Montaña de Luz - Honduras Kitchen Remodeling · Kitchen Remodeling Final Project Documentation 1. Preamble a. Team Members and Other Participants Audra Hoffmeister [email protected]

Montaña de Luz - HondurasKitchen Remodeling

Final Project Documentation

Date: 3/9/13-3/17/13

Professor: Dr. John Merrill

Course: ENGR 4692.01S

Kitchen Remodeling Final Project Documentation

Table of ContentsList of Figures and Appendices .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1. Preamble.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4a. Team Members and Other Participants.....................................................................................4b. Location of Project...................................................................................................................5c. Abstract/Executive Summary...................................................................................................5

2. Background Narrative.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53. Stated Scope of Work.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

a. Narrative...................................................................................................................................5b. Information Included................................................................................................................6

i. Problem Statement..........................................................................................................6ii. Customer Information.....................................................................................................6iii. Needs Assessment...........................................................................................................6iv. Scope of Work................................................................................................................6v. Deliverables....................................................................................................................7

vi. Sustainability Statement.................................................................................................7

4. Research and Design.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7a. Participant Roles and Responsibilities.....................................................................7

b. Pre-Trip Project Schedule..............................................................................................8

c. Narrative.............................................................................................................................10

i. Design Process.......................................................................................................10

ii. List of materials and sources............................................................................11

iii. Tools and materials to be brought from Columbus..................................12

iv. Tools and materials to be obtained in Honduras.......................................13

v. Pre-trip Budget and Cost Analysis.................................................................13

5. In-Country Implementation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14a. Implementation/Installation.....................................................................14

i. Window............................................................................................14ii. Cabinets............................................................................................16iii. Ceiling Fans......................................................................................18iv. Speed Control...................................................................................19

b. Issues Encountered...................................................................................20c. Testing Results.........................................................................................20d. List of Materials and Tools given to Customer........................................21e. Actual Schedule.......................................................................................21

6. Post-Trip Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24a. Objectives Achieved/Deliverables...........................................................24b. Final Budget and Cost Analysis...............................................................24c. Conclusions Regarding Project and Technology.....................................25d. Lessons Learned.......................................................................................25e. Recommendations....................................................................................25

7. References.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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8. Acknowledgements.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269. Appendices.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

List of Figures and Appendices

.................................................................................................................................27Appendix B: Kitchen Team Agreement...................................................................28

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1. Preamble

a. Team Members and Other Participants

Audra Hoffmeisterho [email protected] 216-644-8065Civil Engineering Lead Documentation

Andy [email protected] 513-205-6009Engineering UndecidedHead of Research

Will [email protected] 513-490-1355Mechanical EngineeringDesign Lead

Lauren [email protected] 732-232-7698Industrial Systems EngineeringTreasurer

Sarah [email protected] 614-600-7493Civil EngineeringCommunications

James [email protected] Volunteer at MdL

Dr. John [email protected]

Dr. Edgar [email protected] Honduras – Resident Director

Carlos [email protected] Honduras – Assistant Resident Director

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mailto:[email protected]










b. Location of Project

This project will take place at Montaña de Luz in south-central Honduras. Specifically, the remodeling tasks that will be accomplished will take place in the kitchen.

c. Abstract/Executive Summary

Montaña de Luz (MdL) is a non-profit organization with a large facility in south-centralHonduras. Their facility houses children with HIV/AIDS and the staff who care for them. The kitchen used by the staff to prepare all meals is unable to perform at the necessary level. The lower cabinetry is deteriorating and the general ventilation is not keeping the room cool enough. Repairs will be made on the existing exhaust fan, one set of lower cabinets will be replaced, the existing ceiling fan will be replaced, and a new window will be installed.

2. Background Narrative

MdL is a home for children who have been diagnosed with HIV/AIDS. It is a large complex located 105 minutes south of Tegucigalpa, Honduras, consisting of many buildings one of which is a kitchen. The kitchen has served the children, volunteers, and staff at MdL for many years and has worn down over time due to the extreme heat, humidity, and normal wear and tear. Currently, there is residential grade chipboard and Formica cabinet set that has not held up with the conditions of MdL. One of the problems seems to be a lack of ventilation in the kitchen which causes extreme heat. Currently, there is a ceiling fan, an exhaust fan mounted into the wall, and two fume hoods above the stoves. The ceiling fan does not function and the exhaust fan is not turned on due to its noise.

