • ProFab - 888.933.4440 gave me - bates distro - Jimmy - 601.656.1583 wrong distro., 601.656.5866 - misssouri 601.656.3855
    • Heatmor - woodheat@heatmor.com; darrell@heatmor.com; mgalusha@heatmor.com; MN - 800-834-7552, Local: 218-386-2769
    • Mahoning - WI - 715-627-2788
    • Central Boiler MN 56726 Tel. 1-218-782-2575 (International) - See more at http://www.centralboiler.com/contactus.html#sthash.gtamY2Ab.dpuf. Local MO - 660-562-0501, chilicothe - 660-707-3866, 660-867-5770 + many more in local area
    • Hardy Heater - (601) 656-3855 - outdoor - bbssm@bellsouth.net
    • Polar Furnace - Montana - 1 855 582 2233 LM , info@polarfurnace.com, sales@polarfurnace.com
    • LEI Products - Kentucky -Toll Free: +1.877.458.6928, Office: +1.270.326.2006, E-mail: sales@leiprod.com

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Learning Outcomes

  • CEB Construction
    • Machines, workflow, techniques, stucco wall finish
      • Pressing of Stabilized Bricks
    • Compressed block, stabilized block, insulating block
  • Carpentry - all classroom + hands-on
    • Using a carpenter’s level, square, chalk line (1 min), self-leveling laser level
    • Using a miter saw, skil saw, jigsaw, and and cordless drill
    • How to frame a window
    • How to frame a door
    • How to build structural, insulated roofing panels
    • How to put
  • Plumbing
    • Hooking up a sink, toilet, and bathtub + hands-on
    • How to make water pipe connections to install wood-stove hydronic heating
    • How to install a hot water storage tank
    • How to install a 4-season outdoor water hydrant
  • Heating
    • Installing a wood stove for hydronic heat + hands-on
    • Installing a charcoal kiln for heat and charcoal production
  • Electrical
    • How to make a connection to a breaker box and install new breakers
    • How to run cable underground
    • How to wire outlet boxes, install a ground rod, Ground-Fault Connection Interrupt outlet
  • OSE and the Global Village Construction Set
    • History, status, and future direction - Marcin
    • Design and Build Techniques - Extreme Manufacturing
  • Design
    • How to run effective Design Sprints
    • Reading the landscape
      • Wind, sun, water, dust, noise, snow, soil, vegetation, food production
    • How to design a CEB house using Open Source Ecology’s techniques
      • Component Library
      • Using Component Library to build structures
    • How to design a water system for a house
      • Indoor, outdoor, hydronic heat circuit design
      • Plumbing techniques
    • How to design an electrical circuit for a house
      • Outlet, light, switch, and breaker box wiring
      • Ground rods, GFCI, lightning protection
      • Transfer switches for off-grid power
      • Combined heat and power systems
    • Basic structural design

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Design Sprint Modules

Shopping List for Design Sprints

Resources and Links

  • Google Sketchup of Foundation- Needed for brick layout and design instructions
  • Wall - Modules- Interior - similar
  • Brick floor modules for bricklaying instructions for pattern and process
  • Door Modules- Instructionals can not really be reused from previous versions as amendments are needed for the new wall-2” EPS insulation - inside/outside stucco - totaling 14.5”-15” width - with ability to finish stucco agains the Door/Window module without use of additional trim.
  • Window Modules- Instructionals can be reused from previous versions with minor amendments
  • Roof Modules- Sketchup for new designs for panels
  • Hydronic Stove

MicroHouse 4 Links

  • Foundation

  • Walls
  • Brick floor

  • Doors

  • Windows

  • Roof Modules

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MicroHouse Goals

  • To build an open source, low cost, code-compliant, ecologically friendly Housing Construction Set - that lends itself to viral replication - based on Compressed Earth Blocks and other open source technologies.
  • To develop an open source, Extreme Production enterprise model that provides a scalable, mainstream alternative for the construction of Zero Energy, natural homes at ⅓ the cost of conventional housing - that are buildable on a complete schedule of under one week for 500 square foot starter homes.
  • To disseminate the Extreme Production enterprise blueprints freely as a basis for potentially viral replication by open source entrepreneurs worldwide.

