D E S I G N / B U I L D 2 0 1 5
College of Design Architecture + Landscape Architecture
Design / Build Studio Summer 2015
College of Veterinary Medicine Zoological Teaching Animal Unit
Ashleigh Brewer
Marty Needham
A collaboration between the
John Griffioen
Mitch Caldwell
Morgan Parrish
College of Veterinary Medicine
Scott Hammer
Jonathan Currin
Jason Patterson
DVM students and the College
Ashley Kirby
Sarah Dunsford
Yuzhou Peng
of Design Architecture and
Anthony Cerreta
Olivia Hargett
William Sendor
Landscape Architecture students
Katherine Cassady
Raphael Hatley
Matt Teti
at NC State University.
Adeline Noger
Braxton Hinkle
Michael Wengenroth
Kyle Farmer
Skylar Kitchen
Annie Zipper
Hannah Gardner
Nicole Martinez
Elizabeth Hyde Elizabeth Sablotny
Randall Lanou
Fernando Magallanes, ASLA
Erik Mehlman, AIA
Diane Thompson, PE
Dr. Michael Stoskopf
Ellen Cassilly, AIA
Joel Lubell
Dr. Suzanne Kennedy-Stoskopf
Scott Metheny
Joshua Leab
Kenneth Satterwhite
Book design by William Sendor
August 2015
CONTENTS 1
Project Overview
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Design Process + Mock-Ups + Site Visits
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Site Preparation
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Footings
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Steel Brackets
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Floor Structure
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Posts + Beams
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Framing + Siding
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Roof
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Windows
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Doors
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Polygal
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Finishing + Painting
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Landscape
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Entry
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Counters + Floor
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Completion + Team
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1
Project Overview
Size: 384 s.f.
As part of the ten-week summer 2015 Design / Build Studio at the NC State University
Budget: $25,000
College of Design, architecture and landscape architecture students worked as a team
Architect: Erik Mehlman, AIA
to design and then build a wild animal husbandry facility for the Zoological Teaching
Engineer: Diane Thompson, PE
Animal Unit [ZTAU] at the College of Veterinary Medicine. DVM students in the ZTAU
Location: NC State University College of
program collaborated with the programming and construction aspects of the project.
Veterinary Medicine Materials: concrete foundation, welded steel
The design development and construction processes each took approximately five
brackets, PT posts, glulam beams, reclaimed
weeks, with some overlap in the middle. The Construction Document [CD] set was
tongue-and-groove roof decking, corrugated
submitted to the NC State Construction Office [SCO] and the NC State University
roofing, polygal, custom-built cypress windows,
Architect’s Office [UAO] in June. Construction was complete by July 31, the day of the
reclaimed walnut siding
final review for the studio.
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DESIGN PROCESS The design process began with a class site visit, where the students first experienced the challenges of the facility’s location: a densely wooded area past several locked, electric, and/or barbed-wire fences, and a biosecurity washing station. After the site visit, students participated in a four-hour model-building design charrette to identify the design ideas of the class. Then students worked in teams to produce five schematic design presentations with straightforward site strategies and formal architectural gestures. In a directed decision, the instructors and veterinary clients chose the “Wolf Trot” scheme [a play on the dogtrot house type] for it’s simplicity and functionality, especially in plan. The team worked to further define and realize the Wolf Trot scheme [later named “Wolf Prowl”] during the schematic design [SD] phase. The students pushed for a more dynamic roof form than the basic shed roof that had emerged from the directed decision, and they explored a range of tectonic, material, and structural solutions for the building design as a whole. The directed decision specified a site location and orientation that brought significant challenges, including clearing a number of large trees and digging far into the grade of the site. A group of students worked hard to reconcile this vision with the realities of the site, creating landscape and site plan that would first, require as little tree removal as possible, second, allow for proper drainage across the site, and third, provide an ADA accessible path into the building while still embodying the overarching goals of the scheme. Several students put together the CD set using CAD and 3D modeling software. This set included structural drawings, so the students collaborated closely with the project’s structural engineer, Diane Thompson. An SD set was submitted to the UAO and a CD set was submitted to the SCO for approval before construction began.
