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Construction Manual

Welcome to the Greater Fox Cities Area Habitat for Humanity Construction Manual. This manual was written and is revised annually by a VERY dedicated sub-team of our Senior Crew volunteers based on staff and volunteer feedback!

THE 2019 VERSION OF HABITAT FOR HUMANITY – GREATER FOX CITIES AREA’S CONSTRUCTION MANUAL IS NOW AVAILABLE AND READY FOR YOU!!

As usual ALL changes are denoted by the usual change indicator (‘|’) in the left margin and the changed or added text in RED). A few changes are highlighted below but you are encouraged to check out each of the updated chapters to see what is new for 2019:

  • Chapter 3:
    • Rough openings of closet sliding doors are now an extra ½” (used to be extra ¼”) to eliminate having to trim the metal tracks (that began occurring since the door manufacturer changed door hardware suppliers last year)
  • Chapter 4:
    • Basement doors have been added to the Door and Window Components process so they no longer have to be built when doing basement walls – Yahooey!!!!
  • Chapter 5
    • Basement window headers changed to a “T-header” (same as basement door headers)
    • More info on building basement walls
    • Lots of wall building clarifications……
  • Chapter 9:
    • Exterior door changes
  • Chapter 12:
    • Several air sealing and insulation clarifications
  • Chapter 13:
    • Detailed ceiling rock layout added
  • Other misc changes for 2019 to note:
  • Chalk line color sequence change from Blue 1st, and red to correct or override. We will now start with RED and use Blue to correct/override. The Main reason for this is that RED shows better and is longer lasting AND red will show up better on blue foamboard when doing siding, etc.
  • Paslode nail guns depth adjustments. Please be sure to check and adjust nail gun depth adjustments when nailing OSB sheathing or decking. If you can’t see the nail head it is driven too deep and the holding power is sacrificed. Ideal depth of nail is just below the surface of the sheathing/decking
  • Sheetrocking-new(er) 18v screw guns depth adjustment. Similar to the paslode note above please be sure to verify the depth adjustment before your volunteer crews begin to use them. Remember that screws set TOO DEEP are just as bad as those protruding from the surface!
  • Sill Box foam is changing from 2” to 1” blue foamboard and a 2” button nail thru the center of the foamboard into the rim board, caulking same as before. We will add a layer of 6” fiberglass insulation over the 1” foamboard as well.
  • EXTRA emphasis on cleaning out tub/shower units once they are installed and protecting them with scrap foamboard or fiberglass insulation to prevent damage
  • All roof and deck sheathing must now be spaced 1/8” between sheets along the 48” ends (use an 8d nail for spacing)
  • NO longer remove the back-draft flapper on the range vents or over the range microwave
    • New 18v impact drivers – with the trailer conversion all 18v impact drivers have been updated to more current versions. There is now a speed control (1,2,3) on the base of the tool you set of lower or higher RPM/speed
    • On-site Recycling changes to note:
      • Vinyl siding is no longer recyclable so it will now be put into the dumpster
      • Wood scraps (OSB, plywood, 2x lumber under 12” long, I-joists, LVL) will be stacked neatly along the curb (small pieces to be put into barrel) and available for Sr. Crew, general volunteers and Neighbors to take. Be sure to keep “usable” scraps separate so they don’t get accidentally taken. The goal is to seriously reduce the Wednesday Logistic Recycling Crew work load. Any scrap wood remaining on the last day of the build will then be hauled away by logistics crews.

Below is a short description of what these are and their intended use on the work site:

  • Quick Reference Guides (QR’s) are a one-page summary of steps for performing a specific task (e.g. Installing Interior Doors & Trim). QR’s are strictly a “what to do” guide or checklist and are designed for individuals who are comfortable and well versed in the task but just need a reminder of “what to do” (vs. “how to do it”).
  • Quality Points (QP’s) help volunteers by providing the expectations for each task as it is performed and completed. QP’s also function as a checklist to review before acknowledging the task is complete.

If you have any questions or concerns with the Construction Manual, please contact Kevin Gostomski, Construction Supervisor at KevinG@FoxCitiesHabitat.org or (920) 205-1051.

