BULLERBY HOUSE - From Swedisch Tree to German Home | Full Documentary

in the swedish town of extra homes are manufactured from scandinavian trees including for the german market around 500 swedish prefab houses are built in this factory every year however technical problems jeopardize the schedule it's not good when it stops like this this means overtime the shell of the house needs to be set up in germany in just four days there is no room for delays all this will definitely have to be replaced entirely [Music] small hunt in southern sweden trees are felled all year round in the highlands forests every single tree trunk felled here serves as raw material for a typical swedish house these classic wooden houses are growing in popularity in germany too their characteristics the timber frame design cozy verandas and in most cases dark red wooden cladding [Music] we will follow this house from its manufacturer in esquire till its assembly in germany the melon gordon style is in keeping with classic blurbin style it boasts 176 square meters of living space and costs around 350 000 euros including installation our story begins in the pas le molin forest under the supervision of ulf hilden 500 trees are filled here daily for the production of wooden houses we fill around 60 spruce and 40 pine here we need 120 000 cubic meters of wood to keep our production going all year round at least four of these 450 horsepower harvesters are in operation on a daily basis these machines worth around 500 000 euros a piece harvest 300 cubic meters of wood daily in less than a minute a harvester such as this one fills the tree and saws it into pieces ranging from 3 meters 10 to 5 meters 50. the harvester fells up to 500 trees a day clearing a space the size of a hectare in less than eight hours new trees are planted by the house manufacturer after the existing ones are felled this is enshrined in swedish law the felled trees are around 100 years old and stood up to 50 meters tall you can tell how old a tree is and how well it's grown by the number of concentric rings in the wood thin vex this wood is well suited for construction timber and for panels used for building the timber framing for our houses trees that have grown slowly have a particularly good wood density which gives you the stability you need for building houses structural timber is made from these trees and they serve a supporting function later on the tree trunks travel from the forest to the factory in extra 13 kilometers away at least four trucks carrying 40 tons each travel along this route each day these vehicles have an excess length of 24 meters they would be illegal to drive in germany 10 000 cubic meters of tree trunks are stored on the courtyard adjacent to the lumber mill mill owner anders magnusson takes care of quality control from the moment the timber arrives the wood is already sorted by dimension and quality then it goes into the factory where it's made into construction material and panels you want good quality wood without any knots or surprises for this kind of work thankfully before they can proceed further at the sawmill an enormous sorting machine moves the tree trunks into the correct position [Music] the tree trunks are turned around here so that the thicker end faces us and the narrower part faces away from us we sit here and sword and turn the trunks before they are sawn the trees are fed into the debarking unit with the thinner end going first it strips the bark off the tree trunks the machine works very precisely the wood beneath the bark is not damaged it takes less than 10 seconds to completely debark one tree trunk the bark that has been stripped off is sold later as bark mulch a laser measures the diameter of every single trunk before it is sawn this way the computer can calculate the perfect cut a cut that minimizes waste the result is structural timber such as planks boards beams and battens with enough rigidity for building houses at present the construction timber contains between 20 and 30 wood moisture this is still too high to be used in construction so it's put into a giant kiln they lose moisture inside this electrically heated wood drying machine foreman andreas kielberg monitors the drying process regularly [Music] the wood is laid out to dry for about five days at 75 degrees celsius the worker sticks these two metal rods into the wood to measure its moisture content the device measures electrical resistance the smaller the resistance the more water there is in the wood foam we are measuring the moisture content to see whether the wood is dry enough the moisture content should be 18 maximum the device reads 15 which is ideal for building the wood can shrink and break during the drying process if this happens then it's useless as construction timber the wood is put into interim storage to protect it from the rain before it's used all the construction timber is checked thoroughly for cracks one more time i'm checking to see whether the wood is flawless and fresh and that there isn't any curvature in the battens the wood has to be completely flawless otherwise it would no longer be suitable for building the inspected wood gets a final cut using a high performance carpenters plane a milling machine cuts boards with tongue and groove which will later be made into roof panels the machine stops suddenly a piece of wood has jammed delays like these are not well received by the factory's owner but when sensors stop the machines there's nothing he can do precision is a very delicate subject here if a baton is out by a few millimeters or centimeters when it goes into the machine and a sensor picks it up the machine will stop immediately as quickly as possible the employee is able to retrieve the jammed piece of wood with a pry bar the machine is working again next door a fully automated machine is staining panels to be used in the house's cladding the combination of staining and varnishing serves to protect the wood against moisture and lasts up to six months it's at this point that the final coat of paint has to be applied to cladding at the very latest the wood dries for four minutes at about 60 degrees each day the machine stains 24 000 linear meters of panel for the cladding of a typical swedish house the house that we're following to germany will also get this classic exterior timber framing [Music] depending