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OSE MicroHouse Version History

MicroHouse 2

April, 2014

$5k in materials, no utilities,

216 sf with loft, 1 foot brick wall

MicroHouse 3

August, 2014 (in progress)

$29k in materials, 512 sf, 2nd floor loft, full utilities

double wall, code-compliant design

MicroHouse 1

October, 2013

$12k in materials, 216 sf with loft,

full utilities, 1 foot brick wall

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MicroHouse Philosophy

  • By using an open source, collaborative process, we improve our design and make it the best possible. By drawing from many disciplines, we arrive at a zero energy, autonomous house that produces food, fuel, and electricity for the inhabitants, and allows for self-employment opportunities via modern, open source appropriate technology as a means of reinventing production in a localized setting, from information economy, to local resource-based digital fabrication.
  • We are out to accomplish a big, hairy, audacious goal - amazing housing at ⅓ of conventional costs - while building in full autonomy - at a blazing fast speed of 5 days - while providing immersion education. Granted - many purists will rebel at the notions of speed compromising any sense of quality. And we say - no - we will accomplish both - at a leisurely pace - by using efficient, open source, state of art, modular swarming techniques for every aspect of the build. The key to that is global collaboration and documentation.

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Pathway to a Successful Build

  • Build Process - By using Compressed Earth Block with simplified brick-laying techniques + modular design including panelized components + a parallel swarm build (on the scale of 48-72 people) - we can compress build time about 15-fold.
  • Immersion Education - By incorporating the build into the format of a hands-on, immersion education, skill-building workshop - we provide the hands-on-deck for the build.
  • Open Design - by building upon available designs, culturing a developer community, and contributing back to the commons - we build a community of design/builders while refining the product continuously.
  • Economic Feasibility - by reducing material costs ⅓ via the use of onsite soil, by using open design to reduce R&D costs, by using extremely efficient and rapid build techniques, and by creating education product - we achieve a complete house build at ⅓ the cost of conventional housing.
  • Design Philosophy - We are designing completely around a swarm build. This means that we will not use standard procedures if they are not consistent with massive parallelling of the build, nor will we design Completion Bottlenecks if we can avoid them. The latter is a “Window of Opportunity” approach: we have a finite amount of time allotted for the workshop. We get done what we get done only in that time, without going into time overruns, with the first priority being the completion of the overall house, not overall parts. Part of this means Contingency-based design as a means to avoid Completion Bottlenecks: if one part is not finished, then: (1), either the build is designed for all other parts of build to be able to be completed in spite of a missing part; or (2) an alternative method is used to optimize for house completion while we think on our feet regarding solutions.

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MicroHouse 4 Goals - 1

  • Build upon OSE experience with 3 previous prototypes (MicroHouse Workshops 1-3) to achieve the highest quality (thermal, air quality, structural, sustainable), most rapid build to date.
    • Wall build - 750 square feet, 8’ high walls - develop technique for effective swarm build that allows 8 teams of 3 to achieve an average of up to 1200 blocks laid per a team of 3 people, at a leisurely pace over 4 hours. World record is about 20 times higher than that for mortared bricks, so based on peak performance cases, and simplification of laying to slurry method - we are in a good position to do this.
    • Roof Build - with open source structural insulated panels - to develop a technique for parallel build of 8 panels installed at a time.
      • Key: parallel build on the ground, including mounting structures, so that roof panel install takes only a few hours of leisurely work with 32 people
        • Actual time for focused install is 2 hours. Built-in leeway to allow for up to 8 hours install
        • Key to success: well-thought out workflow using principles of Extreme Manufacturing (parallel build via swarming and modularity)
    • Wall insulation and siding - develop swarm process
    • Hydronic heating system - document entire system and create a Manual
    • Total - 4 days of build during workshop, and 1 days of curriculum - design, build, enterprise
      • Contingency - if there is bad weather and time does not allow for build completion, we will substitute build completion the education session

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Sustainability Requirement

  • Zero Energy Retrofittable - retrofittable with solar panels, and a combined heat and power system.
  • 50% or more of construction material by weight is local (5000 bricks x 15 lb = 75,000 lb, cf 45k lb for foundation)
  • Embodied energy of home is ½ of average stick built homes
  • Has a food producing perennial garden
  • Plastic recycling via 3D printer filament production
  • Vermipost recycling of all organic matter
  • Retrofittable for cooking gas and electric gas production in the future, stored in pressurized Liquid Propane tanks