3. Stated Scope of Work

a. Narrative

The kitchen at MdL has two major problems. The first problem is the temperature inside the kitchen during cooking hours. The ventilation is poor and previous attempts by project teams have only been temporary improvements. Previous attempts include the installation of a ceiling fan and an exhaust fan. However, the cooks are still unhappy with the high temperatures they deal with every day. The ceiling fan is broken, the fume hood does not serve as a useful function, and the exhaust fan can only run at full speed and therefore, very loud. One goal of the project is to increase the air flow through the kitchen in order to cool it down. The ceiling fan will be replaced by two new industrial ceiling fans, which will have more power than the previous one and will be very durable and sustainable. A new control device for the exhaust fan will be installed so that it can

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run at other speeds while reducing noise at the same time. Lastly, a window will be installed next to the refrigerator, close to the stove, in order to provide additional natural air flow throughout the room. These will be permanent changes that will not need any maintenance to sustain them.

The second major problem in the kitchen involves the cabinets. The cabinets were installed less than five years ago but are made of wood and are not practical for the environment of MdL. The climate combined with the wear and tear that comes with substantial daily use made this material impractical for the kitchen. Two cabinets located between the vegetable fridge and gas stove are currently dysfunctional because they have deteriorated so much. These two are worse than the other cabinets, but foreshadow the deterioration of the rest. The goal of this task is to replace these two aforementioned cabinets with new concrete ones. These cabinets of concrete blocks will be much more durable and will stand up to the wear and tear of an industrial kitchen. Plans will also be left for the rest of the kitchen which will detail how the cabinets can be made by future volunteer groups. This will allow for consistent cabinetry throughout the kitchen which will be very sustainable and will maximize the practicality and function of the kitchen.

b. Information Included

i. Problem Statement

The problem is lack of ventilation and practicality of the kitchen cabinets. Specifically, some of the wooden cabinets are rotted, and some shelves and doorshave been broken. Along with the cabinets, there is also an issue with the temperature and ventilation within the kitchen. Currently, there is a broken ceiling fan, a dysfunctional exhaust fan and fume hood, and only two windows that do not provide enough air flow. Therefore, the purpose of this project is to improve practicality of the kitchen to meet the demands of serving MdL. A floor plan of the kitchen can be seen in Appendix A.

ii. Customer Information

Montaña de Luz is a non-profit organization set up to serve children with HIV/AIDS in south-central Honduras. They have one large compound in Honduras to house the children they take in and the staff who care for them. The facilities need to be able to meet their goals of helping the children to heal and grow while surrounded by the love of God.

iii. Needs Assessment

After receiving information from MdL about the status of the kitchen and all of its components, the main needs of the kitchen are the cabinets and the ventilation.Some of the lower cabinetry is falling apart and currently not in use due to deterioration. Ventilation in the kitchen is also a great need as the cooks are in this building many hours of the day preparing food. The heat from the sun along with the heat from the appliances is trapped in the building creating an uncomfortable environment.

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iv. Scope of Work

The top priority of this project is to solve the heat issue by addressing some concerns regarding the ventilation in the kitchen. One of the proposed solutions to this problem is to install a new window to the left of the fridge on the east wall. A section of cabinets will be removed in order for the installation. Another objective is to replace the broken ceiling fan in place with two new fans. This cangreatly increase the air flow in the room. In addition, a rheostat will be installed on the exhaust fan to allow for speed control. To evaluate if these projects have reduced the heat in the kitchen, the temperature will be monitored throughout the week. It will be measured before the projects are implemented and at various stages throughout the installation of the fans and window.

The next priority is to replace the bottom kitchen cabinets between the stove and the vegetable fridge (see Appendix A). The new cabinets will be made with the same materials as the new kitchen island in progress for consistency and sustainability, including concrete block, wood for the shelving, and tile for the countertop. For future reference, designs for the rest of the cabinets will be left atMdL.

v. Deliverables

The results of this project are a new kitchen window, updated bottom cabinets, a rheostat for the exhaust fan, and two new ceiling fans. The new window and ceiling fans will mitigate the heat issues in the kitchen to make it a cooler, workable space for MdL. In addition, the updated cabinets will make the kitchen more practical to meet the demands of cooking and serving food for the children, staff, and volunteers.

vi. Sustainability Statement

The design plan for the new bottom kitchen cabinets will tolerate the use and conditions more than the current materials in place. The use of concrete block will withstand heat and humidity better than the existing wood cabinets and will last longer than wood. The purchase of high quality industrial fans will be worth the investment due to their power and durability. Finally, the window materials will endure the climate of Honduras while providing necessary air flow for the kitchen.

