sun city, az - 1964 - "research house"

8/6/2019 Sun City, AZ - 1964 - "Research House"

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DEL E. WEBB CORPORA TION1964 RESEARCH HOUSESUN CITY, ARIZONA

A Report ByHarvey Shahan

Ccrnmurrity Development DivisionNew Products & . Research Section

January 20, 1965


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TABLE OF CONTENTS

INTRODUCTION PAGE1

SECTION IThe Wall 3The Joint Treatment 4The Wall Coating Treatment 8

SECTION IIExterior Siding 14Solid Faced Carport Fence 15Soffited Overhang 17Vent-A-Ridge Attic Ventilating System 20Homasote Expansion Joint 22Lanai Enclosure 24Lanai Enclosure Removable Panel 26The Like Front Entry Door 28Corkwood Floor Covering 31Incandescent Light Fixtures 33Interior Window Surrounds 35Wardrobe Closet Shelving 37Furnace Noise Control 40


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Electronic Air CleanerAutomatic Sliding Glass Door Closer

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Built-In Ironing Board 47Formica Clad Kitchen Cabinets 49Laminated Plastic Kitchen Counter Tops 52Stainless Steel Kitchen Sink 53Kitchen Sink Mixing Valve 56Food Warmer Appliance 58Fiberglass Tub with Splash & Shower Stall 60

Flexible Showerhead 64Leakpr oo" Cente r Set 66Preprimed Mill Work 68Vinyl Wall Covering 69

SUMMARY 71

EXPERIMENTAL HOUSEQUESTIONNAIRE FORM 15

CONTRIBUTING COMPANIES 19


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INTRODUCTIONThe construction industry and certain elements supporting it havefor some year s tried to develop a new exterior wall which wou:~dlend itself readily to prefabrication, be readily installed" be im,,,: ,:permeable to weather and also be economical. I do not think itwould be excessive to state that some individuals we have en-countered expected to produce some sort of magic as part of thissubject. Wehave seen over the last several years dozens of sam-ples of walls brought forward as the ultimate in the creation of themagic exterior wall. Most of these experiments have been of thesandwich type; namely, some sort of filler, and these have run thegamut from paper to all the plastics, clad by almost every materialknown to the building industry.. Incredibly enough, most of thedevelopers of these magic walls overlooked at least some detailssuch as wiring, plumbing, TVjacks, openings for passage doors,joints, and, most particularly, the surface appearance both insideand out.

As the parade of these various wall specimens passed by, it be-came clear to us that the dimensional lumber was still the cham-pion for exterior walls. The problem was to develop an exteriorclad which would be permanent, economical, appealing to the eyeand acceptable to the public. After considerable research, it

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was thought that we had found a combination of materials whichmight produce this ideal wall. It was, consequently, decided tobuild a Research House in Sun City, Arizona to prove or disprovethe research we had done.

It was also decided, inasmuch as we were building the house anyway,to include as many new and different products or products not pre-viously used by us as possible to gain first hand experience withthem and to subject them to the scrutiny of the Sun City residentsand measure their reaction to them by rrrea.nsof a rna.r'ket researchquestionnaire. The products were selected, the house was designedand construction commenced duringthe last week of September,1964-. The house was opened to the Sun City residents on December 7,1964. It is located on the southeast corner of Audrey Drive andl03rd Avenue inUnit 6, Sun City, Arizona.

This is a report then of the building of this Research House, ofthe products included in it, the costs of these products and mate-rials, and the public's reaction to the products inparticular and tothe house in general.

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SECTION I1. THE WALLThe wall was composed of 2 x 41s framed in the conventional manner.The interior of the wall was finished with wallboard, hung. tapedand textured in the conventional manner. The exterior side of thewall was composed of four parts; namely. a tempered hardboardsiding. the joint treatments, the coating. and finally one coat ofvinyl paint.

It was decided to use tempered hardboard as the outer skin becauseit is permanent and is competitively priced and has been acceptedby the public because of its long and widespread use. The temperedhardboard used on this Research House was made especially forthis experiment by the Weyerhaeuser people. The principaldifference between it and a standard sheet of tempered hardboardwas that the long edges were tapered like wallboard for the samereason that wallboard edges are tapered. These particular sheetsof hardboard were 1/4" thick, 48" wide x 96" long. The screenedback was primed and the edges and other side sealed. The sheetswere attached with the long dimension running with the studs andwith the screened side outward. The spacing at the joints was setat . 125". The field of the sheet was then pneumatically nailed with

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6 penny nails at 8" intervals along the stud. This nailing pattern isexcessive. The joint between the sole plate and the floor werecaulked prior to hanging the wallboard. After the wallboard wasup, the joint between it and the concrete stem was also caulked.The corners, where this hardboard jointed, were capped with ametal wallboard corner bead.

2. THE JOINT TREATMENTThe biggest single problem in the development of a wall suchas the one under discussion is that of developing a satisfactoryjoint treatment. The joint must be able to withstand some move-ment, be permanent, and be invisible.

After searching out as many techniques and materials as we couldturn up, it was decided to follow the technique used in making in-terior wallboard joints, which technique is now satisfactory in allrespects. It was necessary to use other materials because ofproblems confronted on the exterior of an outside wall not found inthe inside of the wall, such as excessive moisture, wind, heatand probably slightly more movement owing to a greater rangeof temperatures on a year-round basis.

Of the various joint compounds evaluated, it was decided to use a


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product called 'I'uff-Kote, Its principal ingredient is lead. Thiscompound was chosen because it is stable, and will retain asufficient degree of flexibility for this usage permanently and,not being exposed to the air, it would remain chemically stable ..

Inthe actual joint treatment, a 3" wide fiberglass tape, 3 to 5mils thick, was imbedded in a thick film of Tuff-Kote. The Tuff-Kote manufacturer recommended bridging a crack or joint ratherthan filling it; however, in field practice, in this instance, theTuff-Kote bled through the glass tape into the joint Ieaving a con-cave bead line all along the joint. Because light would reveal anyimperfection on the joint, and most particularly a straight liner"UnIiingrom the plate to the header", it was decided to patch thisconcave bead. On the north wall of the house another applicationof Tuff-Kote was floated over each joint. It corrected the ob-jectionable bead satisfactorily but because of the viscosity ofthe material, it created a belt which was thought might benoticeable after the finish coating was applied. The King peoplethen took their "squeeze box" and using U. S. Gypsum vinylall-purpose ready-mix joint compound, floated the joints oncemore to fair out the Tuff-Kote build-up. To the eye; it appearedthat the joint treatment would be successful after the final wall

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coating had been applied.

