Seed Home v2 Data Collection

Total Time Budget Spreadsheet

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Notebook Data Collection Snapshots

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July + August

• Day 34 - Fri Aug 6. Rigid foam insulation install. Should go quickly. Then EPDM. EPDM bond - scabs, don't puncture through. Precut on ground, makes it easier to cut. Do it in garage area?
• Day 33 - Thu. Aug 5. Installed roof OSB. Cut insulation box riser - 4" - plywood + mostly 10' 2x4s. Screwed in insulation box riser. Slight rain rained through sloped roof. OSB installation was seamless, no pun intended. Laid first-laid row (row 2 looking from West) west of the 8' mark. Alignment was perfect. Procedure: screw down 0 and 8' marks, so that 2-4-6 foot location joists are movable. Then, lay the first sheet at 4' mark of first-laid row, staggering the pattern with 4' offset. This now locates the corresponding joist. Nowhere do the 2 and 6' locations have an OSB seam - so these can fall anywhere. The point of locating the 4' marks is - the joists can shift N-S, so that alignment of the OSB is perfect and goes fast. As soon as a 32' row is laid, 2 teams can work from this row. Heave-ho of plywood to the top of the roof is accomplished from the short edge of an incomplete row - otherwise it's more difficult to drag the OSB up. Improvement points - power ladder, or grapple for OSB that allows a handle to be used.
• Day 32 - Wed. Aug 4. Roof joists, riser, top plate installed. See picture of dimensions of roof [1]. Note that the measurements of diagonals at top plate were off by 2" - 35'7" and 35'9". At the top of roof box, cross measurements were 35'9" for the NW to SE, and 35'8-3/4" for NE to SW, or near perfect alignment. This indicates that the former measurement, off by 2", is bogus. How can we shift 2" when we measure at the top of roof box. Hint- do not let novices measure at the ring end of tape - have them measure at the reading end of tape because the ring is unclear in terms of where to measure from. 9 AM to 7 PM work day.
• Day 31 - Tue. Aug 3. Roof Joists, riser, top plate of second story prepped. MJ KC visit - Dean Truman
• Day 30 - Mon. Aug 1. Second story built, all day
• Day 29 - Fri Aug 30 - 4 second story windows built, afternoon
• Day 28 - 1st floor finish of joists
• Day 27 - Walls finish
• Day 26 - top plate, walls
• Day 25 - walls
• Day 24 - walls
• Day 23
• Day 17 - modules, window module
• Day 16 - modules with insulation, workshop

Day 9

• 1 hr spent with 2 people - final sand.
• Tree planting + house cleaning + MicroTrac upgrade start - rest of day

Day 8

• 8.33 hr tot, 1.5 cleaning MH 4. With 2 people.
• Finished Stain. Now needs varnish and final sanding.

Detailed Analysis, Long Clip 1

• Total clip - 17:38 min - or 8:49 hrs (1 minute to 30 minute ratio)
• Start - 0:15

  20 - first sand.

• 2:50 - finished sanding. 2:30 means 1:15 hr.
• Caleb did 10 from 21-54 sec = or 33 sec - meaning 3.3 sec per or 1:39 per panel.
• 10 painted from 2:50 paint start to 3:39. Or 2.45 minutes per paint.
• 3:45 to 4:01 break. 7 min.
• 2:50 paint to 5:42 paint - 1 hr 26 min.
• 5:42-6:33 cleaned up from paint, set up racks for 2nd coat. 25 min.
• 6:33 second coat start. 13:26 end - or 3:26 hr. That is 1.03 min per panel. - with 2 people working on it. So 2 min per panel for 1 person. Consistent time is 2 min per coat.
• 9:30-10:44 break. 37 min break.
• If we add up 200 panels - one sand, one coat, second coat - then total time should be 600 minutes. That is 10 hours. of time.

Day 7

Pix - [2]

• 8:20 for 2 people - remove and organize foundation forms, and keep working on 2nd story floor boards. Still a few left on 1st coat, still needs second coat according to procedure - [3]

Day 6

See video tape - [4].

• 8 hrs x2 people - cut all floor boards for 2nd floor from 1/4" sanded plywood, start painting, lesson on sanding and painting. Time spent figuring out jig. Time to cut all joists to size - according to [5]
• Caleb miscut 3 joists by 2 feet. Learning: don't use feet - use inches (189" - not 15'9" - the former cannot be mistaken on a tape measure). In this case, 15'9" was mistaken for 13'9".
• Josh mentioned a local contractor - charged $270k for a 1000 sf home, not including land and utility hookups - just build. Includes labor and materials, some outsourced to subcontractors (electrical, etc).

