Robert Ellenberg
Registered User
I've been posting here for several months but decided to be more open about my current project. I have hesitated because similar ventures have been controversial among code officials as well as others. However, I have found most contributors in this group to be extremely helpful if you have an attitude of striving to do things correctly--which I do.
But first let me tell a little about myself. I was first licensed as a GC in 1971 when I was 21. Since that time I have built for myself, with partners and for large merchant builders. I have built in hot humid climates and cold dry climates. I have built stick frame, masonry, prefab panels and modular. I have built entry level and I have built expensive custom. Much of what I have built--I designed. I have also spent a lot of time evaluating damage for insurers after catastrophes which has given me a lot of insight into what works structurally as well as claims related to mold, water intrusions, etc. As a builder I have always studied the codes because my goal is to do things the right way, the first time.
So what is this "controversial" project? Component houses based on ISBUs (shipping containers). But before you think, "Oh not again", please read on with an open mind. I started on this 6 years ago and since that time hired an engineer to evaluate my structural concepts, tested combinations of materials, fasteners, etc., ran our own controlled tests on the so called miracle ceramic paints, all in an effort to determine what works that is cost effective. And of course spent hundreds of hours re studying the codes (and asking questions here) in an effort to do everything EXACTLY right. I believe the end result will be very marketable as it is going to be a house of high quality, energy efficient, extremely strong and very cost effective. I am still about 6 months to a year away from building the prototype but it will not look like it is built from containers. They are fully concealed within the structure and the exterior is finished with cement board siding. The least exterior dimension is 24' (nothing 8' wide). If you were riding down the street it would simply appear to be a new house of contemporary or modern design (not seeing ugly shipping containers should eliminate neighborhood appearance, zoning and perception issues).
The purpose of this post is to solicit additional questions, comments and input. I find this group to be very anal (I am too) and tough scrutiny only helps improve my concept. I am going to take the time to fully explain the origins of my concept so this will be a lengthy post.
In 2003 my wife wanted to build a weekend cabin in the mountains of Northern New Mexico but I refused to even consider the idea because of the high frequency with which remote cabins are vandalized. The following year a friend made me aware of a hunting camp constructed with ISBUs and steel shutters. I was very familiar with ISBUs as it was what I used on a trailer for securing tools and materials on my job sites so I began to design a simple cabin. About 6 months into it (with several concepts sketched) I did an internet search to see if anyone had ever built with them and low and behold, it appeared it was a thriving niche market! After researching everything I could find over the next several months I came to several conclusions. 1) There were a lot of designers and architects with concept ideas looking for “guinea pig” clients but very little was being built. 2) Most all were clueless regarding the difficulties, code challenges and high costs—particularly the high costs. 3) There was a lot of misinformation out there. Again and again I saw concepts with code and design problems and most were claiming how cost effective they were going to be. As an experienced builder/designer I knew beyond any doubt that building a market-acceptable structure that was also cost effective would be extremely difficult. However, I was intrigued by the idea and still wanted my mountain cabin for myself. As time went on I watched as those that did get built came in at sometimes double the claimed budget and no one has produced a house that I would consider successful by my measurments.
From where I started 6 years ago a lot of what I had planned to do has changed. I believe what I have now developed is attractive (if you like modern, if you only like traditional styles you won’t think so), has many advantages over modular or kit houses and will be very cost effective—the most important aspect. It’s not difficult to build a cost effective home; a sustainable energy efficient home (there are homes putting energy back into the grid); or a stylish home of excellent quality. What is extremely difficult is to attain a high level of success in all three areas with the same house—but I have.
The adoption of the IRC by many jurisdictions makes it possible to design a house that can be put almost anywhere in the lower 48 provided I can accommodate different climate zones and the local code amendments that apply in many locations. I refer to these houses as component houses as they will shipped partially assembled and the price will include everything needed to complete them. I don’t refer to them as a “kit” home as most kits include only the structural parts and they are not assembled. My houses are not modular in that everything will be inspected locally on site, they will be site built homes. There are no closed walls so it is simply a site built home with some prefabricated components.
This just touches on the basics of the concept and doesn’t give much information but is in fact, the first public forum where I have posted any of this and here is why. I am a perfectionist and when we are finally underway I want to be selling a product that does everything I claim it does and that includes meeting all of the applicable codes in every detail. I am guessing that some of you will be curious enough to ask a lot of questions about how I intend to meet different requirements and along the way you may raise some questions I haven’t thought of. I lay in bed at night reading codes (bet you don’t know any other builder/designers that do that) but I still miss some things. If some of you want to know more about the basic designs I will answer as many questions as I can but there are many aspects that are proprietary processes (not necessarily patentable) so I may not be able to share some details.
