Modular magic in Montford: this pre-lab home goes green.

Designer: N/A: Home is modified from a standard modular floorplan, with a site-built upstairs master suite and finished basement

Builder: Innova Homes, LCC. (David Bennert, GC)

Price Tag: Under contract for $374,000

Square Feet: 2,400

Construction Type: Modular-hybrid. Modular main floor, site built upstairs and full, finished Superior Walls System, basement.

"We took on this project as an experiment," asserts general contractor David Bennert of this Montford modular green-build home. A committed Energy Star certified builder, David's company Innova Homes undertook the HealthyBuilt Home certification for the Westover Alley project to find out what level of planning, documentation, and design modifications would be necessary to achieve this more comprehensive green certification. (For more information on HealthyBuilt homes, see page 29.) David and Innova found that working within the modular format presented many advantages to green building: reduction of waste and scrap materials, indoor climate-controlled construction and materials storage, and energy efficient measures already employed by the manufacturer. From there, they took advantage of other opportunities on site, from mulching of trees for landscaping materials to installing CRI Green Label carpets to choosing fiber cement siding and recycled content insulation. The only green building element they planned for, but could not implement due to cost considerations, was the driveway surface treatment. They had hoped to use a permeable surface for the parking area, and in the end, the option proved to be too expensive.

The project was challenging due to site conditions and the surrounding area. The slope on the site was steep--approximately fifty percent grade--which required additional engineering for the foundation, and additional fill and site work to make the lot useable. The slope also forced the use of complex erosion control measures, which occasionally required maintenance to ensure they had the capacity to control silt and soil erosion that occurred before the site was stabilized. To accommodate parking on the slope, a retaining wall was constructed for the parking pad, and a walkway was built to connect the porch to the parking area. In addition, the small lot frontage (fifty feet) limited subcontractor access, material staging, and working space. Fortunately, the slope that frustrated the builders had a big payoff. The house enjoys outstanding views from the rear deck and upstairs master suite.

Modular construction has its challenges, and one of them is that the homes are constructed sometimes hundreds of miles away from their eventual destination. The biggest frustration with this particular project was the arrival of the "boxes" (i.e. the modules that make up the house) and the "set"--the crane-assisted transfer of the boxes from the carrier to the foundation (in this case, a basement). With the site's limited space, the home needed to be delivered on the shortest carrier available; unfortunately, this took two attempts, causing delays in the project. To further complicate matters, the space available for the crane and staging of the boxes was so limited that the crane had to set up closer to the foundation than was desired, creating some difficulty in setup and movement of the crane. These challenges, though frustrating, are common to work within the mountains of Western NC, and particularly in urban areas of Asheville.

The builders wanted to overcome the perception of modular homes as being less attractive or desirable than conventional stick frame homes, so special emphasis was placed on the elevation and interior/exterior details of the home to ensure the home integrated well into the community and was seen as a desirable addition to the neighborhood. They used wider window casings, window grill designs, full size front porches with cedar accents, and other details that are typical to local arts and crafts architecture.

Modular construction offers benefits to both the spec builder and the custom builder. Almost any design can be adapted into a modular format, allowing the builder and homeowner to take advantage of the modular construction process (providing time and cost savings), while still producing a green/HealthyBuilt Home.

Innova Homes was established to build cost-effective, energy efficient homes in Asheville and western North Carolina. They specialize in custom residential projects, green modular construction, and in-fill urban development. For more information, contact David Bennert at 828-252-9998 or visit www.innovahomes.net.

Top Green Points:

Credentials: First modular-based NC HealthyBuilt Home

Efficiency: Energy Star appliances, low-e windows, low-flow showerheads and faucet aerators, compact florescent lighting, high efficiency water heater and 13 SEER heat pump, independent thermostats w/3 zones of control

Low toxicity: Low-VOC paints, CRI Green Label certified carpets with recycled content carpet padding, MERV 11 rated filters on return vents, formaldehyde-free, recycled content insulation

Environmental: Drought-resistant landscaping, fiber cement siding and exterior trim, recycled-content gypsum wallboard.

What are Healthy Built Homes?

This is healthy and affordable home that reduces energy and water usage and has low impact on the environment. Construction materials and processes are designed to reduce pollution and the waste of natural resources. There are many varying ways of certifying a home as Healthy Built.