4. Research and Design

a. Participant Roles and Responsibili ties

The Kitchen Remodeling Team consists of five members that equally contribute to the success and sustainability of the proposed project. The appointed roles include Lead Documentation, Head of Research, Design Lead, Treasurer, and Communications.

The position of Lead Documentation is responsible for creating and editing all documentsrelevant to the team project. That person must effectively communicate with the team to put discussion and ideas onto paper. Compiling and formatting team documents such as

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proposals are given to that person for final review before it is submitted to the instructor. At every meeting, they take notes of what information was covered at that time and what needs to be discussed at the next meeting.

The Head of Research is responsible for looking up information and coming up with different strategies to execute the project. If the team is unsure on how to go about completing a certain task, this person takes the initiative to find a solution to the problem.This role plays a big role in the engineering design process as far as presenting different viewpoints and ideas to the team. The role of Design Lead creates a physical procedure for the proposed operations. They work with the Head of Research to design a more concrete plan of action. The Design Lead is responsible for creating any necessary sketches or floor plans for tangible evidence of the project. This person takes into consideration what materials and tools are necessary to implement the designs.

The Treasurer is accountable for all finances and transactions relating to the project. Ensuring all materials are accounted for, the treasurer creates a project budget including the quantity and cost of each item. They oversee the overall costs of the team to make sure the proposed budget is reasonable, as well as make sure that the team stays within the budget throughout the project.

The role of Communication is in charge of keeping in contact with the leaders at MdL. Any questions or concerns related to the project are directed to Communications and that person is responsible for creating an email to obtain an answer. With any response they receive, they share that information with the rest of the team. In class, Communications isthe team spokesperson, answering any questions related to the team project.

b. Pre-Trip Project Schedule

Saturday, March 9

Travel to Honduras/Arrive at Tegucigalpa

Pick up supplies (if needed)

Arrive at Montaña de Luz

Determine cable layout and structure of the east wall

Sunday, March 10 Excursion Day

Monday, March 11

First Work Shift

• Take temperature reading

• Begin window construction

- 3 team members

- Take out cabinets on east wall

• Begin cabinet replacement

- 2 team members

- Remove countertops

- Demolish cabinets

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Second Work Shift

• Replace ceiling fan with 2 new fans

- 2 team members

• Continue cabinet replacement

- 3 team members

- Prepare floor for cabinet installation

- Pour concrete base for cabinets

Tuesday, March 12

First Work Shift

• Continue window construction

- 3 team members

- Make hole in wall using concrete saw and tarps

- Begin straightening edges


- 2 team members

- Begin preparing upper portion of cabinets

Second Work Shift


- 2 team members

- Finish detailing edges of wall where window will go


- 3 team members

- Finish upper portion of cabinets

Wednesday, March 13

First Work Shift


- 3 team members

- Install window frame


- 2 team members

- Begin design and cutting of wooden doors

Second Work Shift


- 3 team members

- Install window/ make changes to frame (if necessary)


- Continue designing and cutting doors

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- 2 team members

Thursday, March 14

First Work Shift

• Finish window construction

- 2 team members

- Make any final adjustments


- Finish designing and cutting doors

- 3 team members

Second Work Shift

• Finish cabinet replacement

- 5 team members

- Install cabinet doors

- Place countertops on top of cabinets

Friday, March 15Review all tasks

Leave design plans

Saturday, March 16 Excursion TBD

Sunday, March 17 Return to Columbus

c. Narrative

i. Design Process

Based on the existing dimensions of the wall, a rectangular-shaped design is proposed for the new kitchen window which will be placed in the northeast corner on the east wall to the left of the refrigerator (Figure 1). The section of cabinets inside the yellow box will be removed (not to scale). The primary concerns with this task include the electrical layout of the cables running throughthe wall, if any, the structural stability of the wall, and the dust created from the construction. Tarps will be used to keep some dust from the kitchen. Further contact with MdL is planned in order to obtain more information about the

wiring, structure, and dimensions of the wall and frame.

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Figure : East wall view from inside kitchen

The bottom cabinets that will be replaced are located between the stove and vegetable refrigerator (Figure 2). Supplies for building the new concrete block cabinets will be purchased in advance at a local hardware store near MdL. The following steps are proposed to build the new bottom cabinets:

1) Remove the existing countertops2) Demolish/remove current wooden base3) Pour concrete base4) Insert 2x4 in the center, front for doors close5) Lay concrete blocks6) Cut wood for doors7) Attach the butcher block and tile countertops8) Place wooden doors and handles

∗ The design for the new island will be used to install these cabinets.

