The Wonderful People Cabin: Testing & Developing Our Aera Building System

Our First Aera Systems Test Project

Last summer, we embarked on an exciting project with Chris and Tonya at the Wonderful People Micro Farm: constructing a 300-square-foot cabin designed to test and refine our Aera Building System from the ground up. This project was more than just a build—it was an opportunity to challenge traditional construction methods and learn invaluable lessons that will shape the future of Aera Homes.

With the help of our talented friend Mika Matinazad, we documented every step of the process, sharing behind-the-scenes moments and insights along the way. From perfecting our panel construction system to refining finishes, this cabin was a foundational step in our mission to rethink and simplify sustainable home construction.

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Our Process

Before diving into the core of the Aera Building System, we started by laying a solid foundation—both literally and figuratively. Each step of the process, from flooring to finishes, was carefully designed to test and refine how our system performs in real-world conditions.

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Floor Panel Assembly

The first step after the foundation was assembling and securing the floor panels. Each panel was individually insulated and waterproofed on the underside before being connected to the others. This gave us a strong, stable base to build on and provided key insights into how to optimize floor panel assembly for future builds.

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Wall Assembly

We tested the spline joint system for the cabin's walls, and it performed exceptionally well. Pre-fabricated wall panels were flown into place using a telehandler and anchored to the foundation and flooring. Designed to dry to the outside, these panels help eliminate the risk of mold growth and long-term water damage—key elements for creating sustainable, durable homes.

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Roof Installation

Next, we tackled the roof. Roof panels, flown in and secured, included two layers of insulation to achieve a higher R-value, improving energy efficiency and thermal performance. This reinforced our commitment to building homes that are not only efficient but also sustainable.

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Windows and Door

We tested Andersen flange windows and a sliding glass door as part of our enclosure system. Taping the window edges and backfilling them with wood fiber insulation enhanced airtightness and energy efficiency. Metal trim streamlined installation, minimized bucking, and created a clean finish. The sliding glass door was installed and sealed, completing the enclosure while offering valuable insights for future builds.

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The Finished Cabin Reveal

After about five weeks on-site, the Wonderful People Cabin was complete. This project wasn’t just about building a cabin—it was about putting the Aera Building System to the test. From pre-fabricated CLT panels and spline joint assemblies to multi-layered insulated roofing and a refined enclosure system, every step brought valuable lessons that will inform the future of Aera Homes.

We successfully tested and refined key aspects of the system, like wall installation, roof assembly, and finishes. Every detail, from the windows to the sliding door, was an opportunity to optimize our methods. The cabin represents our focus on creating homes that are sustainable, efficient, and resilient—designed to meet the needs of homeowners today and in the future.

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What Went Well

• Efficient Wall Installation - The pre-fabricated walls, flown into place using a telehandler, made the assembly process smoother and saved valuable time on-site.
• Reliable Spline Joint System - The spline joint proved to be a dependable, airtight solution for wall assemblies, ensuring structural stability and durability.
• Smooth Window Installation - Flanged windows were easy to install and performed well in sealing the enclosure, contributing to the cabin's overall energy efficiency.

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Where We’re Improving

• Cedar Rain Screen Installation - The process was more time-intensive than anticipated. We’re working on making this step faster and more efficient for future builds.
• Pre-Installing Components - Pre-installing windows and sliding doors in the panels before flying them in could simplify assembly and save time on-site.
• CLT Interior Finish - Achieving a high-quality, consistent finish for the exposed CLT interior took extra effort. We’re focused on streamlining this process moving forward.
• Sliding Door Installation - Installing the sliding glass door on-site was challenging. We’re exploring pre-installation during wall assembly for a more seamless process.
• Material Delays - Waiting 2-3 months for materials caused significant delays. Optimizing our supply chain will be a key focus in the future.

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Final Thoughts

The Wonderful People Cabin was a significant milestone for Aera Systems. From its energy-efficient interiors to its durable, weather-resistant exterior, the cabin reflects our commitment to comfort, health, and sustainability in every home we create. This project helped us refine our processes and test innovative solutions, paving the way for the future of Aera Homes.

As we continue to build and improve, we remain focused on creating homes that are thoughtfully designed, resilient, and ready to meet the challenges of the future.

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