MASS PRODUCED BUILDING SYSTEM FOR UNSKILLED LABOR
By:
Angelo Petrozzelli, Boston Architectural Center,
Certificate of Architecture, 1966
A THESIS SUBMITTED IN PARTIAL FULFILLMENT
OF THE REQUIREMENT FOR THE
DEGREE OF MASTER OF ARCHITECTURE
AT THE MASSACHUSETTS INSTITUTE OF TECHNOLOGY
June 1972
Department of Architecture, May 12, 1972
esis
Superv 6r
Chairmnan, Depar aent Oominittee On
Grad
e Students
Rotch
JUN 27 1972
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405 Saratoga Street
East Boston, Massachusetts 02128
May 12, 1972
Dean William Porter
School of Architecture and. Planning
Massachusetts Institute of Technology
77 Massachusetts Avenue
Cambridge, Massachusetts
Dear Dean Porter:
In partial fulfillment of the requirements for the degree of
Master in Architecture, I hereby submit this thesis entitled.
"Mass Prod.uced. Build ing System For Unskilled. Labor".
Respectfully yours,
Angelo Petrozzelli
Enclosure
ABST RACT
A Strategy For Developing A Mass Produced Building System For
Unskilled Labor
by Angelo Petrozzelli
Submitted. to the Department of Architecture on May 12, 1972 in
partial fulfillment of the requirements for the Degree of
Master of Architecture.
It should. be noted that this thesis is a continuation of an
.earlier submission by the office of Imre and Anthony Halasz,
Inc. and. various other participants.
This submission was part
of the H.U.D. Operation Breakthrough Program RFP No. H-55-69.
The reason for selecting the development of a mass produced
build.ing system for unskilled. labor is my reaction to presently
available housing systems that by their size and. complexity
create a physical and human strait jacket Ill suited. to user
participation in any stage of its development or existence.
This thesis prepares the ground. work for a building system
sympathetic to this need and applicable in the immediate
future at minimal cost.
It is the hope that this thesis will stimulate a research program to d.evelop a full-scale model to test and. improve the
system.
The illustrations shown in the text deal with housing, but
the system is not limited to this use.
It seems to adapt
well to other building types with similar clearance and span
requirements.
Thesis Supervisor:
John Steffian
Associate Professor of Architecture
iI
ACKNOWLEDGEMENTS
I wish to express my deepest gratitud.e to Professor John
Steff ian and Professor Waclaw Zalewski for their
participation during this
unselfish
study for my graduate work,
and I
wish to include in my thanks the many faculty members and staff
of the Department
of Architecture.
I wish to thank my associates within the staff
of the archi-
tectural office of Imre and Anthony Halasz, Inc. especially
Imre and. Anthony Halasz for giving me the opportunity to complete my work at the institute and for their contributions to
my academic enrichment.
I also wish to thank them for the
personal relationship which has developed
not only during this
experience, but also within the last five years since I have
known them.
My gratitude extends to Mr. Frank Ransome of the Wheeling Steel
Corporation, and Mr. Kenneth Sisson of American Architectural
Iron,
for help in
obtaining the structural members and universal
connection development.
Finally,
family,
my deepest gratitude to the members of my immediate
especially my parents,
for understanding and unfailing
support over the number of years it has taken me to complete my
education.
done.
Without their
support I do not know what I would
have
I also wish to thank my personal friends who have
encouraged me to continue with my studies.
III
TABLE OF CONTENTS
TITLE PAGE
ABSTRACT
11
ACKNOWLEDGEMENTS
111
TABLE OF CONTENTS
iv
PART 1:
PART 2:
PART
3:
GOALS AND DESCRIPTION OF THE SYSTEM
a.
General
b.
Architectural
c.
Structural
d.
Interior Work
e.
Mechanical, Electrical
f.
Foundations
SYSTEM ADAPTABILITY
a.
Housing Types and Scope
b.
Climatic Areas
c.
Geology and. Soils
d.
Site Topography
e.
Site Size
f.
Site Situations
g.
Changes
h.