Figure : Cabinet between stove and vegetable refrigerator

In order to help mitigate the heat issue in the kitchen, the broken ceiling fan will be replaced with two new fans that will be brought to Honduras. The fans will be evenly spaced on the ceiling on the existing support beam and downrods will be

used to lower them. This is a very easy process due to the simplicity of the task.

ii. List of materials and sources

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The materials required for this project will be purchased from Lowe’s Home Improvement store in Columbus, Ohio and Larach y Cía in Tegucigalpa, Honduras. The list below containsall of the materials that will be used for project construction.

Window:• Window Frame• Window Screen• Cement Grout• Safety Glasses• Work gloves• Dust mask• Sledgehammer • Hammer Drill (with masonry bit) • Cement Screws • Hammer• Saw• Tape Measure• Level• Cut rebar tool

Cabinet:• Gatehouse 3-inch Zinc-Plated Entry Door Hinge• Gatehouse Screen Door Pull• Tile countertops• Cement Blocks• Cement Mix• Mortar• Wood • Rebar• Screwdriver• Trowel• Adjustable Wrench• Pliers

Ceiling Fan:• Harbor Breeze Energy Star Ceiling Fan• 12-inch Ceiling Fan Downrod• Steel City Metal Ceiling Electrical Box• Ideal Plastic Wire Connectors (25 Pack)• Harbor Breeze Brass Pull Chain

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• Harbor Breeze Ceiling Fan Mounting Bracket Kit• Scotch Electrical Tape• 14 AWG 25’ Indoor Non-Metallic Wire• Step ladder• EL-USB-1 Temp. Logger

iii. Tools and materials to be brought from Columbus

The following tools and materials will need to be brought to MdL from Columbus:

• Harbor Breeze Energy Star Ceiling Fan• 12-inch Ceiling Fan Downrod• Steel City Metal Ceiling Electrical Box• Ideal Plastic Wire Connectors (25 Pack)• Harbor Breeze Brass Pull Chain• Harbor Breeze Ceiling Fan Mounting Bracket Kit• Scotch Electrical Tape• 14 AWG 25’ Indoor Non-Metallic Wire

• Gatehouse 3-inch Zinc-Plated Entry Door Hinge• Gatehouse Screen Door Pull• Hammer• Cement Screws• Tape Measure• Level• Screwdriver• Adjustable Wrench• Pliers

iv. Tools and materials to be obtained in Honduras

The following tools and materials will need to be obtained in Honduras:• Window Frame• Window Screen• Wood for Window Frame• Cement Grout for Window• Tile Countertops (same as island countertops)• Cement Blocks• Cement Mix• Mortar• Wood for cabinet doors, bottom frame, and countertop base• Rebar

v. Pre-trip Budget and Cost Analysis

Item UnitCost

Quantity Cost

Ceiling Fan

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Harbor Breeze Energy Star Ceiling Fan 79.96 2 159.9212-inch Ceiling Fan Downrod 7.98 2 15.96

Steel City Metal Ceiling Electrical Box 4.29 2 8.58Ideal Plastic Wire Connectors (25

Pack)2.51 1 2.51

Harbor Breeze Brass Pull Chain 2.48 2 4.96Harbor Breeze Ceiling Fan Mounting

Bracket Kit5.12 2 10.24

Scotch Electrical Tape 1.97 1 1.9714 AWG 25' Indoor Non-Metallic Wire 16.42 1 16.42

Window ConstructionWindow Screen 20.00 1 20.00Window Frame 220.00 1 220.00

Cabinet Gatehouse 3-in Zinc-Plated Entry Door

Hinge3.27 4 13.08

Gatehouse Screen Door Pull 2.97 4 11.88Cement: QUIKRETE Concrete Mix (40

lbs)3.00 1 3.00

Cement Screws: The Hillman Group(1lb)

20.00 1 20.00

Exhaust FanGrainger Dayton Fan Speed Control 44.07 1 44.07

Total: $ 552.59

5. In-Country Implementation

a. Implementation/Installation

i. Window

To begin the installation of the new window, the three upper cabinets to the left of the fridge on the east wall were removed. The cabinet on top of the fridge wasonly connected to the cabinets next to it and not the wall, so that was taken down as well.

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Figure : Kitchen before removal of cabinets forwindow

An outline for the window was then drawn on the wall. The backsplash tile that needed to be removed for the window was then chiseled out. After this, holes were drilled through the six inch brick and concrete walls at each corner of the window.

