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Types of Homes | Plant Pesentation |
The overall Plant size needed is between 50,000 to 80,000 square feet.
[4650 sq meters to 7440 sq meters]. The recommended size is a Minimum of 100 ft/30meters wide X 500 ft/153 meters long. The longer the building the better. This will allow for room to move the boxes down to the next Station and keep them inside the building, out of the weather.
The center area for the assembly should be a minimum of75 ft/22 meters of Open Span Area without any support posts. We recommend having this amount so the boxes or sections can be moved freely to each station.
With an average size house of 600 sq ft/55 sq meters, a typical size would be 24 ft/7.3 meters X 28 ft/8.5 meters. Since these houses will be smaller than in the US, we can build both sections on one Frame and ship them together. What this means is this: The total size of the house is 24 ft X 28 ft or 672 sq ft. This house will consist of two sections or boxes that are 12 ft X 28 ft in size. When these t sections are assembled on the foundation, the house will be 24 ft X 28 ft in size.
By keeping the open span area 75 ft/22 meters wide, we can build 2 sections that are 12 ft X 28 ft long on one frame and move the houses down the line to each station, as more materials are being added. With two sections of 28 ft each on one frame, this is only 56 ft and we will have 75 ft of open span clearance between support posts.
When the building is 100 ft/30.5 meters wide, the side areas are used for material storage. On the Exterior Walls of the Building, there are Overhead Doors installed so that after each days production, the materials used for the day are replaced from the storage room.
So if the building is 100 ft wide, the Open Span area is 75 ft and the 25 ft is used for the materials to be stored at each station. At Station 1, the main materials are the OSB T & G [Tongue and Groove] deck sheathing that is glued and screwed to the wood frame structure. The wood frame is made from 2” X 8” or 2” X 10” joists. The inside walls on both sections come together and meet, forming the Marriage Wall.
The vinyl flooring and under layment is added here as the house is being built. When the floors are finished, they are moved to the next station where the Exterior Walls are built.
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In the storage area of this station, lumber and gypsum board is set within reach for the workers to build the Exterior Walls. At the third Station, the wall studs and drywall are also placed here to build the Interior walls. This takes place at every station. Whatever section of work that must be done, the materials are stored close by so the workers can easily use them. Each evening, after the production run, the materials are replaced so the next days work can be completed.
STATIONS & MATERIALS NEEDED
STATION #1:
Correct size, grade of lumber used for floors; all metal hangers and fasteners; vinyl flooring for kitchens, bathrooms and closets; deck panels either OSB or Plywood; nails, screws and adhesives. Automatic Nail guns and Screw guns.
STATION #2:
Walls for building interior walls; gypsum; screws, nails and adhesives. Nail guns and screw guns.
STATION #3:
Lumber for building exterior walls; gypsum, screws, nails and adhesives. Nail guns and screw guns.
STATION #4:
MEZZANINE [2 Story Deck to build Ceilings]. Ceilings are constructed on an elevated platform. Exterior frame and joists are assembled with drywall placed face down. Foam glue/adhesive is sprayed on the drywall and joists and sets in 10 minutes. Lumber frames are nailed, but drywall and joists only require foam glue. Ceilings require no nails or screws.
ROOFS are also assembled here. For single store homes, Swing Roof trusses are installed with the ceiling joists. For 2 story homes the ceilings are built with the roof trusses separately, depending on the size and style of home ordered.
STATION #5:
Spackling & Joint Compound & Painting work is done here. Once the ceiling is set on top of the exterior walls, the corners of the drywall and the seams are tapped and ‘mudded” with the joint compound to seal and prepare the walls.
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Once these areas are dry, they are lightly sanded and the interior walls are primed and prepared for painting. Walls are Spray painted with several coats of Primer and then 2 coats of Finish Wall Paint.
STATION #6:
Plumbing, Electrical and Wiring and Insulation are added to exterior walls from the outside. Once inspected, the exterior sheathing is glued and screwed to the outside studs and windows and doors installed.
Wood trim is added to the insides of the windows and doors, which includes all casing trim and baseboards. Finish work and details are completed in this station.
Carpeting is installed in the Living Rooms and Bedrooms and all carpeting is covered with plastic sheeting to protect the carpets during transportation to the site. Toilets, sinks, Bathtubs and Showers, Kitchen Cabinets and Countertops are installed and all final finish work is completed in the kitchen and bathrooms.
STATION #7:
Support plates and straps are installed on outside corners to walls and ceilings and floors to strengthen the house for transporting to the building site. If Vinyl Siding is ordered, it is installed here. If the house will have a brick exterior, the house is shipped and the bricks are added on site.
STATION #8:
Final assembly and finish work is completed and the house must pass final inspection by the Quality Control Supervisor. All “Ship Loose” items are placed inside the house for final assembly on site.
House is raised by the Electrical Lifts and the Carrier is placed underneath. The house is strapped to the Carrier and is wrapped in Plastic covering for shipping to the building site. The house is 95% completed at this point.
Estimated time for this house to move down the production line from start to completion is 4 to 5 days. Every day one or two houses are completed per production line. For 2 lines, we can build 2 to 4 houses per day and for 4 lines, we can build 4 to 8 houses per day.
House is shipped and the Set & Finish Crews seal up the house and finish the final 5% to be done on site.