Indigo Pine - Solar House by Jon Pennington

Indigo Pine Solar House Graduate - Fall / Spring 2015 Clemson University Solar Decathlon Team

The Solar Decathlon is a competition held every two years by the United States Department of Energy which challenges university student teams to design and build a fully functional net-zero energy solar home. Teams are allowed nine days to assemble their homes on the competition site then compete with each other in various tasks to demonstrate the functionality of their solar homes. Clemson University participated in the 2015 Solar Decathlon for the first time in the school’s history. The home was given the name Indigo Pine to reflect the past and future cash-crops important to South Carolina’s economy; Indigo and Southern Yellow Pine. What was unique about Indigo Pine was it’s innovative structural system - Sim[PLY] - a system designed and built by Clemson University students that uses CNC cut plywood and stainless steel zip ties. This system was very advantageous in creating a safe work site (no nails) and proved to be a fast construction method. I was part of the “Core Team” - a group of students dedicated to the project for both the spring and fall semesters of 2015. A previous group of students had designed the basis for the project and our job was to see it through to completion. As many of us were new to the project and had never seen the structural system before, we had a lot to learn. My primary role on the team was Internal Parts Fabricator. I quickly became familiar with the CNC router and associated programs that are used to program and tool-path the router. Whether the team needed to analyze a single part or a full-scale mockup, I was the person responsible for programming and cutting the parts needed. Because the house exists as a set of digital cut files and uses off-the-shelf products, Indigo Pine can be fabricated and built anywhere there is a CNC router available. For our competition home, Clemson students traveled to Charleston, South Carolina and used the routers at Fine and Small Homes to cut every piece needed to build. At this point, I was the main person responsible for setting up all of the cut files while overseeing the CNC process. In addition to learning new technologies, my participation on the Clemson University team gave me valuable experience in using Revit and creating a set of construction documents. As part of the “Core Team”, I assisted in preparing the construction documents for submittal to the Department of Energy. During the competition, I was designated to be the team’s “Measured Contest Captain.” In this role, my duties became simply that; to monitor the house and make sure that the house was competing to a high standard.

The Indigo Pine Team ﬁnished 6th place overall; the team also received high honors in Architecture (2nd), Communications (2nd), and Market Appeal (3rd).

Internal Fabrication As Internal Fabricator, my job was to use the CNC router to cut out any parts that were needed to analyze or build with. In the Spring semester, this consisted mainly of small mockups that tested the functionality of our tilt-up wall system. I took a small section of the wall from our Revit model and reduced the wall height to focus more on the tilt-up connection rather than the entire wall. After analyzing the issues with the connection, the mockup was expanded to include a full-size wall mockup. In this we included a corner post, as well as a door and window opening to better understand the system. This mockup would be later disassembled and re-assembled to allow for mockups of the foundation system. Later in the spring and into the summer, I began fabricating wall sections to be used for structural testing. These sections had to maintain a specific height and width requirement in order to fit in the testing apparatus and to allow for easy calculation of structural strength along the entire wall. There were two types of wall sections that we tested; one was a section multiple window openings while the other was a solid wall. These tests gave us insight into sheathing layout and the screw spacing for attaching the sheathing. Near the end of the Summer, I began to prepare the files for the fabrication of our competition home, Indigo Pine West. This consisted of a long process that took the files from Revit to CNC. The parts were exported from Revit and then edited in AutoCAD to reflect the different toolpaths that would be needed to cut: Outside contour, Inside contour, Holes, etc. From AutoCAD, these parts were entered into a nesting software that sorted the pieces and placed them within 4’ x 8’ rectangles indicating the plywood sheets. These sheet files were then sent to Mastercam where they would be toolpathed according to their layer designations. Exporting from Mastercam, the files were finally ready to be sent to the CNC machine.

CNC Router

Corner Mockup

Structure Testing

Cabinetry Fabrication An important part of participating in a project of this type is the need to actually build while you design. This was certainly the case with the cabinetry system. Designed as a stand-alone system, the cabinets followed similar tab-construction techniques found within the Sim[PLY] system, held together with screws. Building the cabinets for Indigo Pine East, our prototype home, allowed us to re-design many of the issues that we found relating to mis-cut parts as well as mortise and tenon joint tolerances. While many of the lessons learned from the Indigo Pine East cabinets were employed for Indigo Pine West, there were still some issues due to time constraints associated with the project. Fabricating these units became a long process that lasted weeks. After receiving the parts, we routed the edges with a roundover bit and sanded the faces. A “record store” of parts was quickly created. We then assembled the cabinets into their respective boxes according to the assembly drawings. After the boxes were all finished, we simulated the floor plan of the house by placing the cabinets in their respective locations in an area marked off in our warehouse space. When all the cabinets were in place, we applied a finish stain to all of the visible faces and edges. My knowledge of the system became integral to the success of the construction of our competition house. Many of the questions that arose during construction were quickly solved simply because they were the same issues we encountered in the first round of construction.

