Construction pics of Jacobs-1 derived home in New Zealand

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Mobius
Posts: 149
Joined: Thu Feb 24, 2005 7:20 pm
Location: Christchurch, New Zealand
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Construction pics of Jacobs-1 derived home in New Zealand

Post by Mobius »

Well, I've been remiss in not posting earlier; ground was broken on December 21st last year, and then promptly stalled for over a month while the "Hot Blocks" were sourced...

Anyway, here's some pictures of what's been going on at 23 Te Pihopa Way, Halswell, Christchurch, New Zealand.

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The floor slab is reinforced concrete atop 50mm of Polystyrene. There are specially reinforced thicker sections where the load bearing walls and concrete block walls will go. The small box in the foreground is where a power socket goes in the floor.

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Pouring of the slab. It only took 3.5 hours to pour, and the job was complete in under 8 hours. The foundation type is all concrete block. This was a screwup. The concrete blocks were only supposed to appear where the concrete block walls are. Ah well... the overall appearance is improved, at some cost. *sigh*

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Finishing the surface in the master bedroom. The box is the drain for the shower. Please note the ugly two story across the street; our home will be a REAL shock to the subdivision.

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Slab down, and waiting on the remainder of the 240mm thick "HOTBLOCK" Concrete blocks. You can see the 50mm polystyrene panels inside the concrete blocks stacked in the foreground. The rubbish "skip" is used almost exclusively by our neighbours to get rid of their crap.

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Some steel inserted to support the large bedroom wing overhangs is visible in the right of the image.

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The blockwork begins in earnest. Because of the "stackbond" system, the walls have almost no strength at all until they are filled with concrete. They can only "lift" 1 metre at a time of concrete due to the incredible pressure the concrete places of the stacks. The blocks are heavily reinforced with wood shoring before filling.

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This is the view from within the "work space"; standard "column" blocks are laid on their sides (after some trimming to ensure fit) to create holes which allow someone in the work space to see a little of the entrance way and the street beyond. Only a little bit, mind you. The work space is designed and supplied by Matisse, using Arc Linea hardware; the world's finest kitchen hardware. It was a tough decision: a 2001 Model Porsche 996 Careera 4 for me, or the kitchen, for us both. In the end, I insisted on the kitchen!

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The block work continues after the third "lift".

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The blockwork is almost complete, including the end of the lounge, and the U-shaped section adjacent the dining area. The old 928S costs a fortune to run to and from the site; gas is the equivalent of USD $9.20 a gallon here. Still, V8 owners have no right to complain about gas prices!

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Here the blockwork is essentially complete. It is beginning to be recognisable (I think), as a home derived from Jacobs 1.

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The very "industrial" study; no windows, only two doors; one into the hallway, one feeding into the "moss and fern garden". The interior walls will remain undressed concrete blocks, finished in a "wet-look" concrete sealer. Power, networking and speaker cabling will travel around the walls in "cable tray" a galvanised long-run, open metal frame. This makes adding power points etc, very easy in the future. The study will have over 20 power outlets. The top left corner gets a small (and very quiet!) extractor fan to remove heat generated by the computers I'll be running in here. The thermal mass of the home is inside the polystyrene insulation. The effect is to moderate internal temperatures effectively both summer and winter.

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View from within the study. There is a single panel double glazed door feeding into the "moss and fern garden, which faces the rising sun. It's also the only place we'll be able to shelter from the very hot and strong Nor'West wind which whips Canterbury in the summer months. This will be a tranquil area, witgh a 2-metre tall stainless steel water feature, making lovely but muted water sounds.

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Here you can see some of the steel required to support the roof. Without Lloyd Wright's massive fireplace (replaced by the work space bench) a large amount of steel is required to support the roof, and the "wall-over", which raises the ceiling level in the work space and bathroom by about 800mm over the living area ceiling.

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Here is the fron entrance and overhang. The small parts poking out support the hidden gutter which drains the large roof. It's over 300mm wide, so cleaning should be a piece of cake!

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My best buddy Hugo thinks it's all good! He's a lighting designer at Rexel, and has made a most oitstanding lighting plan for the home. All on PIR detectors and dimmers throughout.

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IT WORKS!! The blockwork is finished, and masses of steel is fitted. The garage requierd extra steel as the builders refused to consult the garage door makers as I instructed them to do. Much huffing and puffing was required when insisting that my design was NOT conpromised in any way. The garage remains 2.4 metres tall; being 6 x the 40cm units which comprise the "vertical unit" of the home. Conveniently, the blocks are 20cm units.