Introduction

Introduction

Cover page
Table of Contents
Glossary of Terms

Chapter 1

Beam and Sill Plates | View Chapter

1.1 Establishing Square Sill Plate Chalk Lines
1.2 Installing Treated Sill Plates
1.3 Installing Laminate Beam Quick Reference | Quality Points Guide

Chapter 2

Cap Foundation | View Chapter

2.1 Installing I-Joists And Sillbox Quick Reference | Quality Points Guide
2.2 Framing Stair Opening
2.3 Installing Foamboard In Sillbox
2.4 Installing Floor Sheathing (Decking)
2.5 Basement Preparation

Chapter 3

Wall Layout | View Chapter

3.1 Laying Out Exterior Walls Quick Reference | Quality Points Guide
3.2 Cutting Exterior Wall Plates Quick Reference | Quality Points Guide
3.3 Marking Window And Door Locations On Exterior Wall Plates Quick Reference | Quality Points Guide
3.4 Marking Studs On Exterior Wall Plates Quick Reference | Quality Points Guide
3.5 Laying Out Interior Walls Quick Reference | Quality Points Guide
3.6 Cutting Interior Wall Plates Quick Reference | Quality Points Guide
3.7 Marking Door Locations On Interior Wall Plates Quick Reference | Quality Points Guide
3.8 Marking Studs on Interior Wall Plates Quick Reference | Quality Points Guide

Chapter 4

Components and Stairs | View Chapter

4.1 Building Window and Door Components
-Building Exterior Window Door Components – Quick Reference | Quality Points Guide
-Building Interior Door Components – Quick Reference | Quality Points Guide
4.2 Building Stairs

Chapter 5

Build Main Floor Walls | View Chapter

5.1 Framing Exterior Walls Quick Reference | Quality Points Guide
5.2 Squaring Exterior Long Walls Quick Reference | Quality Points Guide
5.3 Sheathing Exterior Long Walls Quick Reference | Quality Points Guide
5.4 Erecting Exterior Long Walls Quick Reference | Quality Points Guide
5.5 Sheathing & Erecting Short Walls Quick Reference | Quality Points Guide
5.6 Completing Exterior Walls Quick Reference | Quality Points Guide
5.7 Straightening Exterior Walls Quick Reference | Quality Points Guide
5.8 Framing Interior Walls Quick Reference | Quality Points Guide
5.9 Erecting Full Height Interior Walls Quick Reference | Quality Points Guide
5.10 Erecting Half-Height Interior Walls
5.11 Installing Top Plates Quick Reference | Quality Points Guide

Chapter 6

Porch, Stairway and Basement Walls | View Chapter

6.1 Framing Porch
6.2 Framing Basement Walls
6.3 Cutting Angle Stairway Wall
6.4 Framing Stairway Closet Platform

Chapter 7

Roof Framing | View Chapter

7.1 Roofing Prep Work
7.2 Installing Roof Trusses
7.3 Installing Porch Trusses
7.4 Sheathing Roof
7.5 Installing Sub-Fascia
7.6 Building and Installing Scuttle Box
7.7 Installing Laterals and X-Bracing
7.8 Installing Truss Timer Screws and L-Clips

Chapter 8

Roofing | View Chapter

8.1 Installing Gutter Apron
8.2 Installing Ice and Water Shield
8.3 Installing Roofing Felt
8.4 Installing Drip Edge
8.5 Installing Started Strip
8.6 Installing Shingles
8.7 Installing Ridge Vent
8.8 Installing Cap Shingles

Chapter 9

Windows and Exterior Doors | View Chapter

9.1 Installing Windows Quick Reference | Quality Points Guide
9.2 Installing Exterior House Doors Quick Reference | Quality Points Guide
9.3 Installing Exterior Door Weatherproofing, Hardware Quick Reference | Quality Points Guide
9.4 Installing Shed Door
9.5 Installing Basement Egress Components

Chapter 10

Vents, Attic Scuttle and Blocking | View Chapter

10.1 Installing Bath Fan and End Cap
10.2 Installing Range Plenum and End Cap
10.3 Installing Proper Vents
10.4 Installing Wind Washing Baffle Guard
10.5 Installing Blocking