Custom ACM Air Diverters I was later given the task of fabricating parts for the mechanical system of the house. Using the CNC, a series of air diverters that would direct air from the air handler to different areas of the house, depending on what rooms were being used. Boxes were made from Aluminum Composite Material (ACM) that was cut on the CNC and folded together while being held with pop-rivets. Panels inside the boxes were attached to a series of bowden cables which, when pushed or pulled by the user, diverted the air to different areas of the house. Off-the-shelf air-tite take-offs, or “top hats” as we called them, were screwed to the ACM boxes to allow the use of ﬂexible ducting. This made for an easy and fast installation.

Construction Documents One of the major deliverables for the competition was a set of As-Built Construction Documents that would represent the ﬁnal competition home. I worked exstensively in assisting the team to prepare these documents, focusing on the structural section of the documents as well as the sheets depicting the cabinetry system. This was my ﬁrst major introduction into Revit and how Construction Documents are set up.

GENERAL NOTES H-00LW

G-S

G-I000

H-00L0

H-00LW

H-00L0

G-I000

VS-I000

H-E0H0

E1 TYPICAL GIRT ASSEMBLY

H-10H0

ALL DIMENSIONS ARE FOR REFERENCE ONLY, ALL STRUCTURAL MEMBER LOCATIONS WILL BE DETERMINED BY STRUCTURAL SYSTEM INTERLOCKING

H-S0H0

VS-E00F

3/16" = 1'-0"

REFER TO PROJECT MANUAL FOR STRUCTURAL DIAGRAMS, CALCULATIONS, AND TESTING RESULTS

REFER TO COMPONENT LAYOUT LOCATED ON SHEETS S-003 - S-005 FOR NAMED PART CONFIGURATIONS

VS-E00F

H-00L0

H-S0HS

H-E0H0

H-10H0

H-00L0

BF-E0H0 BF-E0H1

BF-E0H1

ALL STRUCTURAL MEMBERS ARE TO BE FASTENED AT PREFABRICATED NOTCHES WITH STAINLESS STEEL ZIP TIES, ZIP TIE GUN TIGHTENED AND CUT (TYP.)

VS-E00E

G-S

BF-E0H1

G-E000 VS-E00E

G-E000

H-00LW-1

VS-I000

H-00LW

DESIGN TEAM

H-00L0 B1-EE00

B2-II00

B3-II00

BF-I0L0

BF-IIL0

BF-IILS

F-SIL01-1

B4-EI00

TEAM NAME:

BF-I0L0 F-SIL01-1

VS-000T-1

PIECES NOT SHOWN: B1-EI00, B2-IE00, B3-IE00, AND B4-EE00.

H-000T

H-00L0

ATTACH BEAMS ACCORDING TO THEIR S-JOINTS (B1 TO B2, B3 TO B4). GLUE AND SCREW ALTERNATING S-JOINT ASSEMBLIES TOGETHER. ZIP TIE THE LOWER BF FLANGES TO THE BEAMS BEFORE INSTALLATION. AFTER ELECTRICAL IS INSTALLED IN PROVIDED CUTS IN BEAM STEMS (B1 AND B4), PLACE THE F-SILO1-1 FLANGE AND ZIP TIE TO BEAM STEMS. AS ROOF BEAMS ARE SET IN PLACE, ATTACH GIRTS BETWEEN THE BEAMS ACCORDING TO THE GIRT ASSEMBLY ABOVE. AFTER GIRTS ARE PLACED, ATTACH THE UPPER BF FLANGES AND ZIP TIE TO COMPLETE ROOF BEAM ASSEMBLY.