Day 5

See video tape for complete times. [6]

• 58 minutes for panel #2 - Caleb and Josh. First was figuring out how to do it - punch insulation under blocking.
• Sanded plywood - got a little wet on edges - starts to delaminate easily - it is fragile.
• Steve Grubbs - bible nondenominational - nice guy - contractor from Cameron - 1000 sf house
• Lux Construction Co - Eric
• Ed Riley - contractor
• Bolts - 3/8" for temp structure - not used - just screwed in
• Finishing paint touchup
• Missed part of indoor rafter
• Yesterday - did 1 gallon of 3 of Walnut stain with diesel, should be mineral spirits, but probably ok since the walnut stain itself is really nasty already
• Spraying treated lumber - came out way darker than panels and 1/4s - different wood composition? 'So can spray 1 time and spread with rag to get evenness' and more light color instead of overspraying

Day 4

• At end of it, about 1/2 bucket of white exterior paint is left
• 20 hrs - 17 + 3 hr at end to finish spray. Management - 8:30 hrs. Just Josh + Caleb.

See video tape - [7]

• Tree seeds, bugs, dirt get on beadboard on floor. Set up on floor only under clean conditions. Probably needs retouch. Many places where ridges didn't get filled in totally - bad angle on floor. Standing up gets ridges. Needs a jig to hold up panels leaning against each other, maybe touch-up of small holder points at end. Or design touch-up-less holders that allow full access to panel
• Got airless sprayers for stain fixed - 2
• One sprung a large leak, with walnut
• Finished on one
• 8-7:40 MJ
• 8:30 hr for Caleb and Josh
• Used 60% Jarrah Brown to 40% diesel for red stain - 2 coats + touchup
• Started with full Jarrah Brown - way too dark or airless
• Airless goes super fast - no point at all for HPLV Purple - 10x speed increase on airless - sucks 1-5 gallons at a time before refill
• Not a single clog
• Needle flipped for purging
• Nozzle must be released sometimes if 3000 PSI pressure locks up nozzle
• Nozzle must be exactly lined up - otherwise it will backspray on operator
• Wear safety goggles - can penetrate skin
• Prime with setting down
• Spray with setting on forward.
• Use high pressure setting
• It takes one breath to paint a panel
• Difficulty bending down
• One camera bumped - mini usb charge port seems to have gone out
• Beadboard Panels on back of pickup - lay them all out - easiest way to spray regarding all at one time
• Vast majority of time is materials handling - people can't keep up with sprayer re moving panels into place
• Do not use purple gun any more - night and day difference - if all laid out it would probably take 3 hours to paint everything
• At end, ceiling and trim went very quick
• Data on materials moving times______________
• Body count of empty 5 gallon jugs and paint remaining______________ - for gloss, white, red, walnut
• Seems like I have too much 2x6 PT stained - ____________ - needed- band holder = 100' = 6 long ones, that's all. But also - the roof hold-down? Another 6, so probably 12 total?
• One side trim paint for carport and window trim?_______
• Should be 2 sides trim for decorative band?______
• What actually got 2 sides - any?

Day 3 - 4/29/21

See video tape - [8]

• 20.5 hours + 7.5 hr management (did some lifting)
• 3 hours Matthew, 5.5 Brayden, 6 for Josh and Caleb
• Laid all panels on ground for spraying, with pro pump sprayer. Goes fast.
• Made racks for putting up the exterior treated lumber for staining and did all exterior treated
• Did 8 of the carport ceiling.
• Painted all purchased interior panels, needs second coat on about 24 (not finished) +28 (pile from first Sunday and Katie Crew).
• Laid out _____many____ beadboard panels on driveway and elsewhere
• Used up ____27.5_____ buckets of paint so far (120 sf/gallon - ridiculous - for ~120 panels).
• Used up _____lots_____ gallons of stain so far. 9 counted in garbage.
• Used up _____2.5______ High Gloss Exterior so far, 1.5 left ? 4 total?
• Interior panels got wet under tarp.
• Some 1/4" sanded ply got wet under tarp on edges
• Cleanup of 3 guns from oil paint takes 1 hour with one person.
• Conclusion: airless sprayer is a must. Each panel takes a minute or even less - check the video tape
• For trim and exterior stain outside of panels - limiting step is material handling, not paint time with HF purple gun.
• Compressor with 3 sprayers - works well. Airless is an absolute must next time - get everyone materials handling, and one person spraying.
• Beadboard - must be sprayed from 2 sides for it to get in cracks.
• Caleb hated the sticky stain
• Matthew went at it - self directed - we set up 5 staining racks total.

