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Knife Plates 101: What Are They & Why Do We Use Them?

We talk a lot about our prefabrication method and, more specifically, the benefits of utilizing our pre-cut heavy timbers for your installation process. However, something we don’t discuss nearly as often as our pre-engineered heavy timbers are what we use to keep our posts looking beautiful over time and protected from moisture build-up and rot — aka knife plates.

Knife plates are steel connection hardware pieces welded to fit seamlessly with our pre-cut heavy timber posts. When used during construction, knife plates create a buffer between our heavy timbers and the structural footing below so any moisture in the foundational concrete can’t easily seep up into the wood. Knife plates also keep our heavy timbers rooted firmly to your foundation, creating a sturdy framework for your structural shell. Additionally, these hardware pieces help keep the connection between your structural concrete and posts hidden so you can enjoy a cleaner look for your exterior framing components. With all these benefits to consider, it’s easy to see why we implement knife plates as part of our process. That said, it’s important to understand some key differences* between our standard knife plates and those we offer as an available upgrade.

*The information listed below applies to exterior installations only. When used for interior applications, our standard knife plates create a clean, seamless appearance for your heavy timber posts. See below for reference:

Our Knife Plate Options & Their Benefits

At DC Structures, we offer two different choices for knife plates — the first being our standard knife plates. Our standard knife plates are powder-coated steel connection pieces that are installed on elevated concrete pedestals poured above your structural footing. These concrete pedestals provide a solid, weatherproof barrier between the ground and posts, making our standard offering a practical option for clients in areas that experience heavy rain and snow.

Our second option, on the other hand, is our horse-friendly knife plates. These are steel connection hardware pieces that are hot-dipped galvanized and powder-coated for maximum protection. The primary difference between this option and our standard is our horse-friendly knife plates are bolted directly into the structural footing and feature an I-shaped design that raises the bottom of our posts to a pre-determined elevation.

One of the reasons why customers like our horse-friendly knife plates is because this option creates a sleek, polished appearance for your posts once your finished surfaces are complete. Instead of resting on concrete pedestals, your posts will appear as though they’re sitting right above your finished surface, providing a seamless look for your exterior. Another advantage to our horse-friendly knife plates is that your crews can install them before adding your surface material. By situating your posts above the area where your finished surface will be, your framing crews can easily map out and complete your drainage, utility hook-ups, and mechanicals before installing your surface material.

Most importantly, our horse-friendly knife plates are a great investment for horse owners and pet owners alike because they offer optimal safety for your animals. Because of the way our horse-friendly knife plates are designed, our clients can use sand, pavers, or other types of horse-safe material for their finished surface. This gives our customers who prefer softer surfaces for their turnout, paddock, or stall areas more leeway in deciding which surface material is best for their horse barn or riding arena project. Additionally, this option means our clients don’t have to worry about their horses tripping or injuring themselves on pesky concrete pedestals surrounding their posts. With your knife plates completely hidden and chew protection added to exposed corners of your posts, you can keep your heavy timbers in great shape and your horses protected from preventable accidents.

The choice between our standard knife plates and horse-friendly knife plates ultimately comes down to your preference. For instance, if you live in an area subject to inclement weather, you may be inclined to choose our standard knife plates as a precaution. Even so, there are plenty of ways that we can make your selection work for you and achieve your desired appearance and function.

Interested in learning more about our standard and horse-friendly knife plates? Be sure to visit our Options & Upgrades page or give us a call at (888) 975-2057 to speak with one of our representatives.

ADU Kits: Six Designs for Your Backyard Build

If there’s anything we learned in 2021, it’s that demand for housing is exploding across the U.S. From major cities like Chicago and Seattle to rural communities in Colorado and Tennessee, we saw an influx of eager home buyers snap up listings left, right, and center, with many homes flying off the market within hours of being listed and often well over asking price. The red-hot housing market has created somewhat of a catch-22 for home buyers, considering mortgage rates remain historically low while dwindling inventory means stiff competition and fewer options across the board. But the challenges of finding affordable and livable housing aren’t exclusive to home buyers; renters are also feeling the financial and mental strain of the booming U.S. housing market. 

According to Fortune.com, rent prices in the U.S. rose more than 10% in 2021 and will likely continue to climb in 2022. In cities like Dallas, where the population grew by 120,000 residents in the last year or so, renters are having an increasingly difficult time finding affordable rentals throughout the city – and they’re not alone. With thousands of empty-handed home buyers leaving the housing market and millions of Americans continuing to move states, the rental market in 2022 is on track to become even more saturated than the previous year. And while this may seem like bad news for renters, there is a solution that could help alleviate the housing crisis in cities across the U.S. and open new doors of opportunity for current and future homeowners.