on its size the melon gordon model is made from at least 300 building components and will offer 176 square meters of space this swedish house is designed to be a family home but the owner wants two units containing 12 rooms in total in the factory's office five engineers and seven architects are working hard to make even the most unusual dream home a reality swedish customers for example have completely different tastes to their german counterparts in sweden we tend to sell modern houses our german customers love the typical swedish style red houses with white window frames and that's why these clients often turn to us so they can get a real swedish house and you can choose between so much more than just different types of cladding a prefab house is not actually a completed house that will be suited to all customers every prefab house is tailored to customers individual tastes in sweden too if customers request something that is above and beyond our standard model the house can become considerably more expensive [Music] this customer for example wants an unusually high number of rooms more rooms than the standard model offers this house will cost around 350 000 euros including installation [Music] once i've finalized my drawing it goes on to the design office where the production drawings are created for the factory there are approximately 200 employees in the entire factory almost 500 swedish houses are built per year inside this six thousand square meter large workshop under the supervision of production manager daniel schwager so producer functions in such a way that the operator sees the drawing decides which wood parts they need and then the sensor gets the part that matches the data exactly the machine is pre-configured for cutting man and machine work hand in hand a worker cuts at different angles and lengths with the help of the computer and the plan he will have completed all the construction timber for a whole house over the course of one working day banked ragnarsson and his colleagues fit around 100 windows into all wood frames every day at the window station these will later be incorporated into the components for the exterior wall it's especially important further down the line that the window frame is watertight we achieve this with a rubber seal in germany windows are often installed using foam rather than a rubber seal and this can become porous over time swedish houses are not least because of their window technology particularly watertight and highly energy efficient more and more german customers value this that's why the expert knows straight away which windows to use in a house that's destined for the german market the windows we manufacture for the german market often have glazing bars like these some windows even have more bars than there are on this one it gives them a certain charm the basis for the exterior wall components is built here at this station one worker inserts the wood cased windows into the wooden frames and then insulates the cavities with mineral wool 30 windows are fitted into the walls the melon garden house consists of 25 external components in total 120 linear meters of wall are to be built here over the course of a day but suddenly everything has ground to a halt sales director yagi zari is responsible for the german market he tries to keep abreast of the build's progress but now things have ground to a complete halt what's going on here can you get it working again we're not sure what the cause is will it take long before it's up and running again is there anyone here who can repair it we'll call someone i'll get the phone the computer system has crashed yarizari quickly tries to get someone from it support on the phone it's not good when it grinds to a halt like this we have to meet certain quotas of linear meters each day so this means working overtime [Music] overtime and financial loss i.t services have to provide support over the phone as quickly as possible now that the experts on the phone have advised them what to do what buttons they need to press and so on 20 minutes later and it's all up and running again the guys have got things under control again finally the software problem has been resolved the machine is working again and the wall component makes its way onto the next station the workers treat the inside of the wall with a breathable foil also known as a vapor barrier next come the counter battens which are secured with the help of a nail gun and a second layer of insulation using mineral wool a wall structure is always made in such a way that the interior has a vapor barrier which prevents moisture from getting into the house the exterior however is open so that the structure can breathe while the barrier ensures that moisture does not get in here the inside of the components for the exterior wall are sealed with osb panels the workers then turn the wall over now they have to consider several details that will become important when the components are transported to the construction site this includes thinking about transportation loops depending on how you insert it you can see how many kilos it can bear a timber structure has to be able to breathe otherwise you'll quickly find a buildup of mildew and fungi that's why the wind barrier that the workers are now mounting onto the exterior of the wall components is breathable counterbattens come after the draft shield onto which the timber frame will be fixed further down the line the content is the counter battens are very important because the structure is open and able to breathe but the wooden cladding also needs to be ventilated and that's why we have this air gap behind the timber frame and that's how the exterior wall is built vapor barrier insulation with mineral wool draft shield counter battens and then the exterior frame the air gap between the counter battens and the timber frame is extremely important here this rear ventilation of the cladding prevents long-lasting moisture and hence the buildup of fungi and mildew the workers also go to great lengths to protect the house against other unwanted roommates this here is what we call a mouse grate [Music] and this stops mice from getting into this area which has been rear ventilated and on which the timber frame will be installed next [Music] the workers lay the panels for the typical swedish wooden cladding