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COST ESTIMATION + BUDGETING During the design process and throughout the construction phase, the team continually made critical design decisions with the overall budget ($25,000) in mind. Below is a list of construction materials that the students sourced and ordered for the project.
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NC MUSEUM OF ART A T
W WADE A AVENUE
BLUE RIDGE RO AD
SITE
NC STA TATE TA ATE STATE UNIVERSITY CLUB COLLEGE OF VETERINARY MEDICINE MEREDITH COLLEGE
NC STA TATE TA ATE STATE FFAIRGROUNDS FAI RGROUNDS JC RAULSTON ARBORETUM
2015 DESIGN BUILD SUMMER STUDIO NCSU COLLEGE OF DESIGN PROJECT TEAM
ASHLEIGH BREWER, MITCH CALDWELL, JON CURRIN, SARAH DUNSFORD, OLIVIA HARGETT, RAPHAEL HATLEY, BRAXTON HINKLE, SKYLAR KITCHEN, JOSH LEAB, NICOLE MARTINEZ, MARTY NEEDHAM, MORGAN PARRISH, JASON PATTERSON, YUZHOU PENG, WILL SENDOR, MATT TETI, MICHAEL WENGENROTH, ANNIE ZIPPER,
INSTUCTORS RANDY LANOU, ELLEN CASSILLY, ERIK MEHLMAN, SCOTT METHENY, JOEL LUBELL
WOLF PROWL
ZTAU Wild Carnivore Animal Husbandry Shed
G100 G101 C100 A100 A200 A201 A300 A400 S100 S101
COVER SHEET BUILDING CODE SUMMARY SITE PLAN FLOOR PLANS AND PLAN DETAILS ELEVATIONS FRAMING ELEVATIONS SECTIONS DETAILS STRUCTURAL FOUNDATION AND FRAMING PLANS STRUCTURAL DETAILS
CONSTRUCTION DOCUMENT SET Several students consolidated the ideas from the brief schematic design phase into a comprehensive CD set. The following pages show the final record drawing set submitted to the SCO. These drawings represent the team’s basic design intentions of structure, enclosure, materials, and assembly. In addition, students utilized crucial shop drawings, communicative sketches, and on-site decisions throughout the construction phase to refine and complete the project.
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STABLE & LEVEL MATERIAL 6" METAL EDGING WITH 2" ABOVE PATH TAMPED SOIL 4"
4'
STABLE PAD
PROPOSED BUILDING FFE: 427.65
+
427.65
+
5%
6'
% 426.43 3.5
PLANTED WITH NATIVE SHADE TOLERANT GRASSES
DISTURBED AREA TO BE PLANTED WITH NATIVE SHADE TOLERANT GRASSES
EXISTING TREE TO BE REMOVED
EXISTING TREE TO BE REMOVED
%
3.5
426.78 +
18'
426.78 +
18'
427
427 +
2%
6'
426.43
6' WIDE DOUBLE DIRECTIONAL GATE 4' WIDE GATE 2%
6' WIDE DOUBLE DIRECTIONAL GATE 4' WIDE GATE
+ 427.25 % .25 3DISTURBED 427.35 + TO BE AREA
427.35 +
429
+ 427.25
3.2
428 429
428
427
427
426
426
427.65
2%
+ 426.79
18'
STABLE & LEVEL ACCESSIBLE PATH (DETAIL SP 1)
2%
2%
STABLE & LEVEL ACCESSIBLE PATH (DETAIL SP 1)
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STABLE PAD
12.47'
12.47'
PROPOSED BUILDING FFE: 427.65
+
429
429 32.5'4'
32.5'
5'
ACCESSIBLE PATH DETAIL ACCESSIBLE PATH DETAIL C 1 NTS NTS
428
427
428
427
426
426
5'
C 1
STABLE & LEVEL MATERIAL 6" METAL EDGING WITH 2" ABOVE PATH TAMPED SOIL
4"
2%
+ 426.79
427.15 +
18'
STABLE & FIRM SURFACE
STABLE & FIRM SURFACE
427.15 +
SITE PLAN
SITE PLAN
C
C
STABLE & LEVEL MATERIAL 6" METAL EDGING WITH 2" ABOVE PATH TAMPED SOIL 4"
426
5'
ACCESSIBLE PATH DETAIL NTS
429
428
427
C 1
4'
32.5'
STABLE PAD
12.47'
PROPOSED BUILDING FFE: 427.65
+
5%
+
6'
426.43
427
427.35 +
2%
6' WIDE DOUBLE DIRECTIONAL GATE 4' WIDE GATE
429
+ 427.25
3.2
428
427
426
427.65
DISTURBED AREA TO BE PLANTED WITH NATIVE SHADE TOLERANT GRASSES EXISTING TREE TO BE REMOVED
%
3.5
18'
426.78 +
2%
STABLE & LEVEL ACCESSIBLE PATH (DETAIL SP 1)
STABLE & FIRM SURFACE
2%
+ 426.79
18'
427.15 +
SITE PLAN
C