The solution we’re referring to is accessory dwelling units, otherwise known as ADUs. Often added to one’s backyard space, an ADU can serve as a detached guest suite, an office, a workshop, or a personalized man or lady cave. In the context of this blog post, an ADU creates a mutually beneficial opportunity for renters and homeowners, considering long-term renters provide homeowners with a stable source of passive income in exchange for a quiet, flexible rental within their budget. Not to mention, an ADU can substantially increase the value of one’s home, making it a lucrative investment that virtually pays for itself and more.  

Whether you’re planning to build a new home or considering adding to your existing home, an ADU is a wise investment that offers numerous benefits for homeowners and renters alike. If you’re in the market for an ADU of your own, take a look below at some of the prefabricated ADU kits we offer that might just be the perfect solution for your property: 

McKenzie Cabin Kit:

With 651 square feet of conditioned living space, our McKenzie Cabin Kit can serve as a detached one-bedroom rental perfect for solos or couples. 

Modern McKenzie Cabin Kit: 

This modern, sloped cabin design offers slightly more square footage than our classic McKenzie Cabin Kit, boasting 721 square feet of flexible living space.

Deschutes Cabin Kit: 

The Deschutes Cabin Kit is a 776 sq. ft. post and beam structure designed with one bedroom and one bathroom. With the help of our designers, you can add a second bedroom to the existing design or customize your floor plan entirely. 

Modern Deschutes Cabin Kit: 

The modern take on our Deschutes Cabin Kit, the Modern Deschutes is a simple one-bedroom cabin design with room for creativity.

Rogue Cabin Kit:

This two-bedroom, two-bathroom cabin kit features a cozy master suite, an open-concept living space with vaulted ceilings, and a charming covered porch. With its classic cabin appearance, the Rogue offers the warmth and comfort of a small home or cottage. 

Modern Rogue Cabin Kit: 

Coming in at 948 square feet, the Modern Rogue Cabin Kit offers ample room for two bedrooms, two bathrooms, and open-concept living. Like our classic Rogue, this cabin design includes a covered porch. 

Need inspiration for your ADU project? Check out our project gallery to see how our clients transformed their kits into the perfect ADUs for their homes! 

If you’re ready to get started on your ADU build, give us a call at (888) 975-2057 or request a quote here.

Supply Chain Issues & Your Project Timeline

In recent months, the global supply chain crisis has become a major cause for concern for those eager to build a new home or structure. With everything from windows and doors to dimensional lumber experiencing long lead times, many homebuyers are finding it difficult to jumpstart their construction with several of their key building components severely backlogged. Though analysts predict supply chain shortages will continue well into 2022, there are numerous ways that clients can expedite their project timelines while saving time and money in the process. If you’re considering investing in a pre-engineered building kit from DC Structures, here’s what you need to know about the materials shortages we’re currently experiencing and how you can move through our process quickly.

Supply Chain Shortages Impacting DC Structures

As with every building kit producer here in the U.S., we’ve had to adjust our pricing to meet the demands of the market and then some. On top of lumber prices hitting all-time highs this year, we’ve also seen lead times for several other building materials increase exponentially over time, with some being six months to a year out from the job site. Of the materials shortages we’re experiencing at DC Structures, the most prominent by far are windows, entry doors, pre-finished siding, and garage doors.

While it may be disappointing or concerning to think of how this can affect your project timeline, there are a few things clients can do to maneuver around long lead times. For example, buying products locally can significantly reduce lead times, as local products are transported over shorter distances than those shipped internationally. At DC Structures, we purchase most of our building materials here in the Pacific Northwest to help minimize delays and ensure better overall quality for our building kits. However, we can also custom quote windows, doors, siding, and more from materials suppliers in your area if you prefer to buy them locally.

Ways to Expedite Your Building Process

Aside from materials shortages, there are many other factors that can significantly extend the time it takes to start building your structure, including delays in permitting, site preparation, and selections. Here’s how you can avoid unnecessary setbacks in the building process by taking a proactive approach to your construction project.

Communicate Design Changes As Soon as Possible

Design changes are an inevitable part of crafting a new home or building. From minor changes like swapping out standard windows for an available upgrade to making major structural modifications to your pre-engineered building model, our clients are bound to tweak a few or more details of their design to better suit their needs. At DC Structures, we view this as a perfectly normal aspect of the design phase and are always happy to help clients tailor their structures according to their tastes. However, where this starts to affect your project timeline is in the communication breakdown, as design changes that are communicated right away help us move you through our process that much faster than those that are submitted days or weeks later.