in the tongue and groove method on the counter battens metal rails hold them in the correct position we measure the upper edge for quality control purposes and correct anything that is offset this is important because this edge for example might need to fit with another edge further down the line and that's why the panel in front of the upper wall has to match the one in front of the lower wall a high-tech nail machine secures the panels the device presses the nails into the wood with compressed air and 500 kilos per nail head this machine worth 500 000 euros has a 0.1 millimeter precision factor within four minutes 500 nails have been sunk into the wall component the workers secure the windows and doors the first exterior wall of the house is ready after four and a half hours here too sales director yahi zari checks to see whether everything is running according to schedule so here we have the interior wall production for our german houses the interior walls are also constructed according to the timber frame construction method 28 interior wall components will be needed for the house [Music] yeah here come on now you can see some of the structure here and then when it's on site the team will install the electrical lines the sewage pipes into the walls and once that's done it will be sealed with either firmacell boards or plasterboard the swedish house gets nine exterior walls and 15 interior walls on the ground floor [Music] before the upper floor can be put in the engineers lace ceiling cassettes on the walls [Music] these cassettes form the ceiling for the ground floor unit and the floor for the upper floor the ceiling has to be able to take 250 kilos of weight per square meter once it's built carpenter zamel johanson and his colleagues use an extremely stable wood this is the station where we build the ceiling cassettes for the swedish houses they're made out of keto beams which comprise several layers you can see here why they're so special these cattle beams are made from plywood boards that have been glued together and that's why they are extremely stable they're very straight and will not warp the insulation is made from mineral wool on the exterior it's 600 millimeters thick for thermal insulation between the floors it's 450 millimeters for soundproofing a chipboard panel then closes off the ceiling cassette there are 11 sealing panels for the house that will soon be delivered to germany dainty gables and dormers make the swedish house feel even more homey roof trusses are needed for this part these are the load bearing parts of the gables and dormers a worker assembles every single truss by hand the alignment is carried out using a modern laser which ensures everything fits exactly to the millimeter [Music] i can see exactly whether the batten is in line with the wooden beams using the the carpenter joins the batons using nail plates the machine compresses the panels with 35 metric tons of pressure 100 of these roof trusses are built here in this way each day of course some of them even get the same classic swedish exterior timber frame that is used for the exterior walls it's not just wooden cladding but wooden houses in general are growing in popularity among germans too however sales director yarizarri often has to combat stereotypes when you hear things like wooden houses burn down quickly wooden houses are dangerous you ask yourself why do we swedes have a long tradition of making wooden houses do we want dangerous houses here in sweden sure it's not like that at all we see our standard structure this wall that we see here now with a fire resistance rating of f30b and this means that it would take at least 30 minutes for the flames on the outside to reach the inside many historical towns in sweden have houses that are several hundred years old they brave the adverse weather conditions and in so doing prove one thing in particular longevity swedish houses are largely made from renewable resources and are very energy efficient this doesn't just go down well with the swedes the demand is also steadily rising among the germans andes lindholm is a third generation manufacturer of swedish houses the owner of this factory which makes prefab housing remembers how it all began the first swedish house to go to germany was in 1961. bernie i think that those who wanted a scandinavian house had links to scandinavia or sweden in the first place maybe they had been here on summer vacation maybe they had immersed themselves in the world of astrid lindgren and saw these beautiful red and white houses that are typical for sweden so then today marks another house's journey from sweden to germany the finished building components for the 500 houses that leave the factory each year are stored on 8 000 square meters [Music] warehouse manager jonas dalton starts loading the house [Music] the trucks must be loaded in the right order it's important everything that is delivered in the first truck is needed on site at the beginning of the build and everything delivered last is what's needed at the end the workers load the building components onto the truck according to a sophisticated system and strict sequence at least 300 building components are sent on this journey for every house being built four trucks travel a distance of 1173 kilometers within four days fully loaded with individual parts for a swedish prefab house the parts travel from exchange in sweden smolland to tekte in germany's westphalian region the preparations for installing the swedish house have been underway here for weeks the base plate including integrated pipes those used for underfloor heating among others is ready to be built on the connections for water sewage and electricity run through all of the low energy base plates layers the plate is doubly insulated and has integrated underfloor heating the plan is to erect the 176 square meter large shell of the house in less than four days it consists of 300 building components the customer has asked for two living units this means the build will take considerably longer to complete the builders still have to keep to their timings the installation team from the german partner firm have decades of experience with swedish houses nevertheless a challenge awaits site manager iphone kombach and his team with this build sole plates are mounted onto the base plate these are secured