K. Hovnanian Inc.: Freehold Township, NJ

Frost-Protected Shallow Foundation

• The builder needed to make informed decisions about type of insulation, fastening to the foundation, and how to cover the exterior surface of the insulation.
• Although the builder obtained code approval during the permitting process for the FPSF, the field inspector halted work on the FPSF for several days before granting approval.
• Because only vertical insulation was required, the builder was able to pour the foundation with conventional wood forms and add the insulation at a later date.
• Radiant heat (although not part of the studied technologies) had a direct positive impact on the performance of the FPSF—raising the temperature around the foundation to help prevent frost heave.
• Because radiant heating pipes were attached to the mesh in the concrete slab (mesh would normally be lifted during placement of the concrete for crack resistance, but could not be moved), a special concrete mix containing reinforcement fibers was used, therefore, increasing the cost of the concrete slab.
• The mason installed 2’ x 8’ sheets of vertical foundation insulation by cutting the sheets to size, predrilling into the concrete, and inserting a plastic fastener with a large plastic washer. Then, he drove a nail into the plastic fastener to anchor the system.
• The builder originally used plastic sheeting to protect the exterior surface of the foam board. However, the sheeting was aesthetically unacceptable and was replaced with a synthetic stucco finish.

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Concrete Floor Finishes

• Variances in pressure applied during stamping were apparent in the finished stamped surface.
• The finished appearance, according to the builder, was not marketable for a living area, but may be acceptable in a patio or basement.
• Concrete stamping delayed other trade contractor’s schedules.
• The homebuyers felt the floor was unsightly. The terms of the sale agreement included the installation of new flooring covering over the concrete.

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Steel Floor Framing

• Due to the higher cost of the steel floor framing system, the builder spaced the floor joists at 32 inches on center, and used 1-1/8 inch OSB subfloor.
• The manufacturer of the steel floor framing system provided the design.
• It is important to line up the evenly-spaced tabs of the rim joist with structural members under bearing walls. However, the design did not specify where to begin attaching the rim joist, which caused delays at the beginning of the project.
• The steel joist members, despite being longer than conventional wood joists, were lightweight and each member was installed in about 3 minutes.
• Installers found the best tool for fastening screws was a low-speed, high-torque screw gun. For cutting, a metal chop saw was the best. After obtaining the correct tools and fasteners, installation proceeded smoothly.
• Some steel framing details were unfamiliar to the crew inexperienced with metal framing.
• The builder attached steel hat-channels at 16 inches on center for attaching the drywall to the first-story ceiling since it wasn’t possible to attach drywall to joists at 32-inch spacing.
• Attaching the extra-thick OSB to the steel joists was labor intensive and included trial-and-error for finding the right fastener.
• The steel system caused some problems for the plumber who could not notch the joists.
• Insulating the doubled-end joists required spray foam.
• Including delays caused by the learning curve, the builder estimated labor for the steel floor system at 50 percent more than conventional wood.
• Prospective homebuyers liked the stiffness of the floor system and felt it was a good value. The sales agent felt that it was an effective selling point.

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Cross-linked Polyethylene (PEX) Water Supply Piping

• The builder used a hybrid manifold/tree-type distribution system in order to compare installation with a manifold system installed in another house. Ultimately, cost was about equal, because additional material costs offset labor savings.
• The plumber felt that the fitting tool was cumbersome.
• Tubing was stiff in the very cold weather experienced during installation.
• Kinks were removed with the use of a heat gun. However, the manufacturer recommends uncoiling the tubing to avoid kinks.
• The crew did not like transitioning between copper and PEX in the hybrid system.

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HVAC Duct Installation within Conditioned Space

• The main supply ran perpendicular to the second-floor joists. Therefore, a bulkhead was framed to accommodate the ductwork.
• Minimizing the duct length by extending supply register to the interior of rooms (rather than to exterior walls) saved a large amount of materials.

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Drywall Finishing Accessories (Drywall Corners)

• The finished appearance of the pre-finished drywall corners was attractive.
• Since the crew usually applies two coats of joint compound, there was some labor savings with the product. However, due to the need for precise measuring and cutting, labor time was increased.
• Potential homebuyers liked the bullnose corners and appreciated their durability.

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Additional Information

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Frost-Protected Shallow Foundation

• The innovative foundation saved the builder about $750 in installation costs.

Concrete Floor Finishes

• The floor finish cost about $5 per s.f.

Cross-linked Polyethylene (PEX) Water Supply Piping

• The builder reported that the system saved about $200.

HVAC Duct Installation within Conditioned Space

• The cost was similar to conventional duct system, when factoring the shortened duct length and the additional bulkhead construction.