Chapter 11

Siding and Soffit | View Chapter

11.1 Siding Prep
11.2 Installing House Siding
11.3 Installing Shed Siding
11.4 Installing Soffit
11.5 Installing Fascia
11.6 Installing Shutters
11.7 Site Cleanup

Chapter 12

Air Sealing and Insulation | View Chapter

12.1 Building Science Facts
12.2 Preparation
12.3 Air Sealing Quick Reference | Quality Points Guide
12.4 Installing Insulation in Wall Cavities
12.5 Installing Poly Vapor Barrier Quick Reference | Quality Points Guide

Chapter 13

Ceiling Sheetrock | View Chapter

13.1 Preparation
13.2 Planning
13.3 General Installation Rules
13.4 Installing Ceiling Sheetrock Quick Reference | Quality Points Guide
13.5 Assembling Scuttle Box Cover
13.6 Finishing Scuttle Box Cover

Chapter 14

Wall Sheetrock | View Chapter

14.1 Preparation
14.2 Planning
14.3 General Installation Rules
14.4 Installing Wall Sheetrock Quick Reference | Quality Points Guide
14.5 Finishing and Cleanup

Chapter 15

Painting | View Chapter

15.1 Preparation
15.2 Priming, Painting, and Staining Quick Reference | Quality Points Guide
15.3 Clean-Up
15.4 Preparation for Next Build Day

Chapter 16

Subfloor, DRIcore and Finish Stairs | View Chapter

16.1 Installing Underlayment & DRIcore
16.2 Finishing Stairs

Chapter 17

Cabinets | View Chapter

17.1 Laying Out Kitchen Cabinet Upper Units
17.2 Installing Kitchen Cabinet Support Strips
17.3 Installing Kitchen Cabinet Upper Units
17.4 Installing Range Hood
17.5 Installing Kitchen Cabinet Floor Units
17.6 Kitchen Countertop Preparation
17.7 Installing Kitchen Countertop
17.8 Installing Bathroom Cabinets

Chapter 18

Interior Doors | View Chapter

18.1 Swinging Doors Quick Reference | Quality Points Guide
18.2 Sliding Doors Quick Reference | Quality Points Guide
18.3 Bifold Doors

Chapter 19

Interior Finish Work | View Chapter

19. 1 Installing Floor Trim
19.2 Installing Closet Shelves And Poles
19.3 Installing Bathroom Accessories
19.4 Hanging Mini-Blinds
19.5 Installing Appliances
19.6 Installing Basement Stair Grip Strips
19.7 Completing Caulking
19.8 Completing Air Sealing
19.9 Installing HVAC Vent Covers
19.10 Installing Scuttle Cover

Chapter 20

Exterior Finish Work | View Chapter

20.1 Installing Storm Doors
20.2 Installing Toe Kick Board
20.3 Installing Porch Rails
20.4 Installing House Numbers
20.5 Installing Mailbox
20.6 Air Sealing Exterior Penetrations

Chapter 21

Clean House | View Chapter

21.1 Completing Punchlist
21.2 Cleaning House
21.3 Installing HVAC Warm Air Vent Covers
21.4 Installing Clean Furnace Filters
21.5 Finishing Touches

Chapter 22

Shed Construction | View Chapter

22.1 Building Shed Floor Quick Reference | Quality Points Guide
22.2 Building Shed Walls Quick Reference | Quality Points Guide
22.3 Building Shed Roof Quick Reference | Quality Points Guide
22.4 Assembling the Shed Quick Reference | Quality Points Guide
22.5 Finishing the Shed Quick Reference | Quality Points Guide

Chapter 23

Garage Construction | View Chapter

23.1 Establishing Chalk Lines
23.2 Measuring and Cutting Wall Plates
23.3 Marking Window & Door Locations on Exterior Wall Plates
23.4 Marking Studs on Exterior Wall Plates
23.5 Erecting Garage Walls
23.6 Straightening Garage Walls
23.7 Installing Top Plates and Sheathing Walls

Chapter 24

Picnic Table Construction | View Chapter

24.1 Cutting Picnic Table Components
24.2 Assembling Picnic Table
24.3 Finishing Touch
24.4 Materials Sheet

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