Day 2 - White Paint - 4/25/21 Sun

Video Tape - [9]

• Time budget - 9 hours work. 10.5 actual. Lots of moving things, HVLP is definitely not to be used here. Works, but takes too long. Not for production, but may be ok for 1-off. Calculate total time if Purple HVLP - compare economics to airless. Still probably faster than rollers.
• Katie Ousley, Daniel + Andrew Wilson
• Painting/staining - painted 28 panels white, but needs finish coat)
• Purple HVLP - needs 2 coats or more. Not easy to do full hide - too slow.
• 3.5 hr with 3 people. But - setup for taking panels down, and putting up interior panels for spraying.
• 3 hr at best with 3 people if exclude equipment setup (not spraying, clogged upon startup)
• check video for actual time
• I believe we used no more than 3 gallons - one bucket - which was not full - for the 3 hrs of 3 people.

Day 1 - Finishing Temp Structure + Stain

Video Tape - [10]

• House time budget - 15 hours. 10 hours stain, 6 hours concrete polish including 1 hr setup. 2 people.
• Prior time total from Foundation - 42 hrs, and Stain - 7.2

Exterior Stain Spraying

• Usage: 6 gal for 56 panels=300 sf/gallon. Half the stated max. Windy conditions outside + fuzzy surface can be the culprits. This includes stain from winter staining indoors, 9 panels per gallon about.
• 29 done - Randy + Caleb - Randy started at 11 AM. Caleb + Randy = 4+6=10 hr for about 30 panels so 20 minutes each. Check the video tape.
  • 27 left
  • Total was - 59+24=83 total
• Josh - all day on concrete polish. 3.5 hours on 50 grit and 1.5 on 500 grit. (before that, setup water, and finish of temp structure). Total hours from 8 AM to 5 PM.
  • 4 hours - temp structure frame finish up to trusses going on top starting at the 16x16 already done (1.2 min at 3 sec interval = 2 hr), water hookup, practice, comparison of triple grinder with single - both worked just about same speed, so settled on 1 grinder. Caleb finished putting up the trusses, after getting them to the top with Josh.
• 7" grinding wheel - for 500 sf minus the bathtub area and minus the stair area. Rest was not attended to since boundaries for cabinets are not clear.
• 1.5 hr on 500 grit - but that is too fine so that did not really do anything, as expected because one cannot skip steps.

Paint Available - as of Day 1

• Walnut 3 gal
• [3] 5 gal exterior semigloss - turned to [4] + 1 more or 21 gallons total.
• [1.5] interior white (one extended). Used up [0.5] already.
• 6 Jarrah Brown. Have 1 left.
• Return - 4 gold

Need

• Jarrah Brown - for 27 panels left. 17 need to be double sided.

Day -1

See the video tape - [11]

• Did the temporary covered structure - Caleb finished trusses 8-10 AM

Development Time Comment

Overall dev time until SEH 2:

• Former builds - 50 people*80 hours - 1 workshop - 4000 hours
• 30 people * 40 hours = 1200 hours
• 2 full person years direct development - 4000
• 1 full person year background - 2000
• Ancillary systems and machines - 1 full year of development time - 2000

Total - 13.2k hours of development.

Why large scale development is needed? - and the reason is that it takes tremendous effort to deliver the above stated goal. In practice, the Extreme Enterprise Manual can only set a pattern for one house model, but with the information provided, other models can readily be derived. First model will require about 40,000 hours of development/documentation to give it full digital scalability. Each additional model will probably require 1000 hours of development. The numbers add up to 24 hrs*2000 people = 48000 hours, where 1000s of hours (estimated time spent already is 8000 hours to get to the design core).

Wall Panel Predictions

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Stain

• Jarrah Brown - 9.2 panels sprayed per gallon, full strength.
• 60/45 PSI setting on both guns. 60 PSI initial, 45 PSI during spray
• Both guns on Ingersoll Rand gas compressor, 1 gas tank for 8 hours, about 2 quart?
• Initial panels - 52 minutes to stain. Have to brush them off before spraying.