This image graphically demonstrates the "Floating Roof" concept I was trying to achieve. This photo is taken on the sidewalk opposite the home. You can clearly see that the roof is "flat" from this angle, and thus walkers can see in through the clerestory windows at the front of the house, and straight out through the windows above the Quintuple-fold doors of the lounge. The roof will appear to hover in mid-air over the lounge.

The clerestory windows are all electrically operated throughout, and I will connect them to a computer controlled system which will automatically open and close them depending on inside temp vs. outside temp. Manual over-ride is a given.

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Here's a better look at how the roof will float over the lounge.

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Panorama shots taken from the rear corner of the section. It's 11:30am on almost the shortest day of the year in the shot. Still undecided if I'll have the builders cut down the overhang in the far right of the image. It is larger than I intended. I may hang bicycles from the soffits...
Last edited by Mobius on Mon Jun 02, 2008 11:24 pm, edited 1 time in total.
How many escape pods are there? "NONE, SIR!" You counted them? "TWICE, SIR!"

*Plotting to take over the world since 1965
SDR
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Post by SDR »

If you intend the house to speak of its connection to Wright, I'd leave that overhang as it is ! It's a vital part of his aesthetic -- and mine, for what it's worth. Looks good to me !

Thanks for the pics. Keep up the good work.

SDR
Mobius
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Joined: Thu Feb 24, 2005 7:20 pm
Location: Christchurch, New Zealand
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Post by Mobius »

Thanks. The original home only has about 60cm of overhang there. This is double that: 120cm. I imagine it will stay the way it is; changes cost dollars!

To date there have been absolutely no changes from our plan. Many of our friends and associates said we'd have multiple changes. However, having built the scale model, and the 20 minute 3D walk through, and knowing the specification intimately, there is no need to make any changes!
How many escape pods are there? "NONE, SIR!" You counted them? "TWICE, SIR!"

*Plotting to take over the world since 1965
hypnoraygun
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Post by hypnoraygun »

Looks great, thanks for the update and the photos! It looks like you are coming a long way! Very jealous! Keep it up..

This isn't a critique, just a question/comment.. Is the height taller than Jacobs I? Or is it just because the walls aren't all up yet? It just seems a bit larger and bulkier.. How does it compare to the original as far as dimensions..?
Paul Ringstrom
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Post by Paul Ringstrom »

I like the look of the concrete Hot Block walls very much like a Usonian Automatic. Do you have a website of the company that made them for you?

Also, the see-thru clerestories is a nice touch and will look fabulous at night lighted from the inside.
SDR
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Location: San Francisco

Post by SDR »

I admit it still disappoints me to see the author of this design leaning on the Wright association, after having emasculated Wright's architecture so thoroughly -- but I do look forward with interest to seeing the result, judged on its own merits.

And that 928 sure looks good, too !

SDR
Mobius
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Post by Mobius »

The concrete hotblocks are a completely standard type of block in New Zealand; as a temperate/island climate region, and sitting just a few degrees above 45 NZ tends toward "cold but not outrageously so" in the winter time. http://firth.co.nz/ is the address of the manufacturer.

As a result a single layer of concrete blocks (no matter what the thickness) does not provide adequate insulation of a wall according to NZ building codes - particularly in the "cold" southern region - where we are. In the past, builders have used two layers of "150 series" (150mm thick) concrete blocks, filled with concrete while leaving a 50 mm air space between the two layers. This is an extremely expensive type of wall to build, and reduces floor area dramatically as the walls are 350mm thick.

Of course, Lloyd Wright was a fan of "finishing a wall as you go along", which means not treating the interior or exterior in any way - so the hotblock achieves this nicely.

Hotblocks are much more expensive than standard blocks, and more expensive to lay also, and then, even more expensive to do in "stackbond" layout. However, these extra costs more than make up for the fact that internal wooden walls, insulation, gib-stopping, and painting are not required.

As to the height of the building, I believe it is extremely close to the original (within 20cm) but because Jacobs 1 is lower than the street, it might appear shorter. Plus, it is an unfortunate fact that our home is built somewhat out of the ground - although the floor is only about 150mm from the ground at the master bedroom. I would have preferred no drap whatsoever - but the building code does not permit this, especially in a flood plane, which is where we've built. (The water will actually be 1.4 metres deep in a Waimakariri flood event, with the water speed at less than 1/20th of a knot.)

The home might also appear slightly taller than Jacobs due to the 3 degree pitch to the roof lines, and the way I had to slot them together in order to make them work properly. I wanted to retain the significant "step-up" into the work space.
How many escape pods are there? "NONE, SIR!" You counted them? "TWICE, SIR!"