Feedback

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Replicability Requirement

  • Create definitive method for laying on average 200 bricks per person per day and attaining wall finishing - using a 24 person team, with pre-pressed bricks.
    • Includes insulation and stucco on wall sections in regular intervals of 4’ for insulation and 27” for stucco metal lath
    • Latex paint on inside of wall, tuck point smooths walls on inside.
  • Define a method for modular roof building for spanning 14’ of interior space
  • Add warehouse elements of design
    • roof, window, and door modules - Sketchup, LibreCAD
    • Wall module - Sketchup, LibreCAD
    • Foundation Module - Sketchup, LibreCAD
    • Hydronic heating module (2D in Google Presentation)
  • Define a construction set for an open source bathroom with tub, toilet, sink, and on-demand water heater
  • Attain a workflow compression factor of 30
    • This is work of 30 days with 1 person compressed to 1 day with 30 people
  • Define a clear documentation protocol for 4 people, including nightly upload of media, and an ongoing Manual Template - filling in pictures into specified placeholders. Prepared as part of 2 week documentation sprint prior to event.
  • Complete video and step-by-step of all techniques, plus timelapse video produced

Feedback

1

1

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Water System Requirement

  • Water lines trenched prior to Build Event
    • Freeze Proof hydrant install during the event
  • Hydronic system whole house heating
    • Bathroom connection option for hot water heating via hydronic system in addition to on-demand hot water system
  • Integrate hydronic system for hot water in cold weather
    • Allow for annual heat storage via hydronic outlet to future year-round greenhouse mass bed heat storage

Feedback

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MicroHouse 4 Addition

module 4 - addition of a triple-sized module that could have a second/bigger bathroom (where it connects to the existing utility wall) and a large room with a long table for team meetings/lunches/dinners, and double as work room for 2 people. This module wouldn't need a loft.

bath

room

garden

module 1

(kitchen/bathroom/lounge)

module 2

(bedroom/closet)

module 3

module 4b - hydronic stove, wood storage, recycling bin, compost bin, food storage, freezer, mops/buckets, garden tools, chainsaw, laundry

Stove

MicroHouse 4 is added

to the back of this:

office

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Landscaping and Finishing

  • MH 1 Porch
  • Perennial edibles
  • Outdoor hydrant
  • Integration with Charcoal Combined Heat and Power system for backup power using Honda EU2000i wood gas conversion?

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Shallow Insulated Footer Foundation

gravel

Concrete Footer 8"x12"

Gravel

Gravel

6 mil poly Barrier

6" wider pea gravel on each side of footer

2” EPS insulation

CEB Brick

Brick

Flashing

6 mil black poly

Soil level

4"x6" brick face

2" insulation stretches 4' around house

2 layers of 6 mil poly below entire foundation

Ground Level

½” rebar

(Outside)

Brick

sand

Washed Gravel Base - 6"

CEB Floor

metal lath

for stucco

stucco

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Site Work Concept

Micro

House 1

base of footer

6” down

16’ out

8‘

36’ out

drainage swale

MH 1

access road

16’

2’

15’11”

Excavation Area

Excavation:

  • Dig 6” down below footer of Microhouse 1
  • Go out another 8 feet - sloping down 2” over the 8‘

  • Do a drainage ditch after going 8’ out. Do this on North and East sides.
  • Ditch should be 8’ wide and 1’ deep

Rationale:

  • 16’ required until foundation wall
  • 8’ out for sloping moisture away
  • Another 8’ for smooth drainage ditch slope so people can walk over that

swale

wall brick pallets (100 4” bricks each)

6’ space between

house and pallets

3” floor brick pallets (125 3” bricks each)

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Site Work Plan

  1. Day 1 - Mark corner posts for area
  2. Use laser level to mark rebar posts on 4 corners + fluorescent paint with rebar
    1. Place corner posts 4’ out to not puncture bobcat tires
  3. Level out foundation area to 40’ N and 24’ E of MH1, 6” below base of MH 1 - for gravel
  4. Dig swale area 16’ wide
  5. Push soil downhill for infill, to be spread back around house at end
  6. Day 2 - Get Gravel
    • 14.5 cubic yards needed for 6” base - truck 1
    • Second full truck - 3” layer around with rest to make new access road
    • Truck 3 to complete new acess road
  7. Day 3 - Do Foundation