as you can hear using special dowels once done the first wall can come off the truck and set onto the plate we have a very compact living space here we talked about there being many walls at the preparation stage and this is why it will take a bit longer to finish the pieces of construction timber on the base plate are called indicative thresholds the walls will soon be positioned onto them this saves time the ground is level so we don't need to straighten the walls the further down the line they will also be dowelled and that's why we put this threshold here you can also set the walls without this threshold but that will lead to more work this here means less work the sole plates have been set then the crane with a weight of 33 tons and a lifting force of 55 tons lifts the first exterior wall out of the truck the crane operator has to place the underside of the wall exactly on top of the sole plate like a plug system precision work with a wall component weighing 1000 kilos it looks like it's stuck on something what it's stuck on something it's caught in the middle stop [Music] is it completely level on your end it looks like it does it rest flat on your end is it flat at your end assembly supervisor deadlift book visa bolts the exterior wall temporarily to the sole plate for more stability he also fixes an iron bar to it until the component can be properly attached later on for the time being we're fixing the exterior wall to the sole plate in just a few places later on we'll tighten it further with a distance as required by the structural analysis however that will be done later when we have more time the longest component for the exterior wall is almost eight meters in length lowering the elements into place between the already installed walls requires exact coordination between the crane operator and the construction team the installation team spends a good three hours setting the exterior walls down all exterior wall components are up assembly supervisor book visa and his employees line up the walls at right angles to each other with the help of a beam grip what's the spirit level doing yeah and that one awkward great very good bean grip or you can also call it a beam tensioner panel tensioner a spring cramp exactly we can use them to align these walls exactly we have two walls that move and we have to bring them into line at a right angle and we can't do that with a vise so we use this thing now come the 15 interior wall components for the ground floor for these the workers mount wooden guide rails to the walls they serve a similar function as the sole plates on the floor in technical jargon these are referred to as bars right here because it's sealed on this side and the slot for the bar is on the other side see that means i'll wiggle it a bit to squeeze it in actually i'll do it with a ladder it's better to do this from above we always have to keep an eye out so that wall and bar stay together [Music] there are numbers here 53 52 and we see the same numbers in the wood meaning the walls and that's how the person working on that part knows where everything goes [Music] the assembly supervisor saws holes in the exterior of the walls for pipes and cables that run along the base plate later on these will be sealed with plasterboard after an additional four hours all 15 of the interior wall components have been installed on the ground floor [Music] three steel beams and a steel support are supposed to provide the house with additional stability the beams are 300 kilograms apiece 160 millimeters tall and about 12 meters long why have steel in a wooden house it's a matter of structural integrity there are certain parts where the walls are so far apart that wood is simply not enough steel has a higher resistance to bending and that's why we use steel in this case now after the steel beams the ceiling cassettes follow they form the ceiling for the residential unit on the ground floor and the floor for the living space on the upper floor it has to come down straight from above yes from the decking element what follows next is the mounting of the ceiling components piece by piece that means that the first one is secured in a few places so that it doesn't move then each component is added on and the parts are glued and screwed together once that's done it's all peachy they'll be secured later on and screwed tight from below at various points the construction team now continues to install the 11 ceiling cassettes after 10 hours the end of their shift is still nowhere in sight carpenter robert cole is tasked with storing a wall component for the upper floor behind the house for later use there isn't enough room in front of the house what is challenging is that the crane operator cannot see the small space between the building site and the neighbor's fence from inside the crane up and down arm down and down slowly stop okay you could move another half meter the wood needs to move further okay okay and down the contest from the crane you can't see a thing and we have a walkie-talkie so he's putting his complete trust in us so that means that if we don't explain things to him properly we're going to have a problem this is a question of trust between the crane operator and the guy whose job it is practically to move the components the first day of the build draws to a close site manager iphone kombach takes another look around the site i'm always happy when i come here because i also do the planning of these pipelines myself and can see that everything is where it's supposed to be does this start here that's definitely the case in here and in there too of course this is noteworthy this ventilation shaft it goes up through the wall and a ventilation grill goes on top and here we have a really airtight house we can also prove that it's as airtight as it needs to be and that's why we need controlled ventilation there are customers who say that they could simply open windows for ventilation and my argument is that of course you can open your windows whenever you want this isn't a house with windows that you aren't allowed to open but if you do so you let your energy escape from the house and run up your bills while the controlled ventilation does this for you and keeps costs down the federal government subsidizes energy-efficient houses swedish houses score highly in this regard this means that the