2 handed spraying with an Ingersoll Rand compressor, 60 PSI with 45psi trigger pressure using the famous Harbor Freight Purple Guns and 32 oz gravity cups. https://www.harborfreight.com/20-oz-h...​. Strained with 60 mesh strainer. https://www.harborfreight.com/pack-of...​. Disclaimer: Harbor Freight is not paying us to advertise their wares.

Works well in sub-freezing weather as in the video. Each gallon of stain covers 9.2 panels. 18 seconds of video at 3 second time lapse interval means 27 minutes of video - or 1 panel stained with Jarrah Brown color every 9 minutes. Includes time to brush panels off with broom, as there is sawdust on these rough cut exterior panels, and time includes straining stain and moving panels. For an entire Seed Eco-Home 2 with 48 of these panels (1536 square feet of panels), that would be 7.2 hours for exterior stain at this rate. Is that good or can we do better?

Spraying Tests

• Note: latex, and acrylic 35F rated with addition of Floetrol, does not spray through HVLP gun. It does not even strain through 70 mesh at 35F.
• Settings on The Purple Harbor Freight Gun - full throttle on fan, minus until it starts to reduce diameter
• Water cleaning results - good results.
• Diesel cleaning results - point is to keep a little oil in the gun to prevent rust. Good. Just pump it.
• Spraying rate - for water at 40 PSI regulator. 350 ml in 2:31 minutes. 1000 ml is 33 oz. 3 oz/min spray rate, looks like. About 5 minutes per small 20 oz stock cup, about 8 minutes per 33 oz 1 l cup.
• Pure walnut for indoor, pure brown for outdoor. No thinner.

Spraying

• Prep - cleaning shop and laying out all of the interior plywood - 53 sheets - started about 2 pm, and finished 5:10.
• Typical camera settings for timelapse - 1 second for the time data videos.

Data

Final Foundation Result

• Length to outside of insulation -
• Length to inside of insulation -
• Lengths of diagonals to outside of insulation -
• Z difference on 4 corners and in mid point of long side -
• Location of plumbing hole -
• Actual locations of anchors (from outside of foundation)

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Grading

• Ample time spend preparing solar power stations for 3 cameras, and making outdoor industrial tripods for cameras for wind and weather and long-term timelapses.
• 7.2 hours machine time on Takeuchi rented tracked 72 hp 8000 lb traction bobcat to grade a pad to +-2". Pad size - 32x64 feet including garage and 8' outer perimeter for scaffolding and drainage later.Additional time marking, clearing with chainsaw, etc. One day of LifeTrac with initial clearing and moving logs.

Moving Gravel

• 26 minutes staking out the new 32x16 location for Rosebud, for actual foundation.
• 1:07 hr moving gravel from load dump to middle of foundation. Note that this could have been done on the spot with the gravel truck, if we got the dump truck here after the foundation pad was graded.

Preparing Foundation Forms

• 2:15 hr - Form Lumber prep. Making and sharpening 68 stakes (12 extra) from 2x2s, combining 2x8x8 to 2x8x16 (only 3 were 16s), cutting 28 supports, and making a 16' gravel screed board. Collecting spacer boards for putting under foundation.

Installing Forms

• 0:38 hr - making 32x16 box. 2 joints made. 1 mistake - joined on wrong side of board where extension was made of two 8 footers. Also, one 16 footer had an extra joint, which was taken off.
• 0:08 hr - Laying out all support boards and stakes next to box.

Day of Pour (Tuesday)

• Started at 9:00 AM, so total hours MJ were 11:30. Final cleanup of trench for 15 minutes. Cutting and bending rebar. Unloading the remesh (nightmare out of van as it gets stuck all the time). 9:28 MJ Day of Pour - trench, rebar, spread + screed gravel, pour, and trowel for about 2 hr more than Gary
• 5:00 Gary (1:30-6:30) - rebar, polyethylene, pour, float and trowel
• 3:00 Catarina - mudsill anchors, rebar, poly. Setting rough plumbing box level. Cutting wood blocks as remesh chairs, but they didn't really work.

Seed Home 2 Data Collection Plan

A part of our unique value proposition is a house that is easy to build, in a way that breaks the Iron Triangle.

The ease must be communicated well.

Ultimately, we say it takes X hours to build the entire house, at a cost of Y based on standard labor.

X and Y are to be the lowest in the industry, for replicable housing - not one-off projects.

Some of the numbers that we need to validate include details of the main build, outside of foundation, which is done typically by a helical pier contractor.

Links

• Seed Home v2