Regional Application
10
SYSTEMS COMPONENTS
15
(Introduction of system as related. to housing)
iv
PART 4:
PART 5:
MODULAR STUDIES (System Applications)
a.
General Site Matrix
b.
Diagrammatic Layout of Housing Matrix
DIAGRAMMATIC EXAMPLES OF HOUSING TYPES
a.
Row House using a 20'-0" Matrix
b.
Row House using a 32'-0" Matrix
c.
Townhouse
33
39
PART 6:
PHOTOGRAPHS OF MODEL
75
PART 7:
BIBLIOGRAPHY
80
PART 8:
MECHANICAL SYSTEM DIAGRAMS
63
V
GOALS AND DESCRIPTION
OF THE SYSTEM
~
-l1-
A.
BUILDING SYSTEM CONCEPT
1.
GOALS AND DESCRIPTION OF THE SYSTEM
a.
General
The basic rationale underlying the concept of this
proposed building system-is that the system should
not only fulfill
the needs for shelter but also
should. become a source of employment, primarily for
the unskilled of our society.
The essential feature
of this system is simplicity, based on the following
objectives and solutions.
1.
Participation by the unskilled or semi-skilled
members of society,
erect,
who would be able to
and maintain the system with minimal
training and. supervision.
ii.
Minimal capital investment for production and
construction so as to allow immediate application in any volume,
anywhere and throughout
the country.
iii. The use of available commercial products in
order to minimize new building components.
A
few of the system components may be especially
fabricated.,
but the parts will be standard.
It is hoped that these components will be
stocked in local outlets.
-2-
iv.
Shop fabrications should be done with minimum
investment on the part of the supplier.
Fab-
rication of some of the components may be
accomplished on the site at first in order to
keep investment to a minimum.
V.
The components shall be of a size and weight
that can be handled. manually by two people.
This will result in
components.
modest spans and small
Small component size will allow
greater individual freedom for different
assemblies and will allow the system to be
adapted to a wide variety of needs.
vi.
Simple mechanically fastened
joints are
intended for the entire system without using
special equipment and skilled. labor.
vii.
A universal
joint is
proposed. at all
inter-
sections of structural members.
viii. The system will expand or contract
in
every
direction due to the use of the universal
joint.
Change and. growth can occur without
disruption of the finished
spaces already
occupied..
viiii. The system will take advantage of readily
available components from other systems that
are practical and usable.
-3-
x.
High standards
of quality,
low cost,
easy
adaptability to individual preferences,
com-
bined with the consumer's possible involvement in the production and marketing process,
should assure his acceptance and identification with the housing product.
Following this
logic the system consists of a
series of independent
replaceable
infill
structural frames with
panels that constitute all
finished surfaces.
Prefabricated mechanical units
will form an integral part of the system.
b.
Architectural
The architectural
i.
character of the system.
Additivity
One of the chief dangers generated by prefabricated and preassembled. industrial systems
is that they often eliminate flexibility.
This system, both in the relationships of its
components to each other and
themselves, is
based on the principle of
additive flexibility.
ment,
be it
settlement,
in the components
The resulting environ-
an individual house or a complex
can be molded. and. articulated
according to specific need.s and human desires
rather than forced. into an imposing preconceived
industrial
strait
jacket.
11.
Component Parts
The principle of additivity is
maintained by
the relatively small size of the basic floor
and wall panels between the structural frames.
Since the assembly of the components is
designed for the utmost simplicity, the
number of joints does not adversely influence cost.
spans,
However, by virtue of modest
small components,
freedom of different
and. great individual
assemblies the system
can adapt itself to a wide variety of needs.
Old. systems based on large component parts
often offended. our sense of human dignity
by limiting additive modulation.
The selec-
tion of the smallest component parts, readily
available through the regular channels of
the construction industry has its
not only in
cost,
easy handling,
advantages
self-help,
etc., but chiefly in that the small component parts enable the user to contribute to
the form of his environment,
and initiative,
exercise choice
and. thus restore his pride in
his place of living because he can adapt the
system to his specific needs and requirements.
-5-
ii1.
Diversity
Since the system consists of relatively small
components and. a very large degree of additive flexibility,
it
can adapt
itself
to
different housing densities, site conditions,
and. individual needs.