Thanks again for all the help I have already received on this forum. I consider it the most valuable one I participate in.
But first let me tell a little about myself. I was first licensed as a GC in 1971 when I was 21. Since that time I have built for myself, with partners and for large merchant builders. I have built in hot humid climates and cold dry climates. I have built stick frame, masonry, prefab panels and modular. I have built entry level and I have built expensive custom. Much of what I have built--I designed. I have also spent a lot of time evaluating damage for insurers after catastrophes which has given me a lot of insight into what works structurally as well as claims related to mold, water intrusions, etc. As a builder I have always studied the codes because my goal is to do things the right way, the first time.
So what is this "controversial" project? Component houses based on ISBUs (shipping containers). But before you think, "Oh not again", please read on with an open mind. I started on this 6 years ago and since that time hired an engineer to evaluate my structural concepts, tested combinations of materials, fasteners, etc., ran our own controlled tests on the so called miracle ceramic paints, all in an effort to determine what works that is cost effective. And of course spent hundreds of hours re studying the codes (and asking questions here) in an effort to do everything EXACTLY right. I believe the end result will be very marketable as it is going to be a house of high quality, energy efficient, extremely strong and very cost effective. I am still about 6 months to a year away from building the prototype but it will not look like it is built from containers. They are fully concealed within the structure and the exterior is finished with cement board siding. The least exterior dimension is 24' (nothing 8' wide). If you were riding down the street it would simply appear to be a new house of contemporary or modern design (not seeing ugly shipping containers should eliminate neighborhood appearance, zoning and perception issues).
The purpose of this post is to solicit additional questions, comments and input. I find this group to be very anal (I am too) and tough scrutiny only helps improve my concept. I am going to take the time to fully explain the origins of my concept so this will be a lengthy post.
In 2003 my wife wanted to build a weekend cabin in the mountains of Northern New Mexico but I refused to even consider the idea because of the high frequency with which remote cabins are vandalized. The following year a friend made me aware of a hunting camp constructed with ISBUs and steel shutters. I was very familiar with ISBUs as it was what I used on a trailer for securing tools and materials on my job sites so I began to design a simple cabin. About 6 months into it (with several concepts sketched) I did an internet search to see if anyone had ever built with them and low and behold, it appeared it was a thriving niche market! After researching everything I could find over the next several months I came to several conclusions. 1) There were a lot of designers and architects with concept ideas looking for “guinea pig” clients but very little was being built. 2) Most all were clueless regarding the difficulties, code challenges and high costs—particularly the high costs. 3) There was a lot of misinformation out there. Again and again I saw concepts with code and design problems and most were claiming how cost effective they were going to be. As an experienced builder/designer I knew beyond any doubt that building a market-acceptable structure that was also cost effective would be extremely difficult. However, I was intrigued by the idea and still wanted my mountain cabin for myself. As time went on I watched as those that did get built came in at sometimes double the claimed budget and no one has produced a house that I would consider successful by my measurments.
From where I started 6 years ago a lot of what I had planned to do has changed. I believe what I have now developed is attractive (if you like modern, if you only like traditional styles you won’t think so), has many advantages over modular or kit houses and will be very cost effective—the most important aspect. It’s not difficult to build a cost effective home; a sustainable energy efficient home (there are homes putting energy back into the grid); or a stylish home of excellent quality. What is extremely difficult is to attain a high level of success in all three areas with the same house—but I have.
The adoption of the IRC by many jurisdictions makes it possible to design a house that can be put almost anywhere in the lower 48 provided I can accommodate different climate zones and the local code amendments that apply in many locations. I refer to these houses as component houses as they will shipped partially assembled and the price will include everything needed to complete them. I don’t refer to them as a “kit” home as most kits include only the structural parts and they are not assembled. My houses are not modular in that everything will be inspected locally on site, they will be site built homes. There are no closed walls so it is simply a site built home with some prefabricated components.
This just touches on the basics of the concept and doesn’t give much information but is in fact, the first public forum where I have posted any of this and here is why. I am a perfectionist and when we are finally underway I want to be selling a product that does everything I claim it does and that includes meeting all of the applicable codes in every detail. I am guessing that some of you will be curious enough to ask a lot of questions about how I intend to meet different requirements and along the way you may raise some questions I haven’t thought of. I lay in bed at night reading codes (bet you don’t know any other builder/designers that do that) but I still miss some things. If some of you want to know more about the basic designs I will answer as many questions as I can but there are many aspects that are proprietary processes (not necessarily patentable) so I may not be able to share some details.
Thanks again for all the help I have already received on this forum. I consider it the most valuable one I participate in.