How to Build an Arial Home

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How to Build an Arial Home

• March 27, 2009

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Be Prepared Things Usually Go Wrong, Be
Creative and Make the Necessary
AdjustmentsThese are not bumps in the road,
this IS the road.
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This is what you will see when you arrive at the
build site outside of Ensenada, Mexico. There
will be a painted concrete pad with steel U
channels anchored to it to support the wall
panels, a trailer full of building components,
and a lot of sand.
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A concrete pad painted bright blue at the
familys request
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Step 1 Clean off the concrete pad with brooms
and mops
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Arial Home U Channels Anchor Wall to Concrete Base
EternaBond Roof Seal 3 Wide
Wall Panel, Fiberglass on Inside, Steel on Outside
The U Channel is 2.25 high
Painted Surface
Insulating Tape
Concrete Pad
Silicone Caulk
Insulating tape is put under the U channel as an
air and water seal.
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211
810
810
211
Step 2 Pieces of outdoor carpet are put down
first to protect the floor surface
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Note the table on the pad holding the tools,
caulk guns, screws, etc. All tools and supplies
in active use go on the table, not the floor, not
the ground. Inactive items go back into their
bins.
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The Next Slide Shows the Floor Plan for the 380
Square Foot Steel Home You Will Be Building
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Back Wall Front Walls are 76 High
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05
04
03
02
01
07
22
810
08
21
Curtain Wall
Middle Wall is 80 High
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09
27
25
26
23
24
19
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Red Arrows Indicate Tongue Direction
810
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11
14
183 outside, 1711 inside
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15
16
13
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216 outside, 212 inside dimension
Arial Home Version 5.1 Floor Plan
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Back Wall Front Walls are 76 High
06
05
04
03
02
01
07
22
810
08
21
Curtain Wall
Middle Wall is 80 High
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09
27
25
26
23
24
19
10
Red Arrows Indicate Tongue Direction
810
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11
14
183 outside, 1711 inside
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15
16
13
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216 outside, 212 inside dimension
Arial Home Version 5.2 Floor Plan as of March 20,
2009
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The wall panels are checked for how they fit in
the factory
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Entrance
Table 1
Canopy Set Up Here
Table 2
Table 3
Only one chair here.
Table 4
Table 5
This side faces construction area
Quartermaster area. Use 5 folding tables and 1
canopy and 5 chairs for this area. A sixth
folding table should be set up on the concrete
pad to hold tools, screws, etc.
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View from inside the Quartermaster area with bin
labels facing out
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All wall panels are carried from the trailer to
the saw horses for caulking
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Wall Panel Installation Procedure

• Carry the wall panel from the trailer to the saw
  horses, making sure the outside groove is on the
  bottom, Panel Label is facing up
• Caulk the groove with latex caulk
• Carry the wall panel to the proper position
• Level in both directions
• Use wood shims to hold the level position
• One person screws from outside, one from inside
  while panel is being held
• Repeat 27 times

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Be sure to use levels to ensure the wall panels
are vertical
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Use the levels to make sure the walls do not lean
in or out
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Using Four Magnetic Levels to Check Wall Panel
Alignment
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The Following Slides Show the Step-by-Step
Progression for Wall Panel Assembly
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6
5
4
01
7
22
8
13
9
86
27
25
26
24
10
14
18
Red arrows indicate tongue direction
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15
86
16
12
172 inside 177 Outside Concrete 177
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21
20
22
23
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201 inside dimension, 206 outside dimension
Arial Home Dimensions and Floor Plan
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Top Corner T Goes on Next

• This helps square the corner. Do not screw these
  top corner Ts in until all the walls are up and
  all the T pieces are in place.

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Corner Ts Help Square Corners

• Place channel T01 on top to help square the
  corner. Do NOT screw the Ts to the walls until
  all the walls are up and all the roof panels are
  in place to press them down.