Since the wall panels
are designed for additive flexibility,
can adapt to different
they
climatic conditions,
as well as various zoning and building code
requirements.
The main test of every contemporary system
is
its
growth.
behaviors
in
terms of change and
The proposal allows change and
growth on different levels.
It can most easily expand. in every direction
by virtue of the universal
joint.
It permits the alteration
of the standards
of housing units themselves, even in higher
d.ensities, by exchanging components without
interfering with the rest
of the units.
Since the proposal d.oes not concern itself
with a
building as a product,
but with an
additive process it will change itself through
field experience, demand., research and human
ingenuity.
-6-
The ease of assembly implies the ease of
dismounting.
Change and growth demands
addition as well as removal of parts in
relation to the whole,
c.
without disruption.
Structural
1.
Low-rise Construction
The basic structure
consists of a light
gauge metal frames and infill
form all
finished
panels that
surfaces.
A prefabricated
"universal"
which is
at every intersection be-
placed
joint piece,
tween frame members, allows simple attachment of column and. beam units.
exceeds 150 pound.s in weight.
connections
bolts.
in
No element
All frame
the field are by high tensile
Details are such that while all the
frame parts will be prefabricated in a shop,
all
assembly will be handled. by unskilled
labor,
without any hoisting equipment.
All panels,
for floors,
walls and. partitions,
exterior and
interior
are of standard manufac-
ture and are set into the frames by simple
connections.
devices
is
The use of advanced. fastening
contemplated to assure easy,
and safe assembly.
rapid
Fairly large tolerances
O-7-
are employed to avoid the need for exacting
precision.
designed to withstand
The frame structure is
all
vertical loading and the effects of wind.
or earthquake forces.
ii.
High-rise Construction
The system is
adaptable to any building
height with the provision that it becomes a
subsystem in a megastructure whenever it exceeds four stories.
In such a case a basic
concrete frame, consisting of columns, core
walls and. floor slabs at four-story
will be constructed.
a four-hour fire
intervals
The structure serves as
barrier,
both in
vertical
and. horizontal planes, in addition to its
load bearing function.
gauge steel frames and
The low-rise light
infill panels will
be plugged into the megastructure, with provisions for fire protection.
While the megastructure will demand
labor, all
the infill
skilled.
structure will be
manufactured and. assembled exactly as the
low-rise units.
d.
Interior Work
Prefabricated assemblies of stairs,
cabinets,
-8-
partitions and closets are introduced
into the
system, at a wide variety of possible modular
applications, allowing any pattern of growth and.
change,
e.
Mechanical,
Electrical
The general approach, here as well as in the structure,
is
based on the following premises:
i.
Simple mechanical installation by unskilled
labor.
ii.
Individual control of the mechanical system
in each dwelling and independence from
occupants of other units.
iii.
Possibility to change, remove or upgrade the
mechanical installations.
A suggested outline specification has been developed
for some housing units investigated.
These are
included in the Appendix.
f.
Foundations
The system is
points,
designed to be supported at discrete
the cases of the frames.
As such,
it is
applicable to practically any soil condition.
The
flexibility of the steel frames and the tolerances
between infill
panels make the system relatively
insensitive to minor differential settlements of
the supports.
-9-
SYSTEM ADAPTABILITY
-10-
2.
SYSTEM ADAPTABILITY
a.
Housing Types and Scope
The proposed system will allow maximum freedom of
choice and degree of self-participation at densities
up to 15 units per acre.
At these densities the
capacity for growth and change can be employed to
a very large extent.
Simple family detached or
attached homes can expand in all directions in
small or large increments by the use of building
components (stair, mechanical unit) and by use of
columns, universal joints and panels.
The limit of the proposal serving as a primary
system is
in the range of 40 dwelling units/acre.
The accompanying illustration assumes the following
restraints:
100% parking
on-grade parking
limited walking distance from car to units
walk-up with maximum two flights of stairs
emergency and service traffic only within
the residential matrix
no more than four stories (possible duplex
on top)
Residential densities higher than 40 u/a will
adapt the proposed components as infill or
-11-
secondary systems.
