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Each home is constructed on a structurally designed, solid steel, welded I-beam frame (not corrugated). The structural steel front I-beam header, along with full outriggers on 14' wide and 16' wide sections, adds extra support in load-bearing areas. Each frame is sealed with a rust-inhibitive black paint. |
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A reinforced polyvinyl bottom is laid on top of the reinforced wooden frame. Next, a blanket of R-19 fibreglass insulation covers the polyvinyl bottom. The water supply lines are placed within the sub-floor. All electrical cables are also placed within the sub-floor and brought up only where necessary for connections.
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The typical floor is 2 x 8 transverse construction on 16" centres. The floor system is lag-bolted to the frame. Before the floor decking is glued and nailed to the sub-floor framing, quality control checks are performed. The electrical installation must meet strength, apparatus, continuity, operational and polarity checks.
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All exterior and marriage wall studs are securely fastened to the floor and to each roof rafter. Beginning within two feet of the front and rear of the home, tie-down connectors and straps are installed to the floor and between the perimeter floor joist and the outer layer of 3/8" structural sheathing.
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After the wall sections are completed they are hoisted into position and bolted to the floor. All electrical cables and plumbing lines are then brought up into place and a series of quality control checks are completed. The interior walls are now closed with the outer layer of gypsum interior panels secured into place.
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Automation calculates every wall dimension, ensuring each cut will be precise. The walls are built in sections, all wall studs are 16" on centre, the exterior walls are 2 x 6 construction, interior walls are crafted with 2 x 4 studs. The marriage wall (where the home is joined together in the centre) is a double wall consisting of 2 x 4 studs, leaving you with a sturdy 8" centre line wall.
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Between each rigid exterior wall stud a layer of R-19 fiberglass insulation is packed in for maximum energy efficiency. All wall insulation has a paper backing which lays against the interior side of the wall. This method prevents moisture from forming in-between the walls.
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On the underside of the ceiling board the joints are taped and sealed, then sprayed with a vapour barrier primer sealer. At this point a decorative knockdown ceiling is applied.
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The roof trusses are 16" on centre. Each rafter is foamed to the half-inch ceiling boards, this method bonds the board to the rafters, eliminating the use of unsightly fasteners, and also strengthens the ceiling. Each truss is secured to the aligned wall stud with a 26-gauge steel uplift strap. All trusses located within 3' of the ends of each home roof are doubled to strengthen against uplifting winds.
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On top of the roof sheathing we start by putting a layer of one-piece asphalt impregnated shingle underlay, a 12" cement border around the roof secures this layer of underlay. Then a layer of roofing felt is applied, creating a double layer shingle underlay. Next we install asphalt fiberglass roof shingles, DECRA, considered the best in the industry, which come in a variety of colors and carry a 20-year limited warranty. Each shingle is secured into place with six fasteners. |
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After cabinet fittings and furnishings are installed, quality control checks are performed before the home is released for delivery. |