Figure : Wall after cabinet removal before demolition

A concrete saw was then used to cut a physical outline of the window into the wall. In order to make the hole in the wall, the bottom row of bricks within the outline was chiseled out. Once that was completed, a sledgehammer was used to take out the rest of the brick. The hole was very jagged and uneven at this point, so cement was mixed with sand, water, and Quikrete. Two by fours with rebar clamps holding them in place were used to straighten the edges of the hole at the exact dimensions of the window frame. The mixed concrete was spread in between the two by fours on each side and allowed to dry overnight. A finer mix of concrete was then spread over the dried concrete so it would have a smoother finish. After this, the frame was placed into the hole, and holes were drilled through it and into the concrete. Screws were placed into these holes (2 on each side, 1 on the top and bottom).

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Figure : Window after concrete was spread and frameplaced

After the frame was firmly in place, twelve glass panes were positioned in their proper places within the frame and the screen was screwed into place. Future work by other groups and/or Gilli includes repainting around the window, replacing the broken backsplash tile beneath the window, and installing security bars on the outside of the window to protect the glass from flying soccer balls from the soccer field outside.

Figure : Completed window (inside view)

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Figure : Completed window (outside view)

ii. Cabinets

First, the existing cabinets were taken out. They were very unstable and were mostly removed without tools. When the countertop was detached, it was connected to the tile backsplash and need to be cut. A few tiles came off the wall, but will be re-attached with mortar by Gilli. Then, the area was cleaned to prep for the construction of the concrete cabinets.

Figure : Existing cabinets before removal

Second, the two walls of the cabinet were constructed. The following steps were taken to build the walls:

1. Mix concrete outside and cut 6 pieces of rebar, each 17” 2. Put down a layer of concrete on the base3. Lay one and a third concrete blocks on the concrete4. Level front to back and side to side5. Drill 2” hole in wall above blocks and place rebar6. Repeat steps (2) - (5) until the height needed was reached 7. Wait a day for it to dry8. Mix more concrete outside9. Put concrete on outside of constructed walls for smooth finish

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Figure : Construction of cabinet walls

Third, the concrete countertop was constructed. The following steps were taken to build the counter top:

1. Construct wooden frame2. Cut 6 pieces of rebar, each 27”3. Cut 5 pieces of rebar, each 42”4. Drill 6 holes in wall for rebar5. Lay rebar in a grid and attach with rebar ties6. Mix concrete outside (with gravel)7. Pour concrete in frame and smooth/level8. Wait a day for it to dry

Figure : Construction of concrete countertop

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Lastly, the tile still needs to be put on the countertop. Gilli will do this himself when they secure the right type of tile for the countertops.

Cabinet doors with handles with also be attached in the future when the rest of the cabinets have been replace with concrete for consistency.

Figure : Completed concrete cabinets

iii. Ceiling Fan

First, the existing ceiling fan was removed. When the fan was turned on, it did produce a noticeable airflow, but wobbled unsafely. A screwdriver was used to remove the fan. A saw was used to cut the bolts holding the mounting bracket to the angled-ceiling support beam; they were unable to be removed by a wrench.

Figure : Existing ceiling fan before replacement

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The two ceiling fans were then installed. This process included:1. Equally spacing the mounting brackets 4 feet from either side of the

original fan position (center of the room)2. Replacing the given down rods with the 12-inch extension rods3. Assembling the fan heads with the extension rods4. Installing the fan heads onto the mounting brackets5. Installing the fan blades onto the fan head6. Wiring the fan with the wall-switch wires

∗ NOTE: there was no ground wire

Figure : Ceiling fans after installation

iv. Speed Control Device

The goal for the speed control device was to replace the current on/off switch with a more precise rheostat that was compatible with the existing exhaust fan. First, the switch plate had to be removed with a screwdriver. Wire cutters were used to remove frayed ends and wire connectors were put in place to continue the flow of electricity. A flashlight was also used to aid in the visibility of the wires. When the rheostat was tested, it operated accordingly.

Figure : On-Off switch for exhaust fan before replacement

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The steps taken to execute this task included:1. Shutting off the power2. Removing the switch plate3. Disconnecting the on/off switch4. Trimming the existing wire5. Connecting the rheostat wires with caps6. Placing the cover and dial back onto the electric box

Figure : Exhaust fan speed control device after installation

b. Issues Encountered

There were four distinct issues encountered while working. While assembling the ceiling fan prior to its installation, the screws used to hold the wires in place within the original rod were extremely tight and appeared permanent. After initially deciding to forego the down rods for fear of breaking something, Dr. Casale took a second look and was able to properly remove the screws and add the down rods. A second issue occurred while installing the fans. Nothing had been provided with the fan installation set to attach the fan mount to the support beams on the ceiling. These had to be found elsewhere.