On the east wall of the house, that portion of the wall enclosing thebedroom and family room, the King Company elected, as an experi-

ment, to finish the joints using their standard interior wallboardmaterial, namely, paper tape and vinyl-based ready-mix compound.The King people's argument was that since the wallboard tape andcompound would be covered by the finished wall coating and a coatof vinyl paint, they were not apprehensive about any troublesomequantity of moisture reaching the wallboard joint compound

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Physically, the experiment worked out well except that a slightconvex bead appeared over each joint running from top to bottom.This bead appeared when a very slight contraction in the walloccurred causing the paper tape to "bulge out", so to speak, sinceit has no elasticity. This slight bead cannot actually be measuredwith a straight edge, for instance, but any uniform imperfectionwill show up under the light. Needless to say, we don't intend touse any more paper tape.

The experiment was certainly justifiable in that it gave us somefeeling for the amount of movement that we might expect on exteriorwall joints at 4t-O" intervals resulting from temperature changesand also to observe the use of United Gypsum's vinyl all-purpos'e'r-eady-crux Joint compound used alone on an exterio~ wall joint" jtas described above. To date, although we have had fairly heavyrains and freezing temperatures" these joints acros,s the backof these two rooms are holding faat,

The remainder of the east wall and the aouth waH which includesthe south side of the storage room and the two sides facing thecarport were treated in esaent iaIly the same manner as the northwa.Il'described above. It should be added t~M.some pa~ch.ingoccurredon most of the joints on,the south wafk.be cauae the Tuff...Kote had

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been floated on fairly heavily thereby creating a shadow line whichthe spray coats could not take out.

3. THE WALL COATINGMATERIAL

A material called 'I'ex=Oot.e, manufactured by Textured Coatings of

America, Inc. in Los Angeles. California, was selected fromseveral others to be used on the exterior walls of this ResearchHouse. Tex-Cote was developed during World War II when it be-came imperative to have coatings which would protect militaryequipment in all climatic extremes. Subsequently,. it has been

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used in applications on all types of services under all conditionsaccording to the Tex-Cote people. It is presently .being used wide~yin the Los Angeles area on the exterior of many types of buildings.

The material is composed of synthetic elastomer-polyester basewith fiberglass, asbestos, perlite and mica. Pigments used arezinc oxide, titanium dioxide and the most durable of availabletinting pigments when color is desired. The material can bemodified by the manufacturer to create a wide range of textures.The material has a high elasticity characteristic and is extremelyresistant to water. The Tex-Cote Company guarantees this materialfor a lO-year period against flaking, chipping, or peeling.

The material was sprayed on the house by the Pete King people.They had used this material previously and, in fact, the mechanichandling the gun was brought to Sun City to shoot this particularhouse from another job since he had considerable previous ex-perience in applying Tex-Cote.

Inapplying Tex-Cote, the mechanic first sprayed the noeth wallwith a light fog coat and then returned over the same surface witha heavier coat in an attempt to achieve a finished surface. Thissame technique continued around the other walls of the house.

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By the time he had sprayed the lanai on the east side of the house,Jerry King, who was supervising this operation, made the statementthat we should only apply a sufficient amount of this material toachieve the desired texture and then, after the material had cured,roll on one coat of vinyl paint. He said this technique would cost

less money than using a sufficient amount of Tex-Cote to getsatisfactory coverage of the walls and that we would have greatercolor flexibility and a richer appearing color as well. The pigmentsused in this coating have a tendency to have the same characterieticsinappearance that pigments added to the skin coat of stucco has.

When the house was completed, we had used about 55 gallons ofTex-Cote whereas we should have used about 15gallons accordingto Mr. Jerry King. This excessive amount of material usedcame about as a result of continued re-spraying to cover imper-fections at the joints. Whenthis state had been achieved, a coatof vinyl paint was then rolled over the Tex-Cote. The results maybe seen now on the Research House.

After the experience of completing this wall as described above,Mr. Jerry King and his people are of the opinion that the properway to treat the walls would be: (1) to reduce the width of the

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joint between the sheets of hardboard to about 40 mils; (2) toimbed the glass tape in one thin coat of Tuff-Kote; (3) allow theTuff-Kote time to cure; (4) apply a sufficient amount of Tex-Coteto gain the desired texture on the wall surface and, after the Tex-Cote is cured, (5) to roll on one coat of vinyl paint.

COSTThe estimated costs for building exterior walls as described aboveare as follows:

1. Framing (Labor and Material) $ 152. Hardboard Siding 153. Labor to hang sheeting .054. Joint treatment, coating and

painting operation .265. Total cost per square foot $ .61

SUMMARYThe overall impression of this wall is that it is pleasing to theeye. A question regarding it was not included in the market re-search questionnaire since it was thought that an evaluation ofthis feature of the Research House could best be performed byprofessionals. Nevertheless, many of the visitors observed thewall and expressed approval of and satisfaction with it. This

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opinion was sometimes followed by a less flattering opinion ofthe concrete block walls such as is used in the houses in SunCity.

It is difficult, if not impossible, to describe "pleasing", "morepleasing", "attractive", etc; , when evaluating such a subject;however, most of the professional construction people who haveexamined this wall, and this particular specimen can be improvedupon, have found it to be more pleasing to the eye than the finishachieved with stucco. Also, it wonIt crack.

It is fortunate that the house was built when it was inasmuch asa week of heavy rain and freezing weather occurred during theoperations of finishing the joints, applying the Tex-Cote, andpainting the house. Since that time, which occurred early inNovember, we have experienced continued rains and some freezingweather. Beyond question this wall treatment should be observedduring the cycle of a full year, most particularly during the latesummer months, before any final evaluation can be made as toits durability. All of the people whoworked on this house, includingthe Tex-Cote people who contributed the material and the PeteKing people who applied it, are extremely confident regardingthis durability aspect. Inany event, we need more experience in

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applying this material. Since the several materials used incovering this exterior wall are well known and established, itappears there would be a minimum of risk in using such a treatmentat this time on buildings over which the WebbCompany had directcontrol. Additional field experience at this time to permit usingthe application refinements indicated by this experi8aent would beinvaluable.