MH 1

6’ space between

house and pallets

3” floor brick pallets (125 3” bricks each)

15’

1’ down from

surface level

  • Dan digester
  • CNC machine guy
  • SACA
  • Solar Flowers
  • Paul Neelands - torch table
  • China
  • Cesar Harada
  • Troy gasifier

16’

8’

16’ swale

patio

addition

existing road

16’ swale

Note: West side slopes down, no swale needed

new access

8’ to swale

40’ out

24’out

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House Geometry

Excavation:

  • Dig 6” down below footer of Microhouse 1
  • Fill that with gravel; poly vapor barrier on top

Micro

House 1

15’11”

14’

8’

2” EPS Insulation all around house

4 mil

polyethylene

stem wall

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Light-weight, Insulated, Structural Roof Panels - 1

  • 2 are stacked for 11” thickness
  • Span Calculator: 16” centers for 16’ span
    • Top layer of 2”x6” is 16’ long
    • Bottom layer is 2”x6”, 16’ long
      • #1 grade allows 21-7 span with 24” on center
  • 3’x16’ size
  • Made of 2”x6” lumber
  • Build and painted on the ground
  • Layer 1 and 2 is staggered
  • Capped for corrugated roof finish

plywood

panels are not staggered

layer 1 (bottom panel)

hurricane strap into bond beam

Panel Cross Section - 2 layer:

Metal Roofing

Vapor Barrier

Thermal and Support Detail

layer 2

siding

joist hanger

Added Fiberglass insulation

Flashing

2”x12”

2”x6”

Easy Trim

Easy Trim

roofin

includes bottom ⅜” plwood, pre-painted

bottom panel

Note: double stacked insulation (6” fiberglass) costs 75cents/sf for 1’ thickness cf. $1/sf for 12” insulation

top panel

(2x6s on wide face for unskilled roofing screw-in)

fiberglass insulation between panels

2x6s stand vertical

2x6s stand horizontal

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Lightweight, Insulated, Structural Roof Panels - 2

First Attempt.

plywood

corrugated metal roof

Panel Cross Section:

fiberglass insulation between panels

Step 2: nail into bond beam on bottom. Continue layer 1.

Step 1: Nail into top support (arrows show nail direction)

2”x12” attached to back of MH 1

4 mil Poly on bottom of Panel 2 to hold insulation

edge of plywood defines straightness

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Simplified Panels: Requirements - 3

  • Must span 16’
  • Universally-applicable system for structural roofing with 10 psf dead loads and 20 psf suggested live loads for roof - table 3.4
  • They can fit together with good insulating properties
    • No air gaps and minimum thermal bridging
  • Must allow for insulation
  • Light enough for 2 people to lift with ease
    • Ex to the right - about 176 lb - too heavy
      • 79 lb for lumber - 21 lb for a 2x6x16’ - 3.75 of them
        • with 24 on center spacing (21’ span allowed for #1 lumber)
      • 64 lb plywood - 36 lb for ⅜” plywood, or 28.5 lb, or 26 lb, or 34 lb, or 32
      • Insulation- .25lb/sf = 32 lbs
    • Try 2 - 3’x16’ - 142 lb total - use the rest of the plywood elsewhere
      • 70 lb lumber
      • 48 lb plywood
      • 24 lb insulation

4’x16’

Concept: laid on whatever supports, and nailed on top of one another, vertically joined with 12” strips of ⅜” plywood, and nailed to adjacent ones - seams on bottom joined with 8” strips of ⅜” plywood.