These densities will change
the rationale of parking relationships and circulation considerations in general.
The attached. site application addresses itself
to the upper limits of the system in terms of
its
residential densities as demonstrated
in
the
This type of site utiliza-
general site matrix.
tion is a long neglected. prototype for urban
housing.
The well known later d.ay prototypes in the lower
and upper extremes of urban residential densities
did. not fulfill the aspirations and promises of
their
urbanistic conception.
Not only did they
stereotype their architectural presence but a noncompromising social segregation followed..
The
careful study and revitalization of middle density
housing is
system is
most timely and necessary.
The proposed
best suited. to such middle density appli-
cations while still
in
effective
all
other types
of residential development.
b.
Climatic Areas
No restriction.
Steel frame is
designed to resist
zontal and vertical load.
such that any insulation
Infill
any specified horiconstruction is
value is attained by using
an appropriate insulating blanket.
-12-
c.
Geology and. Soils
usable on soils with poor natural
The system is
d.ue to the relative
drainage and unstable soils,
flexibility of the structure which is capable of
adjusting to differential
excessive stress.
settlements without
All infill panels allow minor
distortion without damage to them.
d.
Site Topography
footings with piers of adjustable
At sloping sites
length will allow the use of the system both in
the same form as on flat
the introduction of partial
e.
as well as with
lower levels.
Site Size
adaptable to any site
The system is
f.
sites
size.
Site Situations
The basic concept of the system,
in
its
simplicity
the use of unskilled. labor and finished light
materials that are available anywhere, renders it
applicable to any site situation and. basically
independent
of local labor and material supplies.
The presence of existing or removable structures
d.oes not restrict
g.
the applicability of the system,
Changes
All components are removable or can be added on,
as desired..
Thus the standard. of surface finishes,
cabinets, etc. can be improved at any time by
simple exchange of panels.
Expansion and re-
arrangement are handled. similarly.
In
many cases
the frame may be erected. at the time of construction, to serve as porch or terrace, and. later enclosed by snapping the finished panels into the
frames.
h.
Regional Applications
No restriction.
-14-
SYSTEM COMPONENTS
-15-
PREFABRICATED
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-.33-
Construction Cost ($/L.U.)
Environmental Cost (S/L.U.)
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Max. possibility for self-help
Adaptability and change And
growth for each Living Unit
1-2 stories .detached
Proposed System Primary
1-3 stories attached
-.-.--
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I.
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Adaptability and change and
growth for each Living Unit
CD
3-4 stories attached
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Proposed System subsystem of
High Density
4;r
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possibility for self-help
-Adaptability and change and
growth,for each living unit
SYSTEM APPLICATION DIAGRAM
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SYSTEM APPLICATION DIAGRAM
This diagram is a generalized illustration of the relationship
between cost and type of housing development.
divided into three categories
per acre.
in
Housing is
terms of number of living units
These categories and. the implications of the pro-
posed structural system for each category have already been
discussed.
The solid-line curve in the diagram represents the relationship between construction cost and density of housing.
dashed-line
The
curve represents the relationship between environ-
mental cost and intensity of land use,
i.e.,
the environmental
factors, or costs, necessary to develop a socially and economically successful community.
The underlying assumption is that
the success of a housing development depends not only on the
comforts provided by the living unit itself,
These services range from
services available to the community.
utilities,
open spaces,
but also on the
parks and recreation areas,
schools,
shopping centers, community centers, transportation networks,
etc. to more abstract benefits which determine the quality of
socio-economic life.
Based on past experience with housing
types and community development,
it
is
assumed that the cost
per living unit of these supporting services decreases as the
intensity of land use, hence the sharing of facilities by larger
numbers of living units,
increases.
-35-
However, this relationship is not directly proportional.
The
diagram indicates that the benefits of increasing land use
intensity grow in smaller increments as increasingly high
densities are reached.
These considerations led to the selection of the 15-40 living
units per acre density as the area of intensive study;
shaded area in diagram).
because it
(the
This type of housing was selected
represents the low to medium range in terms of
construction cost and promises better environmental benefits
with increasing land. use intensity.
