First Complete Cross Laminated Timber (CLT) Building in New York State

Featured

60 all clts installed 2.15.17We began raising the first complete Cross Laminated Timber (CLT) building in New York State on our main campus in Farmington, NY in late January 2017. A combination of mass timber, heavy timber, and CLTs, the 21,000 sq ft building will house our fine woodworking division, NEWwoodworks, and offer a bit of storage/shipping for our sister company, Pioneer Millworks. CLT construction is an economically and environmentally conscious alternative to steel and concrete construction, a material that is new to the U.S. building industry.

UPDATE: May 2017 – nearing completion:

Photo (C) Scott Hemenway

Photo (C) Scott Hemenway

Photo (C) Scott Hemenway

NEW CLT building exterior

From site prep to flying the the final CLT panel:



What are CLTs? A quick description might be ‘giant plywood’. More specifically, CLTs are large wooden panels, typically consisting of 3, 5, or 7 layers of dimensional lumber, oriented at right angles, glued together. The panels for our project averaged 8 feet tall and 38 feet long at 3 ¼ and 3 ¾ inch thickness. Using a crane and lulls, the panels were lifted into place and fitted by hand to the supporting timber frame. Each CLT panel has a shiplap edge that nests the panels together and is secured with metal fasteners.

We see CLTs as a wave of the future and we’re investing in our Western New York campus to better position the region and our industry to ride the wave. The opportunities with CLTs are abundant for businesses and housing and offer dramatic environmental benefits. Wood is a naturally occurring and renewable resource which stores carbon. It has proved time and again to preform as well, and at times better than, carbon heavy steel and concrete.

About CLTs one sheetThe CLT panels are pre-designed, highly engineered, of superior quality with precise tolerances – all specific processes and requirements that are fundamental to our timber framing craft. This fits perfectly with our traditional work and parallels the SIPs integration that we’ve spearheaded for years. The project combines the strength of mass (glulam) timbers and heavy timbers with CLT panels, utilizing a timber frame wrapped by CLT walls and topped by CLT roof panels. The panels arrived from Austria, shipped by sea (which had about half the carbon impact in comparison to shipping by land across the US or from Canada) with pre-cut openings for windows and doors. These panels were made using smaller Spruce trees from sustainably managed forests in the EU.

6 second panel CLT


Raising the frame and installing the panels (walls and roof) for this project took just under three weeks. This is our first CLT project and we now know first-hand that time on site is minimized and there is little waste with this product. While there was a learning curve, the process was amazingly smooth. Many accolades for our co-workers who are dynamic thinkers, unstoppable doers, and all around great people. Darren, Mike, Noah, Michael, Quinn, Todd, Anthony, Kevin, Marc, Mike G, and Wes to name a few who spent hours on the ground – also on ladders, in lulls, and on the roof – in chilly, wet, sunny, and snowy conditions.

43_DSC0492

A blustery, snowy day in upstate NY.

44 roof NWW

And a sunny, bright day. Typical to the Upstate region, weather fluctuated greatly over the 3 week raising.

A little dancing was in order as the last panel was installed (see Todd on the far left):

We’re excited to move our fine woodworking division on our main campus. In February of 2015, NEWwoodworks, located in neighboring Shortsville, NY, suffered a catastrophic event as excessive snow loads caused half of the roof collapse over their 70-year-old building (no one was injured). NEWwoodworks will be entrusted with 13,000 sq ft of the new CLT building while Pioneer Millworks will utilize 8,000 sq ft for reclaimed wood storage and shipping. We’ve expanded our Farmington office space to accommodate the NEWwoodworks design and management team, as well as give Pioneer Millworks a bit more elbow room.

office addition new energy worksWe anticipate easier communication and workflow allowing us to better serve our clients by joining NEWwoodworks with our main campus and giving Pioneer Millworks easy access to a loading dock plus covered space for inventory.

A special piece of this project is a Broad Leaf Maple tree sourced by our co-worker, Randy, from his forest in Oregon. The tree was crafted to serve as a main post in the NEWwoodworks section of our CLT building. Mike W connected with this tree from delivery in OR to raising in NY. He had a few words about this post which he affectionately named, Atlas.

Next steps: We’ll be installing a Wood Fiber Insulation on the exterior of the CLT building. Another product which is new to the US, these panels offer 3.5R per inch, are FSC (Forest Stewardship Council) certified, and are another carbon sink – for each 1 m3 used, up to 1 tonne of CO2 is bound within the product. Exterior cladding, radiant heat, windows, and more will round out this new build as Spring 2017 progresses.

Restored, Reused, Reloved: Doors of Heritage

Doors are the transitional pieces, the welcoming elements, the barriers against intrusion—be it weather or other diversions—the room dividers, the separators of space. A high-crafted door is designed to function flawlessly and be in service for decades. Yet over time their movement and environment can impact aesthetics and usefulness. Our fine woodworking group, NEWwoodworks, has had the opportunity to restore doors of heritage, bearing, and beauty for a few special spaces.