*Plotting to take over the world since 1965
Paul Ringstrom
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Location: Mason City, IA

Post by Paul Ringstrom »

So... if one layer of block does not give enough insulation and you did not lay a double wall... how did you meet the requirements ? or did I miss something?

Sorry, I think I found my answer:

"Two key considerations when building with masonry block are waterproofing and insulation. Masonry walls on their own do not meet the insulation requirements of the current Building Code. To achieve the recommended insulation level, there are two main options:

(a) in-wall insulation and
(b) on-wall insulation

In-wall insulation is achieved using the unique Firth Hotbloc - this specialised masonry block features an insulation sandwich of polystyrene."

Picture of the block: http://firth.co.nz/tradeproductitempcid ... id=15.html
SDR
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Post by SDR »

"Fairfaced" is a British term meaning unfinished or uncovered. (It's amazing what you learn by reading British mystery novels. . .)

SDR
DRN
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Post by DRN »

Great to see the progress pics.
The house is better than a copy of Jacobs. It is its own building, not a copy, well suited to its owner, his location, and his finances. It must be judged on its own merits which are many.

The overhang at the end of the wing looks fine as is..interestingly, per Jacobs' book "Building with Frank Lloyd Wright", the corresponding overhang at Jacobs I was identified by Wright during a field visit as being too short. Wright requested a field change to elongate it...the proposed change cost was more than Jacobs would bear, so it stayed "stubby". In a sense, this house has given Wright the overhang he wanted...only 70 years later, and on the other side of the globe.
Mobius
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Post by Mobius »

DRN: Thank you for this information - I had no idea! I even have the "Building with Wright" book written by Herbert and Katherine, but must confess to not taking in that tidbit of knowledge.

So - the large southern overhang will stay as it is!

Thanks also for your kind words about the design. Originally I wanted to produce a carbon copy of the house; but that is clearly impossible given the New Zealand building code, and modern building practices. I even drew the double garage as a monstrous carport with stupendous overhang of 28 feet (!) and a separate work space room for me, but my estate agent friend told me the house would be unsaleable without a double garage.

Once the realisation of not being able to build a replica sunk in, I really spent a lot of time trying to identify the key features within Jacobs 1 that appealed to Emma and I, and tried as hard as I could to isolate the architectural components which created these elements, and to understand them.

Having read a great deal about the Usonian homes (I have several books on the Usonians alone) I also believe I understood many of the philosophies of Wright as he went about creating these homes. I have tried wherever possible to live up to the philosophy, but have been disappointed in many regards: we could not afford a "real" section to put the house on; flat rooves were just too expensive; bricks are a cladding only (My builder buddy calls brick cladding "Veneerial disease"!) and therefore cannot be used; it was not practical or cheap enough to have polished concrete floors, which would require $30,000 of hardware just to heat them, and then a minimum of $250 a month to run; with the garage in place I could not hide the entrance in any way - another big disappointment; cutting an east/west line through the lounge and adding 1.2 metres, and cutting a line through north/south and taking away 1.2 metres was the most horrible thing I had to do - changing the proportions of the lounge dramatically - but I had no option; the section is only 20 metres wide...

It was indeed a tough job; every compromise I made was painful. Every cost escalation awful. Every deviation from Wright's original design wrenched at me as I rubbed out his lines and inserted my own.

I fully realise that a few people here will inevitably consider our house some bastard love child of an incompetent Wright fan, and a know-little Kiwi! That's OK: I'm posting here for the benefit of forum readers who are interested in the project.

As a result, I'd like to invite any and all Wright Chat members to our home, and even to stay a day or so if anyone can make the long trip to New Zealand in the future. So, if you are ever in Christchurch, New Zealand, you'll be made very welcome at the Davies & McRae residence. I can be contacted on my mobile phone: +64-21-69-58-69, or via email: chris.davies AT boardbooks.com
How many escape pods are there? "NONE, SIR!" You counted them? "TWICE, SIR!"

*Plotting to take over the world since 1965
kettle7830
Posts: 11
Joined: Sat Dec 22, 2007 10:28 am

Post by kettle7830 »

Thank you so much for sharing your experience with us. We thoroughly commend you for your energy and dedication to your dream. Something you said in your last post really struck a chord;
" I really spent a lot of time trying to identify the key features within Jacobs 1 that appealed to Emma and I, and tried as hard as I could to isolate the architectural components which created these elements, and to understand them".
Ten people presented with the same challenges you've faced while trying to modernize a Wright home would have ten totally different interpretations of what would be essential. What you've done is moved beyond the replication of Jacobs 1 and moved into the creation of Mobius 1! The true goal should be a home that fits you and yours, not to please the casual observers. Please don't be discouraged by the criticism you've met here; there are many more, like us, that are cheering for you. Best of luck with your dream.
M&L
SDR
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Post by SDR »

I'm misting up. . .any more violins and I may burst into tears.



