Monday, July 23, 2007

What's Taking So Long?




It was Labor Day Weekend '05, when we gave the architect our rough sketches for the house. Now it's July '07 and we still don't have a finished house. What's taking so long?

It started with the architect.

We decided to hire an architect because we felt the scope of our project called for more than a design engineer. We didn't want to make ANY mistakes, like forgetting closets or leaving insufficient room for doors and drawers to open properly. Plus, we wanted it to be artistically and aesthetically "right."

The guy we hired was referred to us by a couple local folks who basically just "knew of him." I called him in Missoula, talked briefly, and liked what I heard. He sounded confident and said he'd worked with SIPS before. So we arranged for him to come to Shorthorse, see the site, and discuss our project.

He assured us we'd have our first drafts within a month, and final plans in plenty of time to start building in the spring of '06.

It was nearly 4 months before we got the first drafts. Our changes were minor, but the second drafts took even longer. And so it went...for more than a year! Each time we'd tweek any little thing, the next drafts took months. His bills were always on time, however.

By the fall of '06, we'd had enough. Our builder, Larry Schuster, shared our frustration and told us he had enough to go on with the current drafts. So we pulled the plug on the lousy architect.

The next delay was due to the SIPS manufacturer. We'd chosen R-Control, out of Belgrade, MT. A freight truck delivered the panels on schedule...and left. A company rep was supposed to be on hand to advise Larry, since this was his first SIPS project. But no one showed up. So Larry was on his own with a two-man crew, trying to figure out these jigsaw puzzle pieces piled next to the building site. Oh...and this was in the middle of January, by the way!

As Larry and crew got into the project, they discovered the SIPS panels DID NOT FIT. They had been cut the wrong size at the company. So Larry had to acquire a special tool to trim these panels on site. This cutting, trimming and fitting stretched an otherwise week-long building project into months.

The roof panels were among the worst. Our design called for 12 valleys (6 gables), and fitting them with the panels was a real chore. The roof wasn't actually closed up until late June!

Other delays have resulted from the LOUSY ARCHITECT's design. The architect made numerous mistakes, drawing things that just could not be built. Shower heads coming out of beams, for instance. Walls coming down on top of fireplaces. Each time Larry's identified such a dilemma, he's been forced to redesign construction. That takes time...time we thought we'd already paid for.

Add to all this the fact that Larry has a crew of just two other guys (and sometimes just one other), and that every subcontractor up there is booked and overbooked about six months in advance.

And then there's this factor of "Montana time." The folks up here have priorities that come before work. They are, in order: family, church, and hunting. It's hard to argue with priorities like that, but it does slow down the building process.

SIPS: A "Foam" House







We'd heard about a new building system called SIPS (structural insulated panels), and it sounded perfect for the kind of house we wanted. SIPS panels consist of about 5 inches of dense styrofoam sandwiched between two pieces of 5/8" plywood. These panels form the outside walls of a house, as well as its roof. They provide super-tight insulation. They're also extremely fire resistant. Because there is no conventional framing with studs, the walls go up fast (they are precut to size at the SIPS factory, and assemble onsite like a jigsaw puzzle.) The walls are also straight and square, which is a builder's dream. Chases for the electrical wiring are pre-drilled in the foam panels.

While SIPS panels cost considerably more than conventional framing, there would be a cost savings in labor. A SIPS home, typically, could be put up in a week by an experienced crew. We also felt a SIPS home would be perfect for the extreme heat and cold sometimes experienced in our part of Montana. And we liked the idea of not having to hunt for studs on exterior walls every time we wanted to hang a picture!

Don built an experimental pump house on the property in the summer of 2005. He was using a kit assembled for him by Premier Building Products out of Federal Way. The materials had been "bargain priced" because they were factory seconds. The pump house went up easily in less than two days. Talk about SOLID! And when the temperature was 90 degrees outside, it's at least 25 degrees cooler inside! He sided it with natural cedar and stained it the same color our house would be.

We were sold on SIPS. Now all we had to do was find an architect and a builder who could make it happen on a larger scale.