owner of this house can receive aid or a low-interest loan from the state-owned development loan corporation [Music] the state of construction after the first day the team has built indicative thresholds external and internal walls have been erected on the ground floor and ceiling cassettes have also been laid the second day of the build has begun it has rained overnight everything is wet what does this mean for the construction team unfortunately it's been raining heavily this is the weakest point if we were to install the cassettes right now in theory some water can run into the insulation underneath we have to keep going we can't just stop when it rains that's just the way it is does it slide that's his light also huh site manager eberhard checks inside to see how much damage the rain has caused full of water everywhere all this will definitely have to be replaced entirely if an area is unaffected by the water we don't need to replace anything but of course we're inspecting every single area the wall will be replaced during the completion of the ground floor interior too bad but we can't help it outside the team is getting the floor transitions ready for the upper floor a breathable vapor barrier is also put to use here to protect against moisture the insulation is also made from mineral [Music] wool the lateral external walls are the only walls that are not built on top of the soleplate but directly on the walls of the ground floor for structural reasons and up and down stop the eight exterior walls for the upper floor have been set within four hours there's a difference between the internal walls on the top and those on the ground floor there are interior walls that have a sole plate in this case we don't have a sole plate we just have a latch on the wall then the wall slips along the latch is fixed and placed on the floor the team installs 13 interior wall components within four and a half hours now the installation team can get to work on the roof [Music] the small roof trusses for the dormers have been assembled in sweden and transported to germany the team cannot assemble the large rafters for the main roof until it's on site isn't too gross they are too big you can't transport these fully assembled [Music] they're too big for that the carpenters fit 30 rafters to the roof trusses using a pry bar in the factory there's a machine that will do this automatically on the construction site this all has to be done by hand yes now we attach the first roof truss to the gable wall in the lower part these will simply be nailed and later we add brackets the team first secures the roof trusses with brackets then they're connected by horizontal purlins in less than four hours the house has a finished roof and so ends the second day of the build the third day of the build has begun assembly supervisor deadlift book visa and his team work on the roof frame this is a sub roof to which the lower tensioning strap will later be added counter battens and roof patterns come at the very end at some point the roof tiles go on this is the sub roof these are those that we nail to the roof frame it's important for us to work fairly quickly because then the house is protected from the rain [Music] the sub-roof is made out of a roof boarding with roofing felt or coated fleece on top counter battens and the roof tiles on top come next the sub-roof construction is designed to drain water and dirt away [Music] the construction team mounts the roof panels onto the trusses these are secured with brackets above and below the truss crossed metal struts stabilize the construction the team has used 141 roof panels for the entire roof even the bay whose roof will serve as a balcony for the living space on the upper floor is sealed with tongue and groove boards [Music] we're bound here by the aircraft we add a sub-roof to the bay on which the balcony will later rest once that's finished we make it watertight a temporary layer of roofing felt follows the roof boards to protect the interior against moisture until the balcony has received proper flooring the third day of the build draws to a close tomorrow the shell of the house has to be finished day four of the build the main roof gets a membrane underlay made from a specially coated polyester fleece this serves to drain away any snow or rain beneath the covering we're now building the underlay on top of counter battens and from time to time we add a running batten so that we can climb up there you're not supposed to step on the fall itself without an attachment because it may tear off or you'll slip off once we reach the top from both sides it's watertight and nothing will happen anymore the team secures the counter battens with nails they use a foam nail seal that is applied to the battens before nailing to prevent any moisture getting through the holes in the membrane after four and a half hours the battens are laid and day four of the build has come to an end it's done the shell has been completed on time as planned in four days the construction team has installed 25 exterior components and 28 interior wall components laid 11 ceiling cassettes and built an entire roof in the following weeks the roof is covered work begins on the interior and the cladding is painted in its classic swedish red color it has been seven months since the customers commissioned the build and now they can move in this swedish house costs around 2 000 euros per square meter including installation so 352 000 euros in total life with that swedish feeling the number of german customers who yearn for this is on the rise the house's traditional wooden cladding needs to be painted every 10 years for this reason they are somewhat higher maintenance than solid houses otherwise they're in no way inferior to them you

Channel: WELT Documentary

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Keywords: full documentary, full documentaries, hd documentary, hd documentaries, free documentary, welt documentary, welt documentaries, full length documentaries, documentary film, top documentaries, reports, factual film, bullerby, bullerby house, scandinavian style, scandinavian house, swedish, swedish house, house bulding, Swedisch Tree, german home, prefabricated house, scandinavian design, scandinavian design house

Id: HQf5PPhII_c

Length: 49min 20sec (2960 seconds)

Published: Sun Dec 13 2020