SDR
DavidC
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Post by DavidC »

Mobius wrote:I'm posting here for the benefit of forum readers who are interested in the project.

Count me in as one who is enjoying seeing your home being built. It's also very interesting to see some of the differences in materials and methods between NZ and the US.

Congratulations on being able to realize your dream!


David
Mobius
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Paranoia sets in - first change to the plan...

Post by Mobius »

The house progresses apace: all the roof joists are in, so the extent of the overhangs are now clearly visible. Last weekend we took a sojourn up to Auckland, specifically the Manukau Harbour, to visit Emma's stepmother.

This wouldn't normally be remarkable in any way, except that she is the CEO of the New Zealand Institute of Architects. We went up to stay at her new "two bedroom bach" (pronounced "batch"). Bach and Crib are what North and South Islanders term "Holiday Homes". To truly qualify as a "crib" or a "bach" the house should be made before 1900, have no insulation, tiny windows, one water tap, rain water, an outside toilet and a septic tank for sewerage - if you're LUCKY!

Her "bach" has the collected rain water and a septic tank - but as you may imagine, the rest of the place is fantastic. Designed and built by famous local architect Gordon Moller: PDF of Moller interview including some projects

If you're interested in seeing how the house came out, check the new thread titled: Not Wright, but not wrong either.

On to the house!

From the initial decision to base our home on Jacobs #1 I have been pestered by people telling me that the kitchen/lounge/dining area does not get any sun.The house faces west essentially, so the bedrooms will be flooded with afternoon sun, but there is almost no morning sun directly in the house, nor does the lounge catch any direct sunlight. I must say I am perfectly OK with that; I despise not being able to see the TV screen in the middle of the day, or seeing nothing but a reflection in it. Nor do I particularly like sitting inside in the sun - I'd prefer to be sitting outside.

I have assured people from the very start that the window wall to the south with box window to west corner, combined with the 7 clerestory windows to the north, as well as the tri-fold doors in the dining area and the clerestory in the kitchen will provide enough light.

I did eventually think they might have a point. So, reasonably early on in the project, I added a floor to ceiling 30cm (1 foot) wide window in the east wall at the start of the hallway. It will catch the morning sun and illuminate the 1.8 meter (6 foot) wide hallway adjacent the pantry and cupboard area leading into the kitchen/dining area.

Now that the west-facing "wall-over" which raises the kitchen ceiling and roof above the lounge area is assembled, I can see another clerestory window in that wall will light the upper part of the kitchen very well.

I have asked for the change.

It's indicated in red in the image below.

I can't believe I never thought to put one in there earlier. Oh well, $1500 now is probably better than $5K later. Fortunately this change will probably not have to go through the local council for authorisation.

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From across the street, the new clerestory is shown. The 1.8 metre overhang covering the walkway and extending only a short distance from the front of the garage is now clearly visible. 1.8 metres doesn't look like a lot in this photo. In life, it looks large. The blue area is a mistook. See below.

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Here's the interior view of the wall-over. The clerestory stretches almost the entire length, bisecting the trapezoid interior wall.

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Here's her ladyship taking the mid-winter sun under the largest overhang on the northwestern corner, facing the street.

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This is where the walkway to the front door will be, covered by the garage overhang. My camera at wide-angle is minimising the real appearance; it's more dramatic than I had thought it would be. There is a mistake I didn't pick up in the working drawings; there is not a roof-over-a-roof here - the garage overhang is only supposed to cover 40 cm of the lounge roof. Otherwise how is it possible to finish and maintain that gap?? The step-back in the garage overhang is a real feature. Another slip of the brain. *sigh*

This project seem to be fairly good at detailing my deficiencies.

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Here's the mistake at a different angle. Who's responsible for this awful omission???? Oh wait, that'd be me.

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Looking along the wall-hung book case through the entrance way, into the Garage. A different view of where the garage overhang won't be..

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This is the detail of the "floating roof" and clerestory windows. The corner is a single-glazed, non-opening box window. The remaining six (there's one on the western wall perpendicular to the block face) are electrically operated for convenience.

That's it for this week.
How many escape pods are there? "NONE, SIR!" You counted them? "TWICE, SIR!"

*Plotting to take over the world since 1965
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