3’x16’

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Simplified Panels: Bottom Panel Fabrication - 4

  1. Note: bottom panel has plywood on one side only. Start with 3x8 plywood
  2. Add first 16’ 2x6 - using straight edge of plywood to make potentially warped 2x6s to conform to it
  3. Add second 16’ 2x6
    • Fill in 6” fiberglass batt insulation
  4. Install horizontal members for top 8’ of assembly
  5. Add second piece of plywood on other side of assembly
  6. Add third piece of plywood on bottom
  7. Add remaining horizontals between 16’ members
  8. Add fourth piece of plywood to bottom
  9. Put in 6” fiberglass batt insulation - sections

See example:

Goal Time to completion with 2 people: 45 minutes

    • Requires length jig for horizontal members
  • Scalable to 12 teams at one time
    • Requires 12 drills, 4 nail guns
  • Need total of 18 panels for bottom and 18 panels for top (36 total)

Concept: use the perfectly cut plywood and its virgin edge to define a straight edge, such that finishing detail will simply mean caulking ceiling seams once panels are installed.

3’x16’

1

2

3

5

6

4

8

7

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Simplified Panels: Bottom Panel Leveling - 5

Concept: bottom panels must be aligned along a plane so the ceiling is level. If the top panels are to be staggered, this allows us to clamp 2 adjacent panel rafters, and bond them with a plate to even out their vertical alignment.

Bottom rafter 1

bottom panel 1

bottom panel 2

Bottom rafter 2

2”x4”

clamp

screwing in from top via a 2x4 piece of lumber levels out 2 bottom panel seams horizontally, assuming clamp force < screw force

plane

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Solar Panels Requirement

  • Sunelec.com - 90W module specs
    • 5 kW System - 56 panels - $5k
  • Ben - installation
  • Newtownbuilders.com - collaboration on Zero Energy with PV?

REQUIREMENT

  • Cost <$1/watt for materials (no labor)
  • Grid intertie inverter
  • Sufficient for Zero Energy home operation (5 kW)
  • Roof mount

Feedback

MH 1

Module 2

40’

16’

40 panels - 36 feet long, 17’ high

53 lb each - 2120 lb total

16 panels - 29 feet long, 17’ high

848 lb - mounted on patio

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Design Library and Design Sprints

  • Assets -
    • MicroHouse 1 Sketchup
    • MicroHouse 2 Sketchup
    • MicroHouse 3 Sketchup
    • MicroHouse 4 Sketchup Concept
    • MicroHouse 4 Interior Design
    • MicroHouse 4 Exterior Design

Microtasks

  • Soil Test
  • Compressive Test
  • Sketchup Library
  • Instructional for Sketchup Library

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Design

Construction

Preparation

Construction Starts

Modules

How to Build

Note: Data & Cost Cycles

MicroHouse Four

Completion

Scope

Quality

Schedule

Budget

Resources

Risk

Project Constraints

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Work Structure

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Build Process Design

1. Work Breakdown Structure Draft (WBS)

2. WBS Dictionary

3. Documentation Sprint

4. Modules Published

5. Scrum Teams

6. Burn Down-Chart

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Extreme Production Principles

1. Scrum Organization

a. Roles & Responsibilities

b. Sprints/Iterative Design

c. Make Work Visible

d. Measure Velocity

e. Continuous Improvement (Lean)

2. XP Engineering Principles

a. User Stories

b. Pairing and Swarming

c. Test Driven Development

3. Object-Oriented Architecture

a. Modular Components

b. Contract-First Design

c. Design Patterns

d. Re-use and Inheritance

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Scrum Team & Build Swarms

1 Scrum Leader + 7 Partners = 8 People = Development Team

6 Scrum Leaders + 42 Partners + 2 Scrum Masters + Product Owners= 50 People + World = Scrum Team

Alpha

Gamma

Beta

Delta

Epsilon

Zeta

Scrum

Masters

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1

2

3

4

17

18

19

20

5

6

7

8

21

22

23

24

9

10

11

12

25

26

27

28

13

14

15

16

29

30

31

32

33

34

35

36

37

38

39

40

41

42

43

44

45

46

47

48

Beta

Gamma

Delta

Epsilon

Build Teams

e one

1

2

3

Alpha

Zeta

e one

4

5

6

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Schedule (Backlog Routine Draft)

  • Breakfast
  • Debriefing with Scrum Masters/Leaders/Safety Session
  • Scrum leaders breakout to roll call teams
  • Introductions, Progress Reports, Announcements and Q & A
  • Combined Task Force Implementation Wave 1
  • Lunch - Group/Team Pictures
  • Debriefing with Scrum Masters/Leaders/Safety Session
  • Scrum leaders breakout to roll call teams
  • Introductions, Progress Reports, Announcements and Q & A
  • Combined Task Force Implementation Wave 2
  • Dinner
  • Debriefing with Scrum Masters/Leaders/Safety Session
  • Scrum leaders breakout to roll call teams
  • Salutations, Progress Report, Announcements, and Q & A

