Building Process

Foundation and Site Work

Before the home is built, the site must be cleared and graded. The basement areas and trenches for the foundation are dug. We use the FORM-A-DRAIN™ system which provided the forms for the footings, water drainage and if required radon venting. After the footings are ready, forms are set for 9′ basement walls then poured. The foundation walls are sprayed with a water resistant coating and expanded polystyrene (EPS) foam insulation is applied before adding gravel around footings and backfilling.

Framing

Once the foundation is set, the first floor deck is installed with great care to keep it level and square. The structural insulated panels (SIPs) are assembled on the deck and lifted in to place to create the preinsulated exterior walls and interior walls are framed. If the design is two stories, the second floor deck, SIP exterior and interior walls are built. Lastly SIP roof panels and/or roof trusses with sheathing complete the shell.

Exterior Finishes

As soon as possible, roofing, windows and siding are added to protect the inside from the elements. From the outside, your home looks almost done. To complete to this stage only takes a few weeks and can give the false impression that the home is nearly ready for moving in.

Mechanical Rough-Ins

Once the interior of the house is properly protected from the elements, the plumbing, electric, and heating, ventilation and air conditioning (HVAC) systems are installed. Each of these disciplines must be skillfully coordinated as each requires access through walls and floors and cannot interfere with the other.

Insulation and Air Sealing

This is one area we take extreme care in providing the best possible air sealing and one reason why our homes out perform all others. Throughout the mechanical rough-in stage, electrical penetrations are calked and sealed. The box sills, the perimeter of the house of each floor deck, receives sprayed icynene® foam. Icynene® is a great product as it is water based, expands 100 times to fill gaps and holes and seals against air infiltration. If roof trusses are used and after the ceiling drywall is installed, icynene® foam will be sprayed in over the ceiling drywall for air sealing with blown-in cellulose over the top for cost effective increased R-values.

Insulation is not required in the exterior walls because the SIPs are already the most efficiently insulated and air sealing system available. The effectiveness our this effort is verified through 3rd party testing.

Interior Finishes

The drywall, painting, cabinetry, doors, millwork and flooring are installed. This is the longest stage, for good reason. Unlike the mechanical rough-in step, work in the interior finish steps usually cannot happen at the same time.

For health reasons, especially if you have young children, we select finishes and products that do not off-gas. You can avoid this by selecting low-VOC (volatile organic compounds) products. Before arriving at this stage, you will have selected a wide range of other environmentally responsible and recycled materials.

Landscaping

This step can occur any time after the finish grading is complete. When landscaping, select native plants that do not require much water. Also consider using pervious surfaces for your walkway and driveway to allow rainwater to filter directly into the soil. These options will help reduce the need to water your lawn.

Walk-Through

A final walk-through before the closing is the time to ensure that everything is completed to your liking. If you see any problems that need to be addressed-these are usually aesthetic-have them fixed before you sign the final paperwork. We will also explain how your home operates, so ask lots of questions.

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