TEAM CLEMSON

ADDRESS:

LEE HALL CLEMSON, SC 29632

CONTACT:

INDIGOPINE2015@GMAIL.COM INDIGOPINE.COM

VS-000T-1 H-000T

H-00L0

CONSULTANTS

H-00LW-1

D1 TYPICAL ROOF BEAM ASSEMBLY

VS-I000

VS-I000 H-10H0

1/4" = 1'-0"

STRUCTURAL H-00LW

H-10H0

H-00LW-1

TY MONKS | NISHKIAN MONKS

MECHANICAL

GENE WILSON | GREENVILLE TECH

ELECTRICAL

GENE WILSON | GREENVILLE TECH

PLUMBING

GENE WILSON | GREENVILLE TECH

H-00L0 A-02

A-01

A-03

A-02

A-01 H-00L0

VS-E00C

H-E0H0

x2 B-01

B-02

B-03

B-02

H-S0H0

B-01

VS-E00C

H-S0HS

H-10H0

VS-E00E

VS-I000

H-00L0

H-E0H0

VS-I000

VS-E00E

C BGB

H-00L0

BGM BGB

GLUE AND SCREW ONE SET OF EACH ROW A AND B TOGETHER TO CREATE THE TWO SIDES OF THE BOX GIRDER. SLOT THE TABS OF PIECE BGM INTO PIECE BGB AND SECURE WITH STAINLESS STEEL ZIP TIES. PLACE THE CENTER BRACES WHERE THE SIDES OF THE BOX GIRDER HAVE OVERLAPPING PANELS. GLUE AND SCREW THE CENTER BRACES INTO THE SIDES OF THE BOX GIRDER.

H-00LW

CLIENT

H-00L0

H-00LW

U.S. DEPARTMENT OF ENERGY

C3 HEADER ASSEMBLY

SOLAR DECATHLON 2015

1/4" = 1'-0"

C1 BOX GIRDER ASSEMBLY W/ CENTER BRACE

WWW.SOLARDECATHLON.GOV

FP-I00S

FP-I00S-1

FP-I00S

3/16" = 1'-0"

IJ- E000

IJ-I000

G-E002

IJ-I000

FP-E000

FP-I000

FP-I001

IJ- E000

SLIDE JOISTS IJ-E000 OVER THE OUTER AND INTERMEDIATE LEVELING JOISTS. SLIDE JOISTS IJ-I000 OVER THE INTERMEDIATE LEVELING JOISTS AND PLACE AGAINST EACH OTHER OVER THE CENTER LEVELING JOIST. PLACE G-E002 OVER THE CENTER LEVELING JOIST. SECURE ALL FLOOR JOISTS AND LEVELING JOISTS WITH STAINLESS STEEL ZIP TIES. B

FP-E000

B1 TYPICAL FLOOR JOIST ASSEMBLY 1/4" = 1'-0"

MARK

FP-I001

FP-I000

DATE

106

DRAWN BY:

ARCH STUDIO

CHECKED BY:

DAN HARDING

ISSUE DATE: COPYRIGHT:

12/1/2015 6:02:03 PM

FP-I00S

A1 LONGITUDINAL REFERENCE SECTION 2

FP-I00S

A3 BASE PLATE ASSEMBLY

1/4" = 1'-0"

FP-I00S

STRUCTURAL ASSEMBLY DIAGRAMS

S-007

1/4" = 1'-0"

02/12/2015 NONE: PROJECT IS PUBLIC DOMAIN

SHEET TITLE

FP-E000

DESCRIPTION

LOT NUMBER:

A-521

MICROWAVE SEE SPECS

2'-6"

A-521

3/4" CNC CUT LAMINATED PLYWOOD DOOR, TYP. AT CABINETS

1'-6 1/2"

4'-6 3/4"

TELEVISION SEE SPECS

4'-6 3/4"

REFRIGERATOR SEE SPECS

5" DR

1'-0"

3'-0"

2'-0"

DISHWASHER SEE SPECS D

2'-1"

3'-0"

4'-10"

4 1/4"

TOP OF SUBFLOOR 1'-7 3/4"

2'-1"

5" DR

5 1/2"

2'-10 3/4"

3'-0"

TOP OF SUBFLOOR 1'-7 3/4"

2'-10 3/4"

6" DR

7" DR

9" DR

DESIGN TEAM TEAM NAME:

TOP OF SUBFLOOR 1'-7 3/4"

4 1/4"

5" DR

2'-11 1/2"

5" DR

2'-11 1/2"

5" DR

2'-10 3/4"

5 1/4"

2'-6 3/4"

3'-2"

TEAM CLEMSON

ADDRESS:

LEE HALL CLEMSON, SC 29632

CONTACT:

INDIGOPINE2015@GMAIL.COM INDIGOPINE.COM

RANGE/OVEN SEE SPECS

D1 KITCHEN CABINET ELEVATION

D4 LIVING SPACE CABINET ELEVATION

1/2" = 1'-0"

D6 BEDROOM 103 CABINET ELEVATION

CONSULTANTS

1/2" = 1'-0"

B5 A-521

7 1/4"

1'-7" EQ

7 1/4" 1'-1 1/4"

2'-2"

1'-8 1/4"

7 1/4"

1'-7" EQ

VINCENT BLOUIN | CLEMSON

ELECTRICAL

VINCENT BLOUIN | CLEMSON

PLUMBING

VINCENT BLOUIN | CLEMSON

EQ TA-2

TA-2

6'-4"

3'-8 1/2"

TA-3

3'-8 3/8"

4'-6 3/4"

3'-3"

TY MONKS | NISHKIAN MONKS

MECHANICAL

7 1/4"

CL 3/4" CNC CUT LAMINATED PLYWOOD DOOR, TYP. AT CABINETS

STRUCTURAL

4'-5 1/2"

1/8"

1'-11"

2'-6"

3'-2"

5 1/4"

2'-10 3/4"

TOP OF SUBFLOOR 1'-7 3/4"

1'-7" 2'-9 1/2"

B1 HALL CABINET ELEVATION

B2 BEDROOM 104 CABINET ELEVATION

1/2" = 1'-0"

U.S. DEPARTMENT OF ENERGY

3'-3 1/2"

9" DR

2'-10"

9" DR

3'-3 1/2"

7" DR

2'-10"

6" DR

7" DR

2'-5 1/4"

3'-9"

CLIENT

TOP OF SUBFLOOR 1'-7 3/4"

6" DR

SOLAR DECATHLON 2015 WWW.SOLARDECATHLON.GOV

TOP OF SUBFLOOR 1'-7 3/4"

1'-7" 2'-9 1/2"

2'-9 1/2"

B4 TOILET AND CABINET ELEV 1/2" = 1'-0"

B6 WASHROOM CABINET ELEVATION 1/2" = 1'-0"

B5 A-521 B

4'-5 1/2"

4'-7"

4'-6 1/4"

MARK

6" DR

9" DR

8/17/2015 4:59:30 PM

2'-8 1/2"

TOP OF SUBFLOOR 1'-7 3/4"

A1 MASTER BDRM CLOSET ELEV 1/2" = 1'-0"

4'-9 1/4"

3'-0"

2'-6 1/4"

A2 MASTER BEDROOM AND HALL ELEVATION

ARCH STUDIO

CHECKED BY:

DAN HARDING

1'-6"

TOP OF SUBFLOOR 1'-7 3/4"

1/2" = 1'-0"

02/12/2015 NONE: PROJECT IS PUBLIC DOMAIN

SHEET TITLE

A6 BEDROOM CLOSET ELEVATION

1/2" = 1'-0"

TOP OF SUBFLOOR 1'-7 3/4"

DESCRIPTION

106

DRAWN BY:

9" DR

2'-8 1/2"

DATE

LOT NUMBER:

ISSUE DATE:

2'-6 1/2"

6" DR

2'-5"

2'-5 3/4"

6'-6 3/4"

TELEVISION SEE SPECS

CABINETRY ELEVATIONS

A-511

Measured Contest Captain As “Measured Contest Captain,” I had to maintain all of the different functions of the house that were measured by the competition. The speciﬁc competitions were as follows:

Comfort Zone Temperature and humidity levels were measured constantly throughout the day in four different areas of the house. These levels had to be within a certain range to receive full points.

Appliances The effeciveness of the appliances were tested based on different criteria. The dishwasher had to achieve a certain temperature while the washer and dryer had to demonstrate washing and drying a full load of laundry to its original dry weight.

Home Life The ability of the home to accomodate living was tested. At certain times of the day, the television and computer were required to be on. At other times, the lights were required to be on and set to a certain level. The teams were also required to host two dinner parties, preparing the entire meal using the home’s appliances.

Commuting Teams were required to drive a fully electric vehicle 25 miles every day to simulate driving to and from work or the grocery store. The car was then required to be charged from the home’s energy system.

Energy Balance This was the ultimate test of how well the house performed. Energy consumption was measured as well as energy production. Full points were awarded for being below a certain amount of consumption as well as having a positive net energy.

Laundry Task

Lighting Task