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Site Preparation Before construction could begin, several key tasks had to be completed on site. First, a crew staked out the footprint of the building and landscape elements. Next, trees were removed and a crush-and-run roadway was built from the cow pasture down to the perimeter fence of the ZTAU site. Approved truck and pedestrian gates were installed to create a new entrance to the site. Several students with experience using earth-moving equipment oversaw the first steps of the construction process, which included digging into the grade of the site to create a flatter space for the building to sit. The final elevation of this flat area was important for connecting an ADA-accessible path from the gate to the building.
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Footings During the design process, the students decided to use cylindrical footings on which the building would rest, so that the remote ZTAU site would be minimally disturbed in the long term. The team fabricated rebar columns in the welding room at the College of Design Materials Lab, built 2x4 ladders for precise spacing, and made bolt assemblies to fasten the lower steel brackets on later. The footing holes were dug, but then before the footings could be poured, it rained overnight, so the team had to remove the muddy water and fix the rebar. The concrete pour process required all hands on deck, with a team near the gate hauling and mixing the concrete, and another team pouring, vibrating, and smoothing the concrete in the footings and sonotubes.
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STEEL BRACKETS To achieve precision connections and a rugged aesthetic, the team decided to connect the main post-and-beam structure with welded, half-inch steel brackets. This would allow the posts, beams, and floor joists to be through-bolted with carriage bolts. Rectangular notch holes were also designed into flat plates on the bottom and top brackets to secure the cable cross-bracing. After careful collaboration with the structural engineer, students sent the final CAD cut template to a steel fabrication shop for plasma cutting. A team took the cut pieces and then worked the steel and welded the brackets together. Finally, two coats of black paint finished off the brackets.
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plasma-cut template CAD file
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Floor Structure With the concrete footings setting up and starting the curing process, the floor was ready to be assembled. During the footing stage, anchor bolts had been embedded in the top of the concrete at eight-foot and twelve-foot on-center spacing using plywood spacers. Once removed [along with the ladder bracing] the anchor bolts were ready to accept the lower steel brackets. Careful attention was paid to lining up, leveling, and squaring the brackets precisely along several translational and rotational axes before tighening with lock washers and nuts. With the brackets in place, the crew quickly installed rim joists from bracket to bracket and hung floor joists using Simpson hangers. The posts were also cut to length and bolted into the brackets during this process. Nonshrinking grout was installed between the steel brackets and concrete [around the anchor bolts] to better distribute the gravitational load of the building onto the concrete footings. Plywood decking was installed atop the joists with construction adhesive and nails to complete the floor.