The 15-40 living units per acre d.ensity was selected for
intensive study because it
appears to be more economical
in terms of construction cost and of environmental cost, and
also offers a desirable range of possibilities for self-help,
adaptability,
and change and. growth for each living unit.
The proposed construction system may be used to develop a
wide range of site plans at a density of 15-40 living units
per acre.
The "General Site Matrix" and the "Diagrammatic
Layout of Housing Matrix" illustrates a possible application
of this system.
-36-
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PARKING
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FEEDER
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PARKING
PEDESTRIAN
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EXPANDS WITH
INCREASE IN
HOUSING UNITS
THIS DIMENSION IS DETERMINED
BY QPTIMUM WALKING DISTANCE
THIS DiMENSION
EXPANDS WITH
INCREASE IN
HOUSING UNItS
DIAGRAMMATIC LAYOUT OF HOUSING MATRIX
DIAGRAMATIC EXAMPLES OF HOUSING
TYPES:
20'-O"MODULE UNITS
-39-
E
VEXP
IB
2B
IB
3B
IB
2B
3B
-7
i~~1
IB
B
(.EXPI-
POSSIBLE FAMILY GROUPINGS
20' UNIT MATRIX
LEGEND
E
EFFICIENCY APARTMENT ,
1B
ONE BEDROOM APARTMENT
2B
~TWO BEDROOM APARTMENT
3B
THREE BEDROOM APARTMENT
C
CLOSET
[SHADED AREAS INDICATE POTENTIAL
EFABRICATED
COMPONENTS
io
0
-I74
-
-
-
-9
-
04
.9
-~-.
-.
-.
IZV
-
-~-
-
-
.8/1
-
119
.9
,~I
1,9
i
I-=
0
U.
E&1B FLOOR PLANS
,7
(C4
'0
sk -
I-
0
..J
2B&3B FLOOR PLANS
2B
IB
E
SECTION 3 STORY
-Jt
V
3B
2B
IB
E
SECTION -4 STOR Y
DIAGRAMATIC EXAMPLES OF HOUSING
TYPES:
32a-O''-MODULE UNITS
-48.
SPACE STANDARDS
It is suggested that another method. of reducing costs in
housing units is by examining present-day space standards.
Significant savings in low-cost housing can be achieved by
a reasonable reduction in these standards.
The following
plans are based on English space standards currently
recommended as minimum standards.
IB
E
IB
E
2B
3B
EXP
EXP
L
L1
--
E
E
IB
IB
IB
2B
EXP
EXP
POSSIBLE FAMILY GROUPINGS
32' UNIT MATRIX
60412@
6
B'
6,4z121
T1
6ON
-4
40
4
STRUCTURAL
LAYOUT
1---tas
LIV.-DIN.
LIV.-DIN -SL.
K
K
BR.
STOR.
1B&E FLOOR PLANS
I 2
4
4
'I,
4'
t
4
4
C~4
4,
c~4
-4
-.
4
--- iv~7C
4'
STRUCTURAL
LAYOUT
1B&2B FLOOR PLANS
E&3B FLOOR PLANS
2B-IB
IB-28
E-IBCINSO
SECTION 3 STORY
-
E-3B
IB-2B
IB-E
E
SECTION 4 STORY
DIAGRAMATIC EXAMPLES OF HOUSING
TYPES:
TOWNHOUSE MODULE UNITS
-58-
ii-
1ST FL.
SECTION
2 ND FL.
2B
1ST
FL.
SECTION
2 NDFL.
2B
1ST FL.
SECTION
2 ND FL .
3B
1ST FL.
SECTION
2 ND FL.
3B
APPENDIX 1
MECHANICAL SYSTEMS DEVELOPED
FOR ILLUSTRATED HOUSE TYPES
HEATING
PLUMBING
ELECTRICAL
PLUMBING
The basic design of plumbing is in accordance with the
"Recommended Minimum Requirements For Plumbing" (Hoover
Report)
as published
Commerce.
by the United States Department
of
Consequently, all sanitary piping is not only
inexpensive, but, as can be observed by inspection of the
drawings,
also lends itself
tion by unskilled labor.
and where there is
in its
simplicity to installa-
In single family isolated units,
no incentive towards inclusion of hot
water, individual hot water heaters are installed in each
unit.