Should this wall fulfill all expectations, its potential can readilybe seen with respect to prefabrication techniques or as a substituteor alternate for stucco and block. The promise suggested by thisexperiment to date holds considerable excitement for the future.A report shall be prepared next November when the house willbe one year old. The report will include the findings duringperiodic inspections throughout the year.

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SECTION IIEXTERIOR SIDINGThe exterior siding used on the front elevation of this house andon the carport fence is a tempered hardboard called Ruf-X-Ninety,manufactured by Masonite. It has a resawn texture on the surfaceand is available in sheets having half-inch grooves at 4 and 8 inchesand in sheets without grooves when batts are to be used. Thematerial is 3/8" thick.

COSTThis material costs approximately $200 M, FOB job site, Florida,Arizona, and California. (See HS-llO, September 4, 1964).

SUMMARYA question on this product was not included in the market researchquestionnaire; nevertheless, the material received much favorablecomment since most people found it attractive. In fact, mostpeople thought it was wood. Even though the material comes witha sealer on it, it must be primed before the finish coat is appliedto achieve a satisfactory finished surface.

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SOLID FACED CARPORT FENCE

This fence is framed with 2 x 4's having 4'-0" panels of Ruf-X-Ninety masonite hardboard nailed to its exterior side. It has aredwood cap.

COSTThe masonite siding costs approximately 20 a square foot asstated in the preceding section. Added to this would be the costfor 2 x 4's, the cap, the labor for framing, and painting costs.These costs will vary slightly from job to job and therefore werenot extended here.

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SUMMARYThe purpose for designing this fence was to elimina.te the open-type. framed fence, having different patterns which we have usedin the past, because of its excessive maintenance problems andcost. Inmost cases, the solid fence would probably have a loweroriginal cost than the open fences. Also, it provides more privacywhich appeals to many people.

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THE SOFFIT ED OVERHANG

A .soffit.ed overhang was included in this house in order to compareits appearance with that of houses nearby having exposed raftertails, and to gain first-hand experience with costs toward the endof eliminating those callbacks common to exposed overhangs. Regularhalf-inch gypsum board was used for the soffit material owing tothe dryness of the area. There is no concern about using interiorgypsum wallboard for this application. It has been used here

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successfully for years.COST (SCFFITED)

Assume an overhang 301 long x 31-0" wide:Wallboard installed .10 S. F. x 30 x 2.5 $ 7.50Paint No DifferenceContinuous Vent-A-Strip .072 x 30(Model 70, Home Comfort Products) 2 .1 6

Labor to installVent-A-Strip .03 x 30 .90

$ 10. 56(NOT SOFFIT ED)

Frieze Boards Installed 33x 15 $ 4.95Paint No DifferenceC-C Exterior Plywood(Cost over C-D)

.035 X 41 x 301 4.20$ 9. 15

The unsoffited overhang figure above does notinclude costs fo;r ~eworking crooked or defectiverafter tails, roofin.g naj Ls, shme r s or callbacks forpaint complaints,

SUMMARYIf a nominal figure is added to the unsofited cost shown above

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for rework or callbacks, it can be seen that the costs of thetwo methods are virtually a standoff. The soffited overhanggives the house a finished look which the exposed rafters do notapproach. The maintenance costs on the soffited overhang willbe substantially less owing principally to the ease of repainting.The soffited overhang should eliminate the callbacks caused byexposed rafters and sheeting described above.

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VENT-A RIDGE ATTIC VENTILATION SYSTEM

Continuous Vent-A-Ridge combined with continuous frieze orsoffit venting provides an attic ventilating system having a uni-form air flow throughout the entire attic regardless of windvelocity or direction. Surnrner attic ternpe r atur-e s can approachthe outside temperatures. Winter condensation in moist climatescan be controlled to more tolerable limits. Vent-A-Ridge pro-vides 18 square inches of net free area per lineal foot. It isavailable in 8 and 10 foot lengths. It is barely noticeable when

in place. Itis less noticeable than dormer or gable end vents.

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COSTThe cost of this material in LTL quantities to Phoenix installed.including connectors and end plugs, is approximately 55 perlineal foot. This does not take into consideration any allowancefor credit for ridge shingles.

SUMMARYFrom the picture above it can be seen that the Vent-A-Ridge makesonly a minimum projection beyond the ridge line. On a year -roundbasis it is a superior system to that which we are presently usingbecause (1) it functions in the desired manner regardless of weatheror wind conditions and (2) provides better ventilation throughoutthe attic. Estimates show that its costs are comparable to thoseof the method we ane presently using.

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HOMASOTEEXPANSIONJOINT

Homasote expansion joint called Homex was installed at the jointbetween the front porch floor and the driveway. This materialis made of wood fibers derived from the repulping of No. 1 grade

news stock with waterproofing ingredients added. It is available inthe standard sizes that all other expansion joint materials areavailable in. Homex expansion joint meets federal specification,HH-F-341a and American Association of State Highway OfficialsSpecification M-153-54, Class Ill.

There is no fill inHomex strip: they will not extrude regardless

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of the weather. It is easy to saw and to bend. This material isthe same color as concrete.

COSTThis material is competitive in price with the asphalt expansion

joint material.

SUMMARYThe chief advantages of this expansion joint over the asphalt impreg-

nated type is that its color blends almost perfectly with the concrete

thereby giving a more finished appearance to the work and also be-

cause women's spiked heels cannot penetrate it in extremely hot

weather.

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LANAI ENCLOSURE

The lanai enclosure framing members were made of architecturalaluminum extrusions now in common use for this purpose, andFiberglass screening. This section of the enclosure was set on a30" high, 6" concrete block wall having an 8" wide cap. The 8IIcap was used for appearance sake but it turned out to be a mistakein that it just catches rainwater dripping from the roof. It shouldhave been a 6" cap. The enclosure has a quality door.

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COSTThere are 33 lineal feet of wall area in this enclosure includingthe door.

Complete Enclosure Costs Installed(Including the door) $ 175.00

Masonry Wall Cost 85.00Total $ 260.00

MARKET RESEARCH QUESTION#11Have you had your lanai enclosed with screen?

Yes 180No 315

If your answer was "no", wouldyou have bought one if the aluminumenclosure with wall on display, at a cost of $300.00, had beenavailable?