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6
5
4
02
01
7
22
8
21
9
86
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25
26
24
10
14
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Red arrows indicate tongue direction
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15
86
16
12
172 inside 177 Outside Concrete 177
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21
20
22
23
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201 inside dimension, 206 outside dimension
Arial Home Dimensions and Floor Plan
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5
03
02
01
7
22
8
21
9
86
27
25
26
24
10
20
18
Red arrows indicate tongue direction
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15
86
16
12
172 inside 177 Outside Concrete 177
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21
20
22
23
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201 inside dimension, 206 outside dimension
Arial Home Dimensions and Floor Plan
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6
04
03
02
01
7
22
8
21
9
86
27
25
26
24
10
20
18
Red arrows indicate tongue direction
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19
86
18
12
172 inside 177 Outside Concrete 177
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21
20
22
23
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201 inside dimension, 206 outside dimension
Arial Home Dimensions and Floor Plan
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6
04
03
02
01
7
22
8
17
21
9
86
27
25
26
24
10
20
18
Red arrows indicate tongue direction
11
19
86
18
12
172 inside 177 Outside Concrete 177
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21
20
22
23
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201 inside dimension, 206 outside dimension
Arial Home Dimensions and Floor Plan
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05
04
03
02
01
06
22
07
21
9
86
27
25
26
24
10
20
Red arrows indicate tongue direction
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19
86
18
12
172 inside 177 Outside Concrete 177
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21
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22
23
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A Perfectly Aligned Corner Avoid the temptation
to put on the Outside Ls until the house is
finished
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05
04
03
02
01
06
22
07
21
08
09
20
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Red arrows indicate tongue direction
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19
86
18
12
172 inside 177 Outside Concrete 177
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21
16
22
23
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05
04
03
02
01
06
22
07
21
08
23
24
27
25
26
09
20
Red arrows indicate tongue direction
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10
18
12
172 inside 177 Outside Concrete 177
22
23
28
17
16
15
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Back Wall Front Walls are 76 High
06
05
04
03
02
01
07
22
810
08
21
Curtain Wall
Middle Wall is 80 High, Fiberglass side faces
the bedroom
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09
27
25
26
23
24
19
10
Red Arrows Indicate Tongue Direction
810
18
11
14
183 outside, 1711 inside
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15
16
13
12
216 outside, 212 inside dimension
Arial Home Version 5.0 Floor Plan, Door with Two
Grooves
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T Channels 15 and 17 tops do not extend all the
way to the side walls to allow room for the side
wall T channels to fit without an overlap.
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Installing the Roof Panels and Sealing them With
EternaBond
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Orientation of the Roof Panels
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Arial Home Ridge Cap Positioning
All tongues face to the right
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10
9
14
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Ten foot sections on either side
190
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1
2
3
4
5
6
Three foot middle section
96
Half Panel
230
All tongues face to the right
Front of house
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Front and Rear Roof Trim (Ls) Installed
Ten foot sections on either side
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12
11
10
9
14
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Three foot middle section
190
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1
2
3
4
5
6
230
All tongues face to the right
Front of house
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Roof Panel Installation Procedure

• Carry each roof panel from the trailer to the saw
  horses, for staging
• Carry the roof panel from the saw horses to the
  proper position adjacent to the home
• Lift into position with enough people on the
  inside of the house on ladders
• Measure overhang to make sure it is 10 on the
  side
• Repeat 13 times

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Set the wood planks on the concrete blocks so the
roof panel lift teams can reach up high enough to
hand the roof panels to the people on ladders
inside the house, as shown in this photo.
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Use multiple volunteers to hand the roof panels
to the inside teams.
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This is how the ladders should be placed inside
the house to receive the roof panels and move
them into the proper position.
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Screw all Ts to the roof panels first do NOT
screw Ts to wall panels until all are screwed to
the roof panels. Three people should stand on
each roof panel when Ts are screwed to the wall
panels to get the tightest fit.
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Sealing the Arial Home Roof with EternaBond
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Step 1 Fill the gap at the roof ridge with
Great Stuff insulating foam.
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Step 2 Put the 3 piece Ridge Cap in place with
a few screws. The ends abut rather than overlap.
Keep the screws more than 2 from the edges to
leave room for the EternaBond seal.
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Step 3 For all EternaBond applications, be sure
to snap a blue chalk line first so you have a
guide to keep it straight. It is permanent once
you put it down. Start with the long edges of
the Ridge Cap. Use the hand rollers provided for
maximum pressure to start the chemical reaction.
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Step 4 Leave the two short seams for the middle
piece until after the longer seams are complete
on both sides.
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EternaBond on the Ridge Cap seams.
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Front and Back L for Rain Water Run Off
One screw every 24, with washer, to hold Ls to
roof panels
EternaBond goes over this seam
3.25
Roof Panel
3.25
This Outside L is bent to 95 degrees to
compensate for the 4 degree slope of the roof
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Step 5 EternaBond the roof panel seams
overlapping the Ridge Cap by a few inches for
extra strength.
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Step 7 The finished roof with EternaBond seams
and roof trim.
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EternaBond on external T channel seam
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EternaBond on inside T channel seam
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Put EternaBond Tape on the Inside and Outside T
seams
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EternaBond Application Sequence for Roof Sealing