Home at the Spa

spa door rehab by newwoodworks

Elements from an original carriage house in Rochester were carefully salvaged, including the main entry doors, for a local spa. Always believed to be arched, during removal it was discovered that the original doors were rectangular. They had hung for years behind an arched opening to give them the look of arched doors.

Original doors, site salvaged.

Original doors, site salvaged.

The craftsmen at NEWwoodworks, lead by door guru, Jay, were tasked with creating arches in the old doors, along with general restoration. The doors were constructed in a traditional way using wedged tenons which were hammered in from the side. This type of old craft construction would close and tighten all of the stile and rail joints. With skill and care, an arch was cut in the doors and components were re-fitted to create truly arched doors. The surface was then wire brushed and mounting hardware was set into the backs of the doors so they could be hung on a wall.

spa door refurb by newwoodworks

Today they greet patrons from their new home where they live as pieces of art behind the spa reception desk.

newwoodworks spa door refurb

University Ave

Though species and finishes play a large role in the durability of wooden entry doors, time and weather will eventually wear through and some TLC will be needed to bring the wood back to life. A set of white oak entry doors on University Ave in Rochester, NY were removed by our craftsmen and transported back to the shop.

univ ave door orig

The original weather-worn oak doors on University Ave.

It was clear the bottom rails were beyond repair which lead the team to dismantle the doors and sidelights. Over 200 oak pieces and all joinery was restored. New insulated glass units and oil rubbed bronze hardware were added bringing a touch of modernization to the doors. Originally the oak was stained dark brown, but for this revitalization, it was requested to keep a natural finish to allow the oak’s patina to be celebrated. The craftsmen employed a polymerized tung oil that will be applied biannually as part of normal maintenance for the revived doors.

university ave door refurb newwoodworks

Eatery Entry

A fun find by a restaurant owner, this tall and slim pair of doors is believed to have originated in India before making their way to the US and eventually to the NEWwoodworks shop for a bit of care.

newwoodworks refurb pine doors detail

The doors were sinch-nailed together, nearly 3″ thick, solid white pine covered in layers of paint and signs of age.

original pine doors eatery entry

Original, as-found pine doors.

The first step was stripping off the hardware and cleaning up the grills. A light wire brushing was applied to the surface to remove some of the rotten paint while highlighting the hard-earned surface character. Structural repairs were required in the moldings and some of the rails, but overall these doors were fairly solid. Frosted glass, new hinges, and a dead bolt completed the overhaul. Today the doors conceal a closet while acting as wall art. Their grills and glass are backlit, warm and captivating in the eatery’s entry foyer.

restored pine doors by newwoodworks

Rejuvenating and repairing, bringing new life and new love to these timelessly authentic doors are stories we’ll tell for many years to come. They’ve influenced and inspired new doors (below) and reminded us of old high craft techniques. See the gallery of door creations here.

Inspired by the adjacent antique doors, the new entry door was crafted by NEWwoodworks using reclaimed Heart Pine.

Inspired by the adjacent antique doors, the new main entry door for the eatery entrance was crafted of Reclaimed Heart Pine by NEWwoodworks.

A Family Retreat on Canandaigua Lake: Designing Spaces

When we last visited Dan & Laurie’s project on Canandaigua Lake, Pete, one of our design group architects and the design leader for the home, walked us through the site planning. I nabbed Pete again, this time to take a look inside the project at the design considerations for creating the layout and formal floor plans.

Lakeside Family RetreatJust like last time, Pete made a quick inquiry about little orange fish crackers. I had to let him down softly; I had nothing. Looking disappointed for a beat, he moved on reminding me that Dan & Laurie’s site overlooked the lake and came with strict site constraints (not uncommon to building near water) including height restrictions, erosion/sediment concerns, setbacks, and more. He explained that the constraints drove the overall siting of the house and garage, but there were still the interior spaces (and floor plan) to negotiate.

“Dan and Laurie’s project is meant to be a multi-generational home that will act as a central gathering spot for family and friends. Overall the home has an open floor plan with the public spaces centralized on both the main and lower levels which can easily accommodate larger gatherings. Balancing that are private spaces on the ends of the home which allow folks the opportunity to enjoy their quiet space or step inwards to join the party.”

Canandaigua lake home timber frame hybrid floor plan

I was curious about what techniques are used to create a division of space in open floor plans, particularly when the same flooring flows throughout the level. “Great question—we like to make psychological breaks to take the place of walls in open floor plans. Although this project is a hybrid using timber frame and traditional construction, the public spaces fall under the core timber frame. We used the main carrying beams, a bigger timber, to bring visual and physical weight and delineate the great room, kitchen, and dining areas. The great room is also vaulted while the dining and kitchen spaces have flat ceilings. The kitchen island provides a further break between food preparation zones and the dining room,” Pete explained.

timber frame kitchen and great room new energy works

“One less common trait in this home is a single point of entry from the garage and parking areas. Without a dedicated breezeway or mudroom, the goal was to welcome visitors and inhabitants through a cleaner entryway in a style more traditional to guest-only entryways. We designed a lower volume with a flat ceiling softened by lifted timber common rafters, which draw the eye through the entry space to the great room and expanse of windows beyond. There is still a need for organizational spaces…a place to take off shoes, a laundry room…We “hid” these just off the entryway, branching to the right beyond a wing wall and screened behind a pocket door,” continued Pete.

canandaigua timber home new energy works entry

View of the entry door.

entry to canandaigua hybrid timber home

View from the entry.