Yes 134

No 181

SUMMARYThe main purpose for including this particular enclosure inthe Research House was to gain the public's reaction to a unitwhich would be virtually maintenance free, more attractive and,with a wall, easier to keep clean and possibly usable more fre-quentlv during inclement weather. The vote tells the story.

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LANAI ENCLOSURE REMOVABLE PANEL

As a further refinement in the technique of making lanai enclosuresusable even during cold and wet weather, the Screen City Screen

Company made some removable panels which were installed on theenclosure of this house. These panels have extruded aluminumframes over which is stretched a clear plastic sheet called Glas sinhaving a thickness of .020. Specifications on this plastic sheet arenot on hand as yet but we have been informed that it is the samematerial as is used in the rear windows of convertible automobiles.The panels mata Ile d on the Research House lanai were fastened

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by m.eans of a spring loaded pin. This pin fastening arrangementwasn't stout enough. Subsequently, a m.ethod of attaching thepanels by using spring loaded clips bas been worked out to compsatisfaction.

COSTCosts on these removable panels have not been developed yet.

SUMMARYMany people who visited the Research House were quite interestein these removable panels. If they can be manufactured for areasonable cost, it appears they would be very desirable. Theywould make the room usable during rainy and windy weather andwould even perrrrit the room to be heated as long as the tem.peraremained in the upper 40's or higher.

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THE LIKE FRONT ENTRY DOOR

The distinguishing feature of the front entry door in this house isthat the exterior skin, which is made of tempered hardboard, hasa burlap-like texture with a contemporary design milled into it.Otherwise, this door is just like any other hollow core door withtempered hardboard skins on each side.

COSTCost for the operation of making burlap texture on the exterior sktn

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increases the skin cost about 10%over a smooth-surfaced temperedhardboard skin normally used for such application. This should bethe only increase in cost for this door.

MARKET RESEARCH QUESTION #1What is your opinion of the entry door?

Very attractive 313O.K. 91Not Sure 26Don't like it 81

SUMMARYAccording to the research questionnaire, the door was well received.It is available with many different decorative details on it or withcustom designs machined on it. Also, the rough texture permitssatisfactory touch up or patching work to the paint in the event theowner mars the door while moving in. The doors in Sun City havebeen painted with a gun for sometime and have, consequently, afine mirror-like surface. This fine surface contained a built-inproblem for the painter, namely, how do you touch it up when acustomer called to complain that the door was scratched. A brushdoesn't work very well under such circumstances. We have minimizedthe problem somewhat in Sun City by having the key receipt man make

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a particular point of the perfect surfaces on all the doors at thetime the customer takes the house. This Like door, in addition

to solving the above problem, and having a distinct appearance ofits own, would lend itself most particularly to the contemporaryelevations of our designs.

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CORKWOOD FLOOR COVERING

Corkwood is a block flooring 3/8" thick and 9" square, tongue andgroove with a grooved back. It is made from grated wood chips im-pregnated with synthetic resin, formed and cured under heat andpressure. It is said to resist indentation 2 1/2 times as well asoak. It may be installed over wood or concrete. It is set in a mastic.It is available in two colors, light and dark.

COSTEstimated coats submitted to us range from 40f per square footinstalled for the large jobs to 70f per foot for small custom jobs.

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INCANDESCENT LIGHT FIXTURES

The incandescent light fixtures in this house were made by ProgressManufacturing Company. The fixtures over the two dressing tablesand in the breakfast nook were designed and made especially forthis house. The fixtures in the entry way, dining room and hallwaywere changed after the house was closed to Sun City residents toother fixtures which were thought to be more appropriate for ourmarket.

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COSTThe fixtures installed in this house cost slightly less than comparablefixtures being used in our present production houses.

MARKET RESEARCH QUESTION#3Which two (2) light fixtures appeal to you most?Name the rooms in which they are located:(Fluorescent kitchen ceiling fixture)--Kitchen(Dressing table fixtures)--Bedroom

SUMMARYThe light fixtures were generally well received. Interestinglyenough, the fixture which received far and away the most votesand comments (and it wasn It even intended that it sh~d be a con-tender) was the fluorescent kitchen fixture by Skyline which wehave been using for several years.

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INTERIOR WINDOWSURROUNDS

Radco Products, Incorporated, has developed an extruded aluminuminterior window surround. It is self -fastening. The fastening isaccomplished by means of a hooked finger-strap attached to thewindow frame which engages with one of a series of taw-tooth-like serrations running along the back of the extrusion. Theextrusion has a 111wide return over the face of the room wallwhich has a luted decorative detail on the face.

COSTThese surrounds cost approximately 25f per foot.

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SUMMARYThe surrounds were quite attractive in appearance. They do eli-minate the cracking and dust collecting normally found on all wall-board returns in such places. Some field experience would berequired to get the wall framing, particularly on the bottom sideof the window at a correct height with respect to the window frame,to make a firm fit for the surround. A question regarding thisfeature was not included in the market research questionnaire.From a number of remarks made by people visiting the house andothers written under the general comments of the questionnaire,it can be stated that a window sill made of some hard materialwould be appreciated by many ladies who find the textured andpainted surface of the wallboard sill impos sible to clean.

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WARDROBECLOSET SHELVING

Three different types of wardrobe closet shelving were used inthis house. One of these was the conventional wood shelving witha clothes pole which we have been using for years. The secondtype was a 3/16" diameter, plastic-coated wire-rack type manu-factured by Pemco.

The third type is known as X-Panda Shelf and is made by theHome Comfort Products Company. They are adjustable shelvesmade from cold roll steel, bonderized, then coated on both sideswith an alkyd baked-on enamel. The units are complete in each

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carton with installation screws, wall brackets, and other necessaryaccessories. Extra mid-support brackets are available for longspans and for joining two shelves together where required. Theseshelves used in the Experimental House were off-white in colorwith the clothes poles having the nickel finish.

COSTVarious estimates on the standard wood shelving with clothes pole,installed and painted have indicated a fair price would be approximately75~ a foot. The cost of the Pemco shelving would run approximately$1. 06 per foot plus installation. The cost of the Home Comfortshelving was comparable with wood shelving with the added advantageof being an absolute known fact whereas handling and set up costsfor wood shelving is thought to be higher by some people thanthe figures used for these estimates.

MARKET RESEARCHQUESTION#16Which one of the three types of shelving in the closets in thishouse would you prefer?