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POSTS + BEAMS In the design phase, the team decided to express the post-and-beam structure of the building by visually exposing the steel bracket connections, as well as the posts and beams. Special attention was paid to the connections themselves. The lower steel brackets were designed to accept both the floor joists and pressure treated posts with bolted connections. The posts were cut, notched, and drilled to fit on-site and placed in the brackets. Then scaffolding was erected on the floor decking to allow for upper bracket and beam installation. For the upper brackets, the posts again had to be cut, notched, and drilled to fit on site. Carriage bolts were used to secure the posts and beams to the brackets. While the posts were going up, two protective clear coats were applied to the glulam beams, which were beveled lengthwise on-site to accept the slope of the tongueand-groove roof. Starting with the end glulams [lower and shorter in length], the students lifted the glulams themselves using a series of scaffolds, due to lack of power equipment on site. The tallest, longest, and heaviest glulam was a significant challenge to lift and set in place.
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FRAMING + SIDING Once the posts and beams were in place, the 2x4 stud framing and shiplap walnut siding were installed. In the design phase, vertical siding was chosen to highlight the vertical nature of the surrounding forest and tree canopy on the site. To achieve this vertical siding aesthetic required the team to create notches in the stud walls to allow for horizontal 2x4 let-in nailers. The walnut used for the siding was reclaimed from the floorboards of a house through the Habitat for Humanity of Wake County ReStore. The team de-nailed, planed, and milled the boards into vertical shiplap siding. These shiplap boards were then installed over quarter-inch luan and building wrap. Due to the large number of windows that were called for in the design, the four-foot stud walls did not provide enough lateral strength, so cross-bracing cables were installed between the lower and upper brackets of the building’s end bays. The upper stud walls [above the windows] were installed once the roof was in place. A structural header was added on-site to provide resistence to deflection over time.
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ROOF During the design process, the team learned of an opportunity to use reclaimed tongue-and-groove [T&G] decking from an abandoned tobacco warehouse near Reidsville, NC. Working the the structural engineer, the team decided to use the T&G for the roof, instead of the traditional rafter + purlin system. The three-inch nominal T&G could span from beam to beam without intermediary supports while providing diaphragm action to stabilize the building in conjunction with the cross shear walls and cable cross-bracing. Several students traveled to Reidsville to select and load the 20-foot-long T&G boards from the warehouse. On site, the glulam beams were beveled to the slope of the two roof pitches. The ridge beam was beveled in both directions to allow the T&G roof decking to meet. The roof framing crew used a ‘controlled random layup’ method to maximize the use of the T&G. The crew started from the centerline of the building and worked outward, using screws to secure the T&G boards to each other and to the glulam beams. For the angled outer portions of the roof, the crew angle-cut the boards and then installed a structural fascia board around the perimeter. A layer of roofing paper and then corrugated metal roofing, with pop-riveted ridge cap, completed the roof.
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10 Windows During the design phase, the veterinary clients expressed their wish to experience as much of the natural, wooded surrounding of the site as possible, even when inside the facility. The students designed a strong horizontal band of windows wrapping the entire building. The class had a tough decision: whether to purchase vinyl replacement windows [more expensive] or build custom wooden windows [more time, uncertainty]. A team of students crafted wooden mock-ups to see if the custom option would work. Eventually, the class decided to pursue the custom option, where each bay of windows would have two fixed and two sliding windows. First, the team cut the rails and stiles of the frames to length and created finger joints, using cypress wood for its weather resistent capability. The frames were glued and squared, and then the frames were trimmed to exact size according to the anticipated rough openings. Next, the students routed a rabbet in each frame to receive the glass. Then the sill and top pieces were cut, beveled for the drip edges, and grooved for the aluminum track, incuding a removable top track for future maintenance. The students crafted custom window stops and handles using scrap aluminum. Finally, the windows were assembled with screens in front of the sliding frame openings.