• 1 - Both long edges of Ridge Cap
• 2 - Seams of Ridge Cap
• 3 - Long edges of Front Roof Trim L
• 4 - Long edges of Rear Roof Trim L
• 5 - Seams of Roof Panels, overlapping the Ridge
  Cap but abutting the edge of the Roof Trim
  EternaBond

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Sequence of EternaBond Application
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12
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10
9
14
13
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1
2
3
4
5
6
Front of house
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A 123 watt Sharp solar PV panel powers the Arial
Home
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Side Orientation of Solar PV Panel when South is
not the Front or Back
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The Arial Home Plumbing System
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Prefabricated pipe connections for plumbing system
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To Sink
12 vdc Pump
To Toilet
To Shower
Water Filter
To Solar Heat Collector
Input Hose from Outside Water Tank
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The through wall bolts go on the lower pipe
clamp
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Images of the Arial Home Toilet and Shower
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The Arial Home Electrical System
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Only two panels have electrical wiring, 23 and 25
Shower
Blue lines are metal conduit, Red line is Wiremold
Bathroom Ceiling Light
Outside power from public utility or solar panels
on roof
Bathroom curtain wall
Bedroom Sconce Light
Kitchen Sconce Light
Family Room Sconce Light
Represents light switch
Solar Front Door Light
Represents an outlet
Electrical Plan for an Arial Home Version 5.2
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The inverter and the 12 vdc pump are wired
directly to the battery terminals using ring
terminal connections on the end of the 8 gauge,
stranded wires. The Red wires go to the
Positive terminal, the Blue wires go to the
Negative terminal.
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Panel 23 Showing DC Power coming in from solar
panel (red pipe), inverter (dangling in photo),
and input hose from water tank (green hose at
bottom).
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Finished Arial Home in SketchUp
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Compact Fluorescent and LED Lighting
Five compact florescent bulbs light the inside of
the Arial Home, each consuming just 14 watts of
power per bulb. The front door light is a self
contained photovoltaic cell/battery unit powering
two LED lights.
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811
23
25
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Shelves
Shelves
Arial Home Suggested Furniture Placement
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Arial Home Kitchen/Dining Area, Ensenada, Mexico,
Sept. 27, 2008
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Note the pipe clamp that holds the curtain rod
securely in place
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Safety Rules No Exceptions!

• Wear gloves when handling panels (they have sharp
  edges)
• Two people per ladder someone is ALWAYS holding
  it when in use
• Wear knee pads when kneeling
• No tools on the pad or ground EVER!
• Pick up any dropped screws immediately
• Trash goes in the trash bags, not on the pad,
  work table or ground
• Tools in use go on the work table, tools not in
  use are returned to the quartermaster
• No running with scissors or any other sharp
  object!
• No jumping off the roof use a ladder that is
  being held

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Example of tools being left in unacceptable
spots. Use the tool cart!
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Beware of the 90 Syndrome

• 90 done is NOT done
• Furniture must be put together
• The house and yard must be thoroughly cleaned
• Everyone picks up trash
• Everyone loads the bins and the vehicles
• After Day 1, most items stay behind, locked in
  the house

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Example of Role Assignments

• Quartermaster and Floor Plan Director - Emily
• Screw Guns Matt, Ben, Eliot
• Panel Positioners Megan, Andrew, Andy, Jeff
• Caulk Gun - Dana
• Plumbing Nuno and Moises

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"Never doubt that a small group of committed
people can change the world. Indeed, it is the
only thing that ever has." - Margaret Mead
Arial Home built for the Vargas family by the
Princeton team, Feb 13, 2008 Tom Cathie Johnson
68, Dick Seggel 68, Jim Sherman 69, Tom Jane
Pirelli 69