WoodshelvingPemco shelvingHome Comfort Products shelving

1391662 08

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SUMMARYThe Home Comforts Products shelving was the popular favoritein this category. There were a number of strong feelings expressedagainst wood shelving in the General Comments section of thequestionnaire particularly with respect to the unsightly appearanceof them after they had been in use for a while.

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FURNACE NOISECONTROL

Noise from the gas furnace blower and combustion has long beena source of customer complaint. An attempt was made here tosolve this problem and it was highly successful. Two principalsteps were taken here:1. The combustion air was taken from the attic rather than

through the furnace door. This eliminated the need for agrille in the furnace door. The back side of the furnace

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door was faced with a sheet of 1/2" Celotex;The entire area of the return air chamber under thefurnace floor and including the concrete floor wascovered with I" ( I 1/2# density) blanket of Johns-ManvilleMicro-Bar.

Of these two steps, the first is easily the more important. This

2.

may be tested simply by opening the furnace room door.

COSTThe cost of taking the combustion air from the attic rather thanfrom the house is about a stand-off. The total cost of liningthe return air chamber is approximately $3. 00.

SUMMARYNo attempt was made to measure the reduction of the furnacenoises accomplished in this house. Wehave guesstimatedsimply by listening that the noise was reduced at least 50%andpossibly as much as 70%. This substantial reduction in noiseshould eliminate one source of the customer complaint. Thepleasant thing about this experiment was that it is easy to d~and costs very little money.

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the air include duat, pollen, lint, cooking grease, and tobaccosmoke; Having this device in a house would tend to keep upholstery,drapes, carpet, and walls cleaner longer. Sinee tests show thatthis device removes 990/0of air-born pollen from the air circulatingthrough it, it could be highly beneficial to people who suffer fromallergies caused by pollens. The device is silent except for anoccasional sharp, snapping noise made when a large particle ofdust or lint is trapped in it. The permanent electronic cell re-quires washing every two to four months. It should be washed inwarm water having dishwasher -type detergent in it. This operationis very simple.

COST1. Operating Costs: It costs about l it z per day for electricity

to operate this machine. It is virtually maintenance free.l. Air Cleaner--Original Cost

On individual installations this device presently costs approxi-mately $400 each installed. The ~oettl Company has, workingat our instigation, through quantitx purchasing potential,designing and making their own case and by simplifying theelectrical hookup, been able to offer us the followiIl$ priQ~;

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A. All houses on a tract $ 175.00 eachB. All housing with refrigeration on

a tract$ 185.00 each

C. Buyer's Option $ 200.00 each

MARKET RESEARCH QUESTION#17Are you interested in a filter which can remove 70%of the particlesfrom the air?

Yes 349No 124

If you answered "yes", are you interested sufficiently topay $250.00 for it?

Yes 175No 166

SUMMARYThe market research questionnaires reflect a strong interestby the residents of Sun City in this device. In fact, it was thesecond most desired product displayed in the house as recordedon the questionnaire by the visitors. The interest aroused bythe filter suggests it could be a powerful sales feature.

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AUTOMATIC SLIDING GLASS DOOR CLOSERThis door closer, called Air-Flo, is manufactured by the U. S.Products Company in Phoenix, Arizona. The device consists ofthree principal parts, a stainless steel aircraft cable, air valve,and piston. These parts are encased in an aluminum extrusion,the 1. D. of which is 1. 125" in diameter. This assembly is attachedto the center style on the fixed glass section with the cable attachedto the leading edge on the movable section of the door. The unithas been operated over 100,000 times in test without failure~ Itis simple enough to be installed on a do-it-yourself basis.

COSTThe prices quoted to us by the manufacturer for this unit rangefrom $15 r.ach in small quantities up to a 15%discount on quantitiesof 1,000 or more. Large quantity buying may be received on aninstallment basis. The maximum installation time has been estimatedto be 20 minutes; a minimum time would be 10 minutes.

MARKET RESEARCH QUESTION #10Would you pay $20.00 for this door closer?

Yes 222No 281

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SUMMARYThis product would be most useful in housing located in warm climatesand where there were children living in them particularly where thedoor was located in a place to invite heavy traffic. Since the unitmay be installed after the house is built and even on a do-it-yourselfbasis, and since there are no children living permanently in SunCity, it is doubtful that this item could be considered importantenough to justify the expense as a standard item.

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BUILT-IN IRONING BOARD

A built-in ironing board made by Iron-A- Waywas installed inthe utility room specifically to determine its desirability forour market. This unit was recessed into the wall between twostuds. The case was made of wood and had a door. The exposed

door and sides of the case were painted the wall color resultin~

inch adjustment up or down, was three feet long. There isin a neat, unobtrusive arrangement. The board, which had a 4-

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storage space for an iron inside the case.

COSTThis particular unit was quoted to us in the $16-18 range inquantities of 50 or more.

MARKET RESEARCH QUESTION #9Which type of ironing board do you prefer?

Portable 290Built-in 224

SUMMARYAs reflected by the question above the majority prefers the portableironing board. One comment which appeared occasionally in thegeneral comment section of the questionnaire was that the boazdwas too short. Longer built-in ironing boards are available onthe market; however, the desirability of including such a boardin our product does not appear to be justified at this time according toour market research questionnaire.

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FORMICA CLAD KITCHEN CABINETS

The use of high pressure laminates for covering the exterior ofkitchen cabinets has been growing in other parts of the country.Buying good kitchen cabinets which comply consistently with ourspecifications, particularly with respect to workmanship and!'lAishis always a problem. For these reasons, it was decidedto use cabinets clad with a high pressure laminate. The finishused was Formica's No. 601, White Tidewood. The interior ofthe cabinets was finished with a grayish-white coat of Zolatone.

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COSTQuotations submitted to us were competitive with the pre -finished

ash cabinets we are presently using.WLARKETRESEARCH QUESTION#4Do you find these cabinets as acceptable as hardwood cabinets?

YesNo

359136

SUMMARYThe finish on these cabinets was very favorably received accordingto our market research questionnaire. Also, there were a numberof written comments approving this type of finish because of itspermanency and ease of cleaning. The interior of these cabinetsleft something to be desired because of the finish coating; however,this could be easily corrected. Some of the doors, which weremade of chipboard, have warped since the cabinets were installedinNovember, a common problem with doors having a high-p~eesurelaminate applied on one surface.