When sketching the outline of the new window it was discovered that a support beam ran horizontally through the wall and through the original placement. The window had to be shifted down to protect the integrity of the support beam. This caused the window placement to overlap with existing backsplash tile that had to be removed and adjacent tiles were knocked off accidentally during demolition of the wall. A similar issue occurred while installing the new cabinetry, the backsplash sitting above the existing cabinet fell off the wall when the existing cabinet was removed. Both back splashes will need repair.

c. Testing Results

During the week, a USB thermometer was left in the kitchen to track and store the temperature in the kitchen as improvements were made with the goal of tangible change in the temperature of the room. Upon returning home and attempting to retrieve the data, it was discovered that the device had had malfunctioned and not begun to collect data until Friday, the last day of work. This gives us the final temperature, but does not give usa way to see if any change was made during the week. No other tests were run.

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d. List of Materials and Tools given to Customer

Many tools were used in completing the kitchen projects. The materials and tools given to the customer include:

1. Steel City Metal Ceiling Electrical Box (2 total)2. Ideal Plastic Wire Connectors (18 total)3. Harbor Breeze Ceiling Fan Mounting Bracket Kit (2 total)4. 14 AWG Indoor Non-Metallic Wire (17 feet)5. Scotch Electrical Tape6. Hammer7. Pliers8. Wrench9. Small Tape Measure10.Duct Tape

e. Actual Schedule

Saturday, March 9Travel to Honduras/Arrive at TegucigalpaArrive at Montaña de Luz

Sunday, March 10Free Day with the kids

Survey East wall and cabinet layout

Monday, March 11

First Work Shift• Begin window construction

- Sarah and Andy- Take out three upper cabinets on east wall- Marked wall with frame dimensions

• Begin cabinet replacement- Lauren and Audra- Took out lower cabinets

• Begin ceiling fan installation- Will and Dr. Casale- Took down existing fan- Assembled pieces of new fan

Second Work Shift• Continue ceiling fan installation

- Will and Dr. Casale- Drilled holes in support beam- Attached two new fans

• Continue cabinet replacement- Audra- Cleaned up area

• Continue window construction- Sarah and Andy- Drilled holes in wall where the corners of the

frame will be - Chiseled backsplash tile

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• Installed exhaust fan speed control device- Lauren- Removed on-off switch- Installed speed control

Tuesday, March 12

First Work Shift• Continue window construction

- All team members and Gilli- Chiseled the bottom row of bricks within the

outline of frame- Began sledgehammering the rest of the wall

where the window must be placed• Continue cabinet replacement

- Lauren, Andy, Audra and Gilli- Mixed cement with Ruth- Placed first row of cinder blocks with cement for

sides of cabinets• Continue fan installation

- Will and Dr. Casale- Wired the ceiling fans

Second Work Shift• Continue window construction

- All team members and Gilli- Finished sledgehammering the wall- Spread concrete on sides of window to straighten

the edges• Continue cabinet replacement

- Lauren and Audra - Finished placing cinder blocks, rebar and

concrete to make sides of the cabinet

Wednesday, March 13

First Work Shift• Continue window construction

- Will, Andy, Sarah and Gilli- Spread concrete on top and bottom of hole to

straighten the edges- Spread fine mortar to outline sides of frame for a

good finish• Continue cabinet replacement

- Lauren and Audra- Spread cement on sides of cinder blocks to

smooth sides of cabinet• Cleaning

- Andy- Cleaned panels on outside of exhaust fan

Second Work ShiftCultural Excursion

First Work Shift

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Thursday, March 14

• Finish window construction- Will, Andy and Sarah- Drilled holes in cement around frame and

screwed frame into place- Installed glass slats and screen- Made last touch ups with cement

• Continue cabinet replacement- Lauren, Audra and Gilli- Spread fine cement on front of cabinet sides- Built a wooden frame for countertop and then

drilled holes in it- Laid the rebar and tied it together- Poured concrete for countertop

Second Work ShiftCultural Excursion

Friday, March 15

First Work Shift• Finish cabinet replacement

- Audra and Gilli- Wooden frame was taken out

• Ceiling Fan- Will and Dr. Casale- Successfully adjusted ceiling fans to prevent

them from wobbling when on full speed• Cleaning

- All team members- Mopped floor- Cleaned up floor/counters around the new

window and new cabinet- Cleaned exhaust fan/fume hoods

Saturday, March 16 Cultural Excursion

Sunday, March 17 Return to Columbus

6. Post-Trip Results

a. Objectives Achieved/Deliverables

To improve the ventilation in the kitchen and address the extreme heat, two new, functioning ceiling fans were installed to replace the existing, non-functioning ceiling fan. A new window was installed on the east wall to allow more natural air to flow through the room. Also, a speed control device was added to an existing exhaust fan on the east wall. This makes the fan more user friendly by enabling to be run on a quieter setting. To improve the functionality of the kitchen one set of wooden cabinetry was replaced with cement cabinetry. This will increase the durability of the cabinet.