Hot water heaters may be gas or electric as dictated
by fuel and energy costs at each specific location.
rent inclusion of hot water is permitted
Where
in multiple
occupancy units, further economies can be realized by providing one hot water heater per building in lieu of one
hot water heater per dwelling unit.
ferrous,
nonferrous metal,
Piping materials can be
or synthetic as indicated at each
location by availability, adaptability, acceptance, and cost.
HEATING AND VENTILATION
Heating of each apartment
is
accomplished
by a warm air
furnace located in each unit and discharging directly into
a ceiling plenum.
The plenum is fabricated under the general
construction, thus avoiding sheet metal work.
The system can
utilize fossil fuel or electricity as a source of heat as
dictated by economic analysis at each location.
The system
requires no skilled labor to assemble in the field.
Techni-
cians are required only during initial firing where fossil
fuels are incorporated. and. not at all
utilized.
Interior
where electric
heat
is
Each apartment will have its own thermostatic control.
bathrooms are exhausted. through shafts constructed. in
the general construction and topped by wind-driven turbine
exhausters.
Interior stairways are also similarly ventilated.
bymeans of wind-driven turbines at the top of the staircase.
Both.avoid expensive wiring, fans, and. maintenance.
Accordingly,
installation of the heating system consists primarily of
setting a single factory assembled warm air
place.
heating unit in
Sheet metal duct work is almost non-existent.
heating system lends itself
The
readily to rent inclusion of hot
water or to individual metering as may be desired.
It also
lend-s itself to future installation of mechanical cooling.
-65-
ELECTRICAL
All wiring conforms to the requirements of the National
Electrical Code.
Individual fuse boxes in
each apartment
permit convenient servicing of the system by each tenant
as well as individual or master metering of electrical
consumption.
Cooking can be electric
or gas.
Branch
wiring is inexpensive aluminum not metallic sheathed cable.
Telephone system can be readily prewired
in the construction.
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PHOTOGRAPHS OF MODELS
-75-
I
e-
--
-
-
-
-BIBLIOGRAPHY
-80-
BIBLIOGRAPHY
Thomas Schmid/Carlo Testa, SystemsBuild.ing--An International
Survey of Methods, Frederick A. Praeger Publishing Company, 1969.
"Aesthetics and. Technology of Preassembly", Progressive
Architecture, October 1 9 64.
"Metals Review", Progressive Architecture, October 1969.
Don Raney and Suzanne Stephens, "Operation Breakthrough--Operation P/R", Progressive Architecture, Pagesl20-137, April 1970.
Wells and Koetter, "Modular Housing System", Progressive
Architecture, Pages 86-87, January 1971.
Helmot E. Schultz, "Structure for Change and Growth", The
Architectural Forum, Pages 60-63, March 1971.
Special Issue on Build.ing Subsystems, Building Design and
Construction,
September 1971.
"Building Systems", Engineering New Record, McGraw-Hill Publishing Company,
October 22,
1970.
"Housing Systems Propoposals For Operation Breakthrough",
U.S. Department of Housing and. Urban Development, U. S. Government Printing Office, December 1970.
"Modular Assembly (The Art of Design with Standardized. Parts)",
Progressive Architecture, November 1957.
N
~0*
"Britain's Clasp System",
The Architectural Forum, Pages 116-
123, November 1961.
"Unskilled Mass Production of Housing Proposed For Type B
Contract", submitted. in response to RFP #H-55-69 for Operation
Breakthrough H.U.D. Proposal prepared. by Imre and. Anthony
Halasz, Inc. and various other participants.
"Wheeling Steel Framing", catalogue of structural framing by
Wheeling Corrugating Company.
Stressed Skin Panels, catalogue of plywood components by
Plywood Fabricator Services,
Inc.
Strong Tie Connector, Structural Design and Load Values,
Simpson Company.
-82-