We are at present investigating another plastic material whichis said to have all the favorable properties of the high pressurelaminated plastics but without the built-in stresses. This featureis said to eliminate the warping problem associated with high

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pressure laminates. A separate report on this material shouldbe forthcoming shortly.

The market research questionnaire contained some unfavorablecomments about the well-known problems with hardwood cabinetsfinished with stains and lacquers, namely, the unsightly scratcheswhich occur at the door pulls, the problems of cleaning them,and refinishing them. It has been clearly established that thereis a substantial degree of acceptability to our market for a satis-factory cabinet having a plastic finish.

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LAMINATED PLASTIC KITCHEN COUNTER TOPSThe kitchen counter top was made of Formica, an old and well known

product that needs no comment here.COSTLaminated plastic kitchen counter tops are competitive withthe ceramic tile product we are presently using.

MARKET RESEARCH QUESTION #5Have you ever had a kitchen with a formica counter top?

YesNo

359156

If your answer to the above question was "yes ", which do you prefer:Formica 301Ceramic Tile 112

SUMMARYIn this survey, the plastic kitchen counter top received an over-whelming endorsement.

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STAINLESS STEEL KITCHEN SINK

The kitchen sink was a seamless, double compartment Elkaysink, Model 43322, drawn of No. 20 gauge non-nickel bearing,type 430, stainless steel. All exposed surfaces have a No. 4satin grind finish. The interior corners of the compartmentshave a minimum 3" radii. A sound dampening material is appliedto the underside of the sink. The mounting rim is integral with thesink (separate mounting frame not required).

COSTThis competitively-priced stainless steel sink would cost us

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surfaces tend to water mark, a characteristic some people findobjectionable. Actually, all sinks should be cleaned after each

use: grease and food cling readily to porcelain. Porcelainmarks and stains easily. While water marks show up moreprominently on the stainless steel, other type.. of marks anddeposits show up more readily on porcelain. The "unsightly"argument between the two is probably a stand-off ..

While the porcelain sink is still acceptable to our market, the factis that the stainless steel people are selling the desirability ofhaving their product to the market with growing success.

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KITCHEN SINK MIXING VALVEThe single handle, single spout mixing valve used at the

kitchen sink was a Delta Model 450 DX. It is a well established,well known product said to have the largest number of installationsin the market of any similar product according to its manufacturer.This unit was of particular interest in this installation since itwas accompanied by a dishwashing attachment and two dispensersfor hand lotion and liquid soap. The containers holding theseliquids are filled simply by lifting up the pump to open the con-tainer throat. The dishwashing attachment has its own reservoirfor liquid soap. =The mixing valve is fairly simple. It has a sphere with twoports and a mixing chamber which control the temperature andvolume as it is rotated back and forth. The only parts in thisvalve said to be subject to wear are two spring -loaded neoprenegaskets.

COSTThe Delta faucet Model 450 DXwith the two dispensers anddishwashing attachment would cost us approximately $16 morethan we are paying for the straight mixing valve presently beingused in our houses.

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MARKET RESEARCH QUESTION #8Doyou consider the dispensers and dishwashing features tobe desirable?

YesNo

307192

If you answered "yes". would you be willing to pay $15.00extra for them?

YesNo

21971

SUMMARYThis mixing valve is attractive in appearance. It is virtually"grabproof". The majority of the ladies liked the attachmentson this valve and a substantial number were willing to payextra for them as indicated by the survey. Whether the dish-washing attachment would cut into our dishwasher sales is notknown. Also, whether the dispensers continue to be used afterthe newness has worn off is also an unknown. The wiser courseat this time might be to continue using a mixing valve withoutgadgets described here. After all, the mixing valve is a fairlyremarkable device in itself and its characteristics are wellknown.

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FOOD WARMER APPLIANCE

-=-~p, ~ ~ - = - - = = , c !, ' :~ ~ / '~1 * - , ; ; : - - ~: ; ; i ; ; ; : _ < - - ='-=

The Salton Hot Tray Model BT-152A food warmer was installedin the island section of the kitchen counter top. The purposeof this appliance is to keep food warm with little or no furthercooking over an extended serving period. The heat is said totransfer inthis electric appliance by radiation rather than byconductance; hence. it is almost burnproof to hands. The appliancehas a switch which can be wall mounted that controls the degree

corner for coffee. The maximum amount of heat generated byof heat as well as the on=off position. It has a hot spot in one

this appliance is 2000F. It uses 115volts a. c..

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FIBERGLASS TUB WITH SPLASH AND SHOWER STALL

_ - _

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Bathing fixtures made of fiberglass. manufactured by the Universa1-Rundle Company. were installed in the baths. These bathing fixtureshave been improved substantially during the last year and a halfowing to improved unit design. production techniques. qualitycontrol procedur es and improved gel -coat materials. (See HS-2,January 6. 1965). These fixtures were white with gold fleck. Thesame fixtures are available in the standard Universal-Rundle fix-

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ture color line at approximately a 5%increase inprice. The wallthickness of these units is approximately 1/8" except the bottomsof the tub and shower which are approximately 3/8". All thesesurfaces are reinforced by glass-resin ribs having about a 1"radius. The gel-coat on the bottom of the tub and shower is appliedto a thickness of about 20 mils whereas the thickness on walls maybe a minimum of 10mils. The surface is not cold to the touchduring cold weather as porcelain is. The gel-coat surface is alsosaid to be 3 1/2 times less slippery than a porcelain surface. TheUniversal-Rundle people state that experienced mechanics can in-stall one unit in 10minutes provided they do not encounter anyabnormal problems.

COSTDirect costs of the fiberglass fixtures installed is comparable tothat of cast iron tubs having a 12course tile splash and with ceramictile shower stalls having 18courses of tile. One extremely importantconsideration here is that a two-bath house normally has threeworking days scheduled for the tile operations while the fiberglassfixtures may be installed inone hour.

MARKET RESEARCH QUESTION #15Wouldyou consider this shower stall to be equivalent to the one

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you have now?YesNo

238156

SUMMARYQuestion 18 in the market research questionnaire asked theviewers to select the one product of all shown in the house thatthey would most like to own. The fiberglass bath fixtures wasthe winner, closely followed by the Formica counter top and theair cleaner. This reaction to the fiberglass bathing fixture wascertainly based on visual appeal since almost nQneof the viewershad any prior exposure to such facilities. The simple, clean lines,the sparkling appearance of the surface and the absence of jointsare the points which impressed them. In view of the public'sacceptance to this product, the substantial improvement in theproduct itself over the past three years and particularly in viewof the necessity for shorter construction schedules and thenecessity of movinp toward pre-fabrication, this product canno longer be ignored.