b. Final Budget and Cost Analysis24


Item Unit Cost

Quantity Cost

Ceiling FanHarbor Breeze Energy Star Ceiling

Fan$79.96 2 $159.92

12-inch Ceiling Fan Down rod $7.98 2 $15.96Steel City Metal Ceiling Electrical

Box$4.29 2 $8.58

Ideal Plastic Wire Connectors (25Pack)

$2.51 1 $2.51

Harbor Breeze Brass Pull Chain $2.48 2 $4.96Harbor Breeze Ceiling Fan

Mounting Bracket Kit$5.12 2 $10.24

Scotch Electrical Tape $1.97 1 $1.9714 AWG 25' Indoor Non-Metallic

Wire$16.42 1 $16.42

Ceiling Fan Total: $220.56

Window Construction Window Screen $0.00 1 $0.00Window Frame $0.00 1 $0.00

Glass Slats $0.00 12 $0.00Window Total: $0.00

Cabinet Construction

Cabinet Hinges (Purchased inTegucigalpa)

$0.40 4 $1.60

Cement Screws: The HillmanGroup (1lb)

$20.00 1 $20.00

Cabinet Total: $21.60

ToolsHammer $9.97 1 $9.97

Pliers $3.49 1 $3.49Wrench $10.97 1 $10.97

Tape Measure $1.98 1 $1.98Duct Tape $3.98 1 $3.98

Tools Total: $30.39

Exhaust Fan Grainger Dayton Fan Speed

Control$44.07 1 $44.07

Exhaust Fan Total: $44.07

Total: $316.62

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c. Conclusions Regarding Project and Technology

One project completed was the installation of a new window. The window was installed according to plan and there are no major flaws in it. The walls around the window will have to be repainted and some backwash tile will have to be replaced. However, a bit of damage to the wall immediately surrounding the window was expected as a result of the methods that were used to make the hole in the wall. There was not a way to keep straight edges and 90 degree angles in the hole using the tools that were available. The newly installed cabinet, while not completely finished, was also a successful endeavor. The walls and countertop were built up using concrete and the only things left to be done include putting tile on the countertop, replacing the broken backwash tile, and installing cabinet doors. They are waiting to put cabinet doors on until all of the cabinets have beenreplaced so this was not due to time constraints. There was no tile left for the counter or the backsplash, so that will also have to be done at a later date either by the maintenance crew or by another project team. The ceiling fans and exhaust fan speed control device were both installed according to plan and no significant problems encountered or flaws inthe design. The entire project was completed using $316.62 out of the $1000.00 budget ($683.38 under budget). This was just a bonus in the overall successful completion of theprojects.

d. Lessons Learned

Several lessons were learned over the course of our projects. First and foremost, we all became more experienced and skilled in the manual labor department. We experienced the entire cycle of designing, building, and adjusting, which will surely help us in future design projects. Other lessons that were learned had to do with preparation and problem solving. We learned that it is very tough to be prepared for a project when contact with the customer is not easily maintained and it is impossible to visit the project site beforehand. There are lots of details that are necessary for a complete picture of the project which are tough for customers without an engineering background to relay. In terms of the development of problem solving skills, we were forced to make due with sub-par tools and to find unique ways to complete tasks. Along the same lines, we learned that it is a lot easier to bring tools to use for manual labor so that you don’t assume anything and know exactly what you will have at your disposal, which will help greatly with preparation.

e. Recommendations

One recommendation for a future project would be to continue the replacement of cabinets. The concrete based cabinet and countertops are much more sturdy and sustainable for their kitchen and the wooden set is in bad shape.

Another recommendation would be for future teams to bring their own cleaning supplies. The exhaust fan and the fume hoods in the kitchen have collected a lot of grease and dirt and it did not come off with just soap and water.