It is worth noting that clients may need more time to evaluate their design plans, which is okay! It is more important to us that you feel completely confident in your design, as we want to be sure you love the result of your partnership with us. If you need more time to review your model, we simply recommend that you continue to share your thoughts and ideas with our designers so they can help you form a design that aligns with your vision. By keeping us in the loop, we can guarantee the best results for your building and help facilitate an efficient, collaborative design process.

Plan for Permitting

If there is anything that can stop your project dead in its tracks, it is permitting. Obtaining a building permit is a necessary part of constructing a new residential or commercial building, considering nothing can happen on your job site without one. Knowing this, it is important to do your research on local standards for zoning, land use, and construction early in the planning stage, so you have a better understanding of what you will need to submit to your local building office. Typically, this will include schematic design with floor plans and elevations and construction documents with structural calculations. However, depending on your location, you may need additional consultants and engineers to submit stamped drawings of your building plans, which could include civil drawings and mechanical, electrical, and plumbing (MEP) plans. Because these requirements can vary drastically by location, we recommend that clients contact their county building office in advance to discuss their project details and determine the next steps for acquiring a building permit.

Lock Down Your Contractor Early

Collaborating with an experienced contractor who can carefully plan and execute your construction is a must for any client, as is partnering with a designer you can trust to carry out your vision. If you plan to build a new home or structure this coming year, it is best to start your search for the right contractor as soon as possible so you have time to evaluate your options and choose the best person for the job. If you do not already have someone in mind for your project or feel you need help with the process, we offer a nationwide builder network comprised of trusted contractors across the country and can help connect you with the perfect builder for your project.

Learn more about our nationwide builder network by clicking here.

Finalize Your Selections Before Procurement

One of the most enjoyable yet difficult aspects of designing a structure from scratch is selecting the features that will go into your home or building, considering there are hundreds, if not thousands, of options to choose from for your design. While it is completely understandable that clients may need extra time to research their options, it is important to note that any selections made or changed after procurement will undoubtedly extend the time it takes to finish your structure. For this reason, we recommend that clients have their selections squared away before procurement to ensure a smooth construction process. Doing so also allows our team to get ahead of long lead times, as any selections that are severely backlogged can be addressed in advance and potentially swapped out for a similar item.

Prepare Your Site for Delivery

Site preparation is a crucial step in the building process. When done correctly, your project can move quickly and accurately through construction, as your contractor is made aware of any anomalies on your site and can maneuver around these issues more carefully. While the process of site clearing, surveying, soil testing, and site planning are all necessary prior to delivery, it is also important to ensure your site is properly staged and designed to allow for an easy delivery process. For example, our pre-engineered building packages arrive on a forty-eight-foot semi-truck. Because of this, we ask that clients make sure their properties are accessible and allow our semis to easily turn around after drop-off. It is also imperative to ensure your job site is set up in a way that keeps your materials clean and organized. For more information on how you can effectively prepare your site for delivery, watch our DC Best Practices video to learn more about DC Builders’ approach to creating a clean and efficient staging area on your job site.

Design in Winter, Build in Spring

Just as the title suggests, clients that design their structures in winter and start construction in spring are bound to experience fewer delays associated with weather on their job sites, considering snow, hail, and frequent rain can significantly impact the time it takes to get your project off the ground. If you do plan to start construction in spring or summer, we recommend contacting contractors early in the year – even as early as January if possible – to start the process of finalizing your builder. This is because seasonal demand usually increases in the summer months, making it difficult to lock down a contractor or subcontractors during this time. By planning ahead for spring or summer construction, you can determine a schedule and budget that works well for you and your contractor and anticipate a much faster construction process than one that begins in the wintertime.

 

Accessorizing Your Pavilion or Pergola Kit

There are many ways to spruce up your outdoor space, but arguably none as striking as adding a timber frame pavilion or pergola kit to your backyard. With a heavy timber pavilion or pergola kit, you not only have the opportunity to elevate the look of your outdoor space but also the ability to enjoy your backyard in any season. At DC Structures, we partner with America’s best suppliers of outdoor living accessories to provide our clients with everything they need for their pavilion and pergola kits. If you’re looking for an all-inclusive outdoor living space, our designers can incorporate your chosen features into a pavilion or pergola design that’s just right for you.