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FLEXIELE SHOWERHEADA flexible showerhead called Unica was installed in the maate rbedroom bath. This head may pivot 1800on its mounting bracket,which bracket may also be raised or lowered as much as 24". Thebar on which the mounting bracket for the head slides may also beused as a grab bar. The head may be removed from the bracketand held in the hand for showering or shampooing, if desired. Thisarrangement is made possible by the use of a five foot flexiblehose made of a chromed brass cable having a neoprene liner. Allthe metal parts in this assembly are made of brass. The watersupply for the flexible shower hose may come through the wallas it does for a conventional showerhead, or lower ifdesired, orthe supply rna,. come from a special tub spout which has an auto-matic diverter and adapter which fits the coupling on the end ofthe flexible hose. This shower as sembly is foreign made.

COSTThis shower assembly was quoted to us at $18.00 in quantities of1 to 50. The adapter spout would cost $6.00.

MARKET RESEARCHQUESTION#13Would you prefer this UNICAshower arrangement to the oneyou presently have?

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Yes 239240o

SUMMARY50%of the viewers voted affirmatively to Question 13. Sincefew, if any, of these people had seen this unit before, thisvote probably should be interpreted as being somewhat strongerthan the actual count suggests. This flexible showerhead wouldprobably be most useful for children, shampooing children'sheads, and for the infirmed. Because of the obvious advantagethis unit has for the infirmed or physically restricted, it mightbe wise to offer this unit on an alternate basis which would belittle trouble since either the shower supply or spout-diverterarrangement could be used.

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NoYes

57

381

SUMMARYThe overwhelming vote for this fitting at an extra cost as reflectedin Question 14 suggests that this item would be a very good salesfe atu r e,

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PREPRIMED MILL WORKAll the interior mill work except the kitchen and family room cabinetswas primed at the mill. The purpose of this experiment was toweigh lts advantages and disadvantages. The,p;-ime coat wassprayed on and artifically dried.

COSTThe estimate submitted for this work was $84.00. This figure didnot include any work whatever on the kitchen cabinets or familyroom cabinets. It should be noted that this was a first estimateand is undoubtedly high.

SUMMARYThe painting contractor stated that it did not eliminate the necessityfor him to reprime this material because of the scob marks inflictedon the material during shipping and because the color and thicknes swere such that it precluded the possibility of a finish coat to coverthe surface satisfactorily. These problems could be corrected.There is no real reason why a satisfactory prime coat could notbe applied at the mill. The question is not one of feasibilityregarding this operation but rather its desirability at this time.More study needs to be given to the matter, particularly whenaction is taken to shorten production schedules.

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VINYL WALL COVERING

This vinyl wall covering made by Colamco is distinctive for itsdeep relief in the pattern. The exposed vinyl has a 3/8" thickurethane blanket backing which is covered by muslin. The patternsare almost unlimited. They are made by the use of ribbon dyes andheat. The material is made in 4'-0" x 8'-0" sheets. The colorsand textures of the vinyls offered are also almost unlimited. Thematerial is hung on the wall by the use of a synthetic adhesiveused for hanging wall paper.

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COSTThis material in quantities of 25 to 100 panels would cost approxi-mately 45 per square foot. Smaller quantities would cost some-what more. Costs for hanging this material would be comparable tothose for hanging wall paper.

SUMMARYMany people found this wall treatment to be quite attractive andeven exciting. It would be particularly effective in many commercialtreatments although its uses for decorative purposes are almostunlimited. The material also has surprisingly good sound deadeningproperties.

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SUMMARYA number of remarkable and even surprising things came outof the experience of designing and building the Research House,most particularly some of the information revealed by the MarketResearch Questionnaire completed by residents of Sun City. Cer-tainly one rewarding thing about this experience was the enthusi-astic interest in the house shown by the residents of Sun City.As a result of a small article in the local newspaper and word ofmouth on the project, some 4, 000 people visited the house duringthe two weeks it was open. These people completed over 1,700Maxket Research Questionnaires, a copy of which is includedin this report. Some of these people spent as much as two andthree hours studying the house and its details while completingthe questionnaire.

Many of these people expressed their admiration for the effortthe Webb Company was making in trying to build a better house,a more attractive house and one which took their special needsinto consideration more extensively.

Perhaps the most startling fact produced by the lViarket ResearchQuestionnaire was thi s market's attitude toward plastic -typeproducts. Question 18, which asked the viewers to select the one

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product of all shown in the hous e which they would most like toown. Of some 25 products and features shown in the house, thefiberglass tub with splash, the fiberglass shower, and the formicacounter top received the most votes. This would suggest that notonly is there no onus attached to plastic products but rather theyare acceptable to the public without re sezvatton,

The electronic air cleaner was another product that created wideinterest and for which many expressed a desire to own. Inviewof its obvious sales appeal aspect and in the reasonable pricingfor it offered by Goettl, this is a product which certainly shouldreceive careful consideration when any new models for retirementcommunities are designed.

The sound reduction experiment on the furnace, which was extremelysuccessful, is another idea which should be given careful considera-tion on any new models. The amount of the sound reduction couldnot be fully demonstrated owing to the fact that the house was un-furnished, usually filled with large numbers of people, and alsobecause it wasn't operating very much. The real improvement

here will be most evident in a house being lived in.Another fact revealed by this experiment, and one which will comeas a surprise to many people is that, to Sun City residents at least,

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the concrete block is not sacred. A question regarding the exteriorwall treatment was not included in the Market Research Question-naire because it was thought that professional construction peoplewere best qualified to evaluate its merits; nevertheless, accordingto the hostess who manned the Research House there was generalinterest in and frequent questions about the wall from the visitors.She said the remarks concerning it were overwhelmingly favorableand often accompanied by unflattering remarks concerning concrete

block, most particularly when exposed on interior walls.