Visual Aids for Team Development & Communication

Progress Board- Daily Swarm Progress

Burndown Chart- Velocity

Team Assignments- Map of Team Staging for Work

Media Slideshow- Daily Capture and Upload

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Waterfall Prioritization

Day One

Foundation-

Bricklaying

  • Floors -
    • detailed instructions - A to Z
    • Electrical - detailed plan
    • Plumbing - detailed plan
  • Walls - Details A to Z
    • Structure
    • Apertures
    • Electrical

Exteriors Apertures

  • Apertures Door One - select a desirable replicable door and provide detailed instructions
  • Apertures French Door - detailed instructionals

Window Frames Sizes

  • Window 1-3 Main room - find one similar in Menards
  • Window Four
  • Window Five
  • Window Six

Bond Beam

  • Hurricane Straps

Stucco

  • Interior
  • Exterior
    • Insulation
    • Stucco

Day Two

Roof Panels and Side Slanted Walls

  • Bottom 18
  • Top 18
  • Chimney stove pipe detail
  • Hot water full detail

Day Three

  • Exterior Insulation
  • Hydronic Radiators Installation
  • Electrical
    • Outlets
      • Number of outlets
      • Type of outlets
      • Locations
    • Outlet Location

Day Four

Roof Insulation

  • Use sketch

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Foundation

Brick Walls

Arperatures

  • Doors
  • Windows

Floors

  • Electrical
  • Plumbing

Exterior Insulation

Stucco Exterior

Requirements

Concept Design/Drawing Detail

Technical Drawing Detail (DXF or …)

Exploded Diagram

1

2

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Stucco Interior

Bond Beam

  • Hurricane straps

Roof- Slide 44

Slide 46

Doors

Windows

Requirements

Concept Design/Drawing Detail

Technical Drawing Detail (DXF or …)

Exploded Diagram

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Hydronic System

Plumbing

Electrical

Dividing Walls

Requirements

Concept Design/Drawing Detail

Technical Drawing Detail (DXF or …)

Exploded Diagram

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Floor Requirements

Historical Sources - MH1-1/2

Design Requirements

Concept Drawings

Sketchup Drawings

15 x 53 ft area ~ 795 sqft

Block pattern

Site Work

Instructionals

Preparation work

Installation process

~ 15 ft

12

4

6

72 sq. inches

180 in sq x 636 = 114480 sq in/72 sq in = ~1590 Bricks

4 Sections

12 People

3 Teams or 6 People on each side

Plumbing Trim Details Needs

Electrical routes

utility raceway

~ 53 ft

1

2

3

4

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Sketchup Drawings - Requirements

Size of Bricks- l x w x h 12 x 6 x 4

Modular Unit - ½ and 1 ft stretching- sheets -

Pattern Development - Two

Floor Sketchup File Here

Note: Need to Add section for stove and bathtub

Sheets

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Instructions--

1. Assign Teams and Roles

  • Teams
    • 2 Teams of 6 or 4 teams of 3
    • Roles
      • Tender - Brick Carrier
        • Communication with team members
        • Organizing the size of bricks
        • Brings brick to mason
      • Mason - Brick layer - Brick place with 6 inch face down
        • Prepares sub-surface for leveling of next brick
        • Communicates desired size of brick for adjacent leveling requirements
      • Detailer -
        • Communicates with both teams members on dynamic needs
        • Fills gaps and levels bricks

2. Developing process

  • Virtual exercise of laying bricks
    • Sketchup
    • Online video
    • Instructionals
  • Hands-on
    • Local
    • Workshop

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Basket Weave with ~1/8th inch lay with offset

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1. Walls with apertures

2. Roof

3. Hydronic heating system

4. Floor

5. Exterior stucco

6. Interior plaster

7. Interior plaster

8. Interior walls/shelves

9. Furniture

Bill of Material Older Links

2013 - Micro House

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Frame

Exterior 85.5

Interior 81.5

Door

82

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