Learn more about some of the outdoor living accessories we offer through Weber, Necessories, Cal Flame, Timber Pro UV, and many more.

Fireplaces & Fire Pits

Bring the charm of a cozy campfire into your backyard space with an elegant fireplace or fire pit from one of our trusted suppliers. Whether you plan to roast marshmallows with the family or keep extra warm in the winter months, a fireplace or fire pit makes an exciting and practical addition to any pavilion or pergola kit.

BBQ Grill Islands

No summer party is complete without traditional barbecue, whether that be hot dogs, hamburgers, steaks, or the classic corn on the cob. Make your pavilion or pergola kit the perfect barbecuing area with a BBQ grill island or stand-alone grill.

Outdoor Kitchens

Add some utility to your pavilion or pergola kit with a complete outdoor kitchen built into your space. With refrigerated storage for your food and drinks and prep center cabinets for easy kitchen tool access, you can truly make the most of your outdoor entertainment area.

Patio Heaters

Pavilion and pergola kits aren’t just useful for the spring and summer months – they’re meant to be enjoyed year-round! If you’re looking for ways to keep your outdoor space cozy and comfortable in any season, consider investing in patio heaters for your selected kit.

Natural Wood Stain & Finishes

If you have a certain aesthetic in mind for your wood framing elements, we offer a variety of natural wood stain and finish options from Timber Pro UV to help you achieve your vision. From transparent options to heavily pigmented colors that make a bold statement, you can choose from dozens of premium color selections to create your desired appearance.


Ready to get started on your pavilion or pergola project? Request a free quote today or give us a call at (888) 975-2057 for more information.

Part II: The Lumber Surge Explained & What This Means for DC Structures

Like every home builder, DC Structures has had to adjust its pricing to match supply and demand as a result of the lumber surge. However, there are a few unique ways we’re able to keep costs reasonable for clients while adhering to desired timelines and ensuring our clients have only top-quality lumber for their projects.

One of the most important things to note about the lumber surge is that the materials in high demand right now are dimensional lumber and engineered wood products. This includes several lumber products that we use in our pre-engineered building kits, including:

  • OSB Plywood: Otherwise known as oriented strand board, OSB plywood is a conventional sheathing material we often use for our subfloors, roof, and wall sheathing
  • TJI Floor Joists: These are lightweight joists, or structural components used to create a rock-solid floor framing system, made from engineered wood.
  • LVL Joists: Similar to TJI floor joists, laminated veneer lumber is an engineered wood joist used for floor framing. We frequently use LVL joists in our building kits, especially when a building has multiple floors.
  • Architectural Glulams: These are engineered wood products designed with an appearance-grade surface. This material is not as in demand as the others.

While these lumber products are driving up the cost of our pre-engineered building kits, we don’t experience the same problems as other home builders when it comes to supply. This is the case for a few reasons.

For starters, a lot of home builders buy from retail lumber yards, which are currently experiencing major shortages in dimensional lumber and engineered wood products. Because they purchase lumber as needed, this means many builders are facing lengthy delays in the material acquisition process. This leaves their clients in a less than favorable position, with many forced to extend their project timelines past their desired move-in date.

At DC Structures, however, we benefit from buying large quantities from our mill-direct suppliers. Due to the volume we purchase, we can get in-demand lumber products that other home builders simply can’t and with quick turn-around times. We’re also fortunate because we have a huge lumber market here in the Pacific Northwest and we have several ways to acquire premium quality lumber for every project. To put it plainly, we don’t have the shortages we’re seeing in other markets and can continue business as usual when it comes to procuring material.

Another thing that’s unique about us is that we primarily rely on FOHC Select Grade Douglas fir timbers to frame our pre-engineered building kits. Our heavy timbers are considered to be a niche item in most conventional structures, with standard homes utilizing faux or box beams instead. The size of our timbers is also uncommon for light-frame construction. Because the most in-demand wood products right now are dimensional lumber and engineered wood products, this puts us in an extremely favorable position with lumber mills here in the Pacific Northwest and allows us to source the finest heavy timbers at competitive pricing for clients.

Lastly, our prefabrication method makes it possible for our team to save clients time and money during construction, as every piece of framing lumber is prepared ahead of time to facilitate a lightning-fast assembly process. Our prefabrication process also takes far less labor than any conventional build and results in less noise, waste, and dust on your job site.

So while there’s no telling when lumber prices are going back to normal, our team can ensure our clients have the best deals on the market and the best results for their dream home.

If you’re interested in learning more about our commitment to keeping costs down during this time, get in touch with one of our design specialists today!