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11 Doors For the larger room of the building, the team decided to build a sliding barn door system of two, three-foot wide doors. A group of students took leftover pieces of the T&G roof decking to the Materials Lab, where they planed, sanded, and re-milled the wood for a clean and even fit. Next, they glued the T&G boards together and cut let-in grooves on the back sides of both doors to receive bracing members, and secured the bracing members with square walnut pegs [leftover from the siding]. A special effort was made to have the two sliding doors meet with a tongue and groove fit in the middle, when suspended from a 12-foot track of sliding barn door hardware. A groove was then made on the front side of the door to receive a six-foot walnut plaque [also using wood leftover from the siding]. The plaque was engraved with the title of the project, student and instructor names, school logos, and a half-tone image of a wolf at the center. This image, made up of hundreds of dots of varying radii, was created using Grasshopper. Finally, the team decided to make recessed handles that would not interfere with the door sliding across the jamb, so they created an elliptical void with a groove for a metal rod handle using Rhino 3d modeling software. The model was then sent to a CNC milling machine to cut the void and groove.
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12 Polygal During the schematic design process, several students were intent on using polygal, a fluted polycarbonate panel material, to bring in filtered natural light. The team decided to use this material as a clerestory above the windows, one that would also negotiate the angles of the roof. A galvanized drip cap was installed at the lower edge of the windows, slightly overlapping the top of the windows. Then the polygal was cut precisely to fit each trapezoidal space. Each eighfoot bay received two polygal panels, with factory edges of the polygal in the middle of the bay. The team created a shadow reveal at the top by painting the outside face of the framing top plate black. Solid and vented tape were applied to the top and bottom of the flutes, respectively, to properly handle moisture. One side of a polygal panel has a UV-protective coating, so the team made sure to position each panel for UV protection.
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13 Finishing + Painting With the project near completion, a group of students set out to paint the large shear walls [along the breezeway] and to clean and apply a protective finish to the T&G roof decking.
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14 LandscapE The landscape design and implementation continued for the entire project, and represented a significant part of the project’s overall success. After the initial site preparation [gravel drive, gates, earthwork], the landscape crew continued to work on several key projects, including a retaining wall, natural stormwater management systems, and an ADA-accessible path. For the retaining wall, the team laid rocks in an organic, natural way, and planted vegetation in the crevices of the rocks. The stormwater management consisted of a stepped log system and a large river rock drainage swale. The path was more formal. It was made of Chapel Hill gravel with a stone border, following a sweeping curve through a grove of trees and into the breezeway of the building. One of the subtle highlights of the design is the series of stone steps that create an alternative path up to the breezeway. Finally, the team added a carefully-selected arrangement of plantings around the building and site.
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15 Entry During the development of the design, the team decided to bring the ADA-accessible path from the gate into the breezeway of the building over a small boardwalk. The decking boards continue through the breezeway and down a stair toward the ZTAU enclosures, highlighting the dynamic circulation of the original Wolf Trot concept. For both the boardwalk in the front and wraparound stair in the back, the students poured puddle footings and then framed the structures with posts, joists, and stringers. Towards the end of the project, the students learned that the path and entry did not meet the slope requirements of ADA accessibility, so the front entry deck had to be removed and lifted up while the path could be adjusted to the correct slope. Then the deck was lowered back down and angled slightly to meet the path and create an overall accessible entry.
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16 Counters + Floor The final step in the construction process was to outfit the interior spaces with a finished floor and counters. The team laid down luan [leftover from the siding] over the plywood subfloor, and then installed a vinyl sheet floor. For the counters, the team build triangluar bracket supports and fabricated custom counters with a vinyl surface and walnut strip along the edge [leftover from the siding]. The counters were installed at two heights two accommodate a range of uses.
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17 Completion + TEAM The team completed the project on Friday, July 31, the last day of class. During a small reception that day, the finished product was described as “brilliant� by the client. The project represents a great effort of and incredible learning experience for the entire team. The following pages display photos from the last few days of completing the project, as well as pictures of the team throughout the summer.
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