7. References

How to Build Window Frame in Concrete Wall

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http://www.ehow.com/how_7247653_add-window-concrete-wall.html

USB Thermometer (EL-USB-1 data logger, software on CD, and battery)

http://www.dataq.com/products/hardware/el-usb-data-loggers/el-usb-1-data-

logger.html#ordernow

Speed Control Device

http://www.grainger.com/Grainger/DAYTON-Speed-Control-1DGV1?Pid=search

Lowes

www.lowes.com

8. Acknowledgements

We would like the thank Dr. Merrill, Dr. Casale, Carlos Montoya, James Bettis, Kristen Mallory, Ruth DeYoe, and Erika Castro for all of their help, insight, and information while designing these projects. We would also like to thank the cooks who worked around our projects while we were inthe kitchen and Gilli for all of his knowledge and help with the implementation of our projects.

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http://www.lowes.com/

http://www.grainger.com/Grainger/DAYTON-Speed-Control-1DGV1?Pid=search

http://www.dataq.com/products/hardware/el-usb-data-loggers/el-usb-1-data-logger.html#ordernow

http://www.dataq.com/products/hardware/el-usb-data-loggers/el-usb-1-data-logger.html#ordernow

http://www.ehow.com/how_7247653_add-window-concrete-wall.html


Appendix A

Appendix B28


Kitchen Remodeling Team Agreement

Project Title : Kitchen Remodeling

Life of Contract: January 22, 2013 – April 18, 2013

A. Team Members:Audra Hoffmeister hoffmeister.7 216-644-8065Andy Dunlap dunlap.233 513-205-6009Will Moore moore.2420 513-490-1355Lauren Renaud renaud.13 732-232-7698Sarah Smart smart.85 614-600-7493

B. Leadership Roles• Documentation: Audra

o Type notes during class and at each meetingo Type, format, and organize all project documents

• Communication: Saraho Communicate with contacts at Montaña de Luzo Relay group project update at the end of class

• Presentation Coordinator & Designer: Willo Assemble all information to present all happenings to classo Create detailed drawings & dimensions of projects

• Research: Andyo Conduct research on solutions to any design related issues o Research existing solutions to ventilation and cabinetryo Help track down materials

• Budgeting/Schedules: Laureno Compile a detailed list of overall goals and day-to-day tasks of the groupo Oversee the costs of supplies that are required for work

C. Participation• Encourage open discussion• All members have an equal say• All decisions will be made as a group• Workload will be shared evenly and all members will participate

D. Responsibilit ies• Each member will come to class and attend all scheduled meetings• All members are willing to adjust their personal schedules and meet outside of class• If a member of the group has a conflict, they will notify other group members ahead

of meeting time• All members will complete assigned tasks on time

E. Communications• All project documents will be stored in Dropbox

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• E-mail and cell phones will be used to communicate between group members• Group members should speak up if they have something to say

F. Meeting Guidelines• Each meeting will begin with a recap of previous work • Any new information discovered outside of meeting will be introduced• Discussion of current issues will take place• Group will assign future deadlines and delegate tasks

G. Approaches to Conflict Resolution• Each member will critique ideas not people• Everyone will listen to all ideas with an open mind• In case of a conflict, remain calm and resolve the issue peacefully• Each member of the group is willing to compromise• If an issue arises, a vote will take place or we will ask for an outside opinion

H. Approaches to Problem Solving and Decision Making• We will build on ideas of other group members• All options will be analyzed before making a decision• All ideas will be considered and not immediately thrown out

I. Post-Trip Work Roles• Audra Hoffmeister

o Head of documentation: compiles, formats, and edits all documents; writing paragraphs for final documentation on Installation of Cabinets and Recommendations.

• Andy Dunlapo Head of scheduling: creates final project schedule with detailed events;

writing paragraphs for final documentation on Installation of Window.• Will Moore

o Head of design details and presentation: provides all sketches; writing paragraphs for final documentation on Installation of Ceiling Fans and List of Materials Given to Customer; Creates prezi for final presentation.

• Lauren Renaudo Head of photography and budget: creates final cost analysis and

organize/select photos for documentation; writing paragraphs for final documentation on Installation of Speed Control Device.

• Sarah Smarto Head of communications: continuing emails with MdL; writing paragraphs for

final documentation on Issues Encountered, Testing Results, and Objects Achieved.

*If agreement is broken, there will be consequences for their actions or lack thereof.

Signatures: Date

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Audra Hoffmeister ____________________________________________________________

Lauren Renaud ____________________________________________________________

Will Moore ____________________________________________________________

Andy Dunlap ____________________________________________________________

Sarah Smart ____________________________________________________________

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Documents

Montaña de Luz - Honduras Kitchen Remodeling · Kitchen Remodeling Final Project Documentation 1. Preamble a. Team Members and Other Participants Audra Hoffmeister [email protected]