The people in Sun City are certainly quality conscious especiallywhere practical considerations are involved. Question 14 askedabout their willingness to pay $10 extra in order to have a lavatoryfaucet carrying a life-time guaranty against leaking. The vote

was an overwhelming 'yes'.The question now arises, IWhat do we do next?' Inthe immediatefuture, it appears that the use of the exterior wall treatment andthe fiberglass bathing fixtures should be used in some limitedprogram in order to gain more experience witp them, to learn

more about them and to in~0A.ge their expoaut"18.o. OUt' ~r~

Most of the oehe r produ.cts and featqres used .in this house should-73-

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be carefully compared with comparable products pre sently beingused during the planning of any new models.

The designing and building of this house was a highly rewardingand informative experience for me and I am confident that itwill produce far reaching returns for the Company in the future.

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EXPERIMENTAL HOUSE QUESTIONNAIRESUN CITY, ARIZONA

1. What is your opinion of the entry door?Very attractiveO. K.Not sureDontt like it

313912681

2. Ifwood flooring were available (at additional cost), wouldyou (a) prefer it to carpet in some rooms?

/No 342Yes 181

(b) Prefer it to tile in some rooms?No 211Yes 193

3. Which two (2) light fixtures appeal to you most?Name the rooms in which they are located:(Fluorescent kitchen ceiling fixture)--Kitchen (Dressing tablefixture) - -Bedroom.

4. Do you find these cabinets as acceptable as hardwood cabinets?Yes 359No 136

5. Have you ever had a kitchen with a formica counter top?Yes 359No 156

If your answer to the above question was "yes", which doyou prefer:

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FormicaCeramic Tile

301112

\6. Would having this food warmer appliance be worth $30.00to you?

Yes 268No 237

7. Which type of sink would you prefer?1. Porcelain 2852. Stainless Steel 231 .If you prefer stainless steel (Number 2 above), would yoube willing to pay $15.00 extra to have it?

Yes 156No 69

8. Do you consider the dispensers and dishwashing features tobe desirable?

Yes 307No 192

If.you answered "yes", would you be willing to pay $15.00extra for them?

Yes 219No 71

9. Which type of ironing board do you prefer?PortableBuilt-in

290224

10. Would you pay $20.00 for this door closer?Yes 222No 281

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11. Have you had your lanai enclosed with screen?Yes 180No 315

If your answer was "no", would you have bought one if thealuminum enclosure with wall on display, at a cost of $300.00,had been available?

Yes 134No 181

12. Which would you prefer?Tub with shower in the master bedroomTub with shower in the hall bath

273193

13. Would you prefer this UNICA shower arrangement to the oneyou presently have?

Yes 239No 240

14. Would you be willing to pay $10.00 extra in order to have awash basin valve carrying a lifetime guaranty againstleaking?

No 57Yes 381

15. Would you consider this shower stall to be equivalent to theone you have now?

Yes 238No 156

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16. Which one of the three types of shelving in the closets inthis house would you prefer?

Wood shelving 139Pemco shelving 166Home Comfort Products shelving 208

17 . Are you interested in a filter which can remove 700/'0 ofthe particles from the air?

Yes 349No 124

If you answered "yes ", are you interested sufficiently topay $250.00 for it?

Yes 17 5No 166

18. Of all the products displayed in this house, which one wouldyou like to own most?1. Fiberglass all in one 582. Formica Counter Tops 493. Air Filter 464. Hot Tray 19

19. General Comments - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Name - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -Address - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

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COMPANYMr. Faber S. DewarTextured Coatings of America, Inc.3025 Exposition PlaceLos Angeles 18. CaliforniaMr. Dean Chris sWeyerhaeuser Company10612 Paramount BoulevardDowney, CaliforniaMasonite Corporation29 North Wacker DriveChicago 6. IllinoisMr. Clayton RobertsHome Comfort Products CompanyP. O. Box 68Princeville, IllinoisHomasote CompanyTrenton 3, New JerseyMr. B. P. DukeScreen City2938 North 30th AvenuePhoenix, Arizona 85017Mr. Saul ZukermanForest Fiber Products CompanyP. O. Box 68Forest Grove, OregonShannon's Floorcovering1844 East Indian School RoadPhoenix, ArizonaMr. Al DamonProgress Manufacturing Company5432 West 102 StreetLos Angeles, California

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CONTRIBUTIONTex-Cote

Tempered Hardboard

Ruf-x -Ninety

X-Panda ShelfVent-A-Ridge VentilationSystem

Homex- -Homasote ExpansionJointEnclosed LanaiPlastic Remov~p~~Panels

Like Entry Door

Corkwood FJoqr Covering

Incandescent LightFixtures


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Mr. Jerry GallantGallant-Friedman and Associates525 West 7th StreetSuite 1007Los Angeles 4, California

Salton Hot Tray

Alsons Products Corporation90 West Fayette StreetHillsdale, Michigan

UNICAFlexible Showerhead

Mr. Robert V. WelshUniver sal-Rundle CorporationP. O. Box 300Redlands, Califorral.,

Lavatory CentersetVitreous China Oval LavatoryWater Closet

Mr. John MerrickUniversal-Rundle Corporation1000 E. Apache BoulevardTempe, Arizona

Fiberglass Tub with IntegralSplashFiberglass Shower Stall

Mr. G. Teryl KochColamco Inc.821 West Santa Anita StreetSan Gabriel, California

Vinyl Wall Coverings

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Radco Products, Inc.3121 Skyway DriveSanta Maria, California

Mr. Kenneth R. WarrenVice PresidentPemco Wheel Company1872 Ravine RoadKalamazoo, MichiganGoettl Brothers MetalProducts Inc.2005 East Indian School RoadPhoenix 16, Arizona

Mr. Lawrence D. NelsonPresidentU. S. Products Company1423 South 28th StreetPhoenix, ArizonaMr. Norman Mayer5045 North 12th StreetPhoenix, ArizonaVayland Woodcraft, Inc.558 West 4th AvenueMesa, ArizonaMr. Al UlibarriUlibarri Sales Company4626 East Lafayette BoulevardPhoenix, ArizonaMr. L. K. GwinnDelta Faucet Corporation

Aluminum Interior WindowSurround

Pemco Rod-Raks

Electronic Air Cleaner

Air-Flo AutomaticAluminum SlidingGlass Door Closer

Portable Ironing Board

Formica CabinetsFormica Kitchen Counter Top

Elkay StainJess Steel Sink

Delta Faucet Soap. andHand Lotion Dispel\~rs

sun city, az - 1964 - "research house"

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