Given the location of the home, I wanted to know about the views. “Below the curved bottom chord king post trusses, glass wraps the frame at close to ninety-degree angles. You can see through the corners resulting in a nearly 180-degree view of the lake. It’s pretty neat,” Pete obliged.

How about solar heat gain? “Always a consideration,” Pete agreed. “There is morning sun only because the room faces Southeast over the lake. Other windows throughout the home are covered by large overhangs and exterior roofs, so the gain won’t be significant there.”

interior canandaigua lake great room timber frame new energy works

“Oh, also about exterior decks and views—we aim to keep them from wrapping the great room because views are more enjoyable when uninterrupted. I don’t know about you, but I don’t like a piecemeal view broken by slats of a deck railing.”

I recalled that in our previous conversation Pete had stressed a desire to have the house set into the land, as part of the land, rather than perched on it. I asked how that impacted the interior light in the lower-level. “Whenever we have spaces under grade we make every effort to bring natural light to as many sides of the space as possible. Dan and Laurie’s home has light on three sides and includes lake views; it’s a pretty good situation. We gave the stairwell carefully consideration and arranged it in an “L” within a rectangular opening so plenty of western light could spill through to the lower-level family room. Plus, we made every effort to eliminate soffits, carefully planning and utilizing open web trusses—this way the lower-level ceiling height remains constant and the space feels more inviting and comfortable.

timber frame lower level stairs new energy works

“Going back to private spaces, the master suite has a vestibule. It is one of those planned rooms that helps create further division from the more public areas. There’s also a private deck accessible only from the master bedroom. The in-law suite is situated down a hallway off the entry, giving it the feeling of a private branch separate from the main core of the home. We know Laurie’s folks are excited about the suite. While we were raising the exterior timber components and decks, they pointed out the timbers going up on their corner exclaiming to onlookers ‘That’s our bedroom!’,Pete smiled broadly, “Their excitement was infectious.”

exterior timber frame raising new energy works

“The lower-level is also the space for guests. A bedroom, a bunk room, a family room, and what we’re calling a lake bathroom. It will be the spot to stop prior to journeying into the rest of the house after a swim or a visit to the shore.”

Giving Pete thanks for the information, I sent him off with a piece of spearmint gum (the best I could do in lieu of orange fish crackers).

Further into this summer, Laurie and Dan’s project will be complete. We’ll share a bit on the interior design and have plenty of finished images for you then. Thanks for joining this journey! If you’d like to see other projects we’ve general contracted, visit our Case Studies. And to learn more about our teams, visit Meet our People.

Q and A with a Timber Framer featuring Jimmy

Jimmy has been with our timber frame team for almost two years. He lives in Mt. Angel, Oregon and works out of our mill in McMinnville, Oregon. Even though the commute one way is at minimum an hour, Jimmy tells us he wouldn’t trade his 1/3-acre peaceful property for anything. His love of nature is also his favorite thing about timber framing. According to Jimmy, “There’s no better place to be than 25 to 30 feet in the air looking at beautiful scenery.”

20161003_184125

Where are you from?
I was born in Newburg, New York and still have family in Brooklyn, New York. When I was 6 months old, our family moved to Puerto Rico. It wasn’t until I was 13 and moved to Missouri that I began learning to speak English. I made my way to Oregon via, Florida and Los Angeles.

What were you doing before NEW?
Before joining New Energy Works, I was a blacksmith, welder, mechanic. When I have time, I restore furniture.

Leaving the frame to check out the region. Darren, Mike, Jimmy, and Adam.

Leaving the frame to check out the region. Darren, Mike, Jimmy, and Todd.

When you aren’t at work what are you doing?
Chilling with Chip (my dog) watching TV or out hunting and fishing.

Jimmy w chip in shop

What’s your favorite truss style or joint?
I don’t have a favorite. I love them all.

What’s your favorite wood species?
I love purple heart and coca bola.

What’s your favorite time of day?
I’m an evening person. I like 6:30 pm, when I walk in to home at night.
 

What’s your favorite curse word?
hijo de puta
 (son of a bitch)

Favorite project you have worked on?
A big barn raising with east coast guys. Huge painted timbers for kind of a modern take on a barn. 

white barn east coast new energy works

What’s best about being a timber framer?
Traveling to new places and the views from the tops of the frames.
 

DSCN3544
What’s Chip’s role at the shop?

He’s the Mill Mascot, my constant buddy. 

shop mascot chip

Design Week Portland: Crafting With Heavy Timbers

badge-wordmark-green

Design Week Portland 2017 has come to a close, but not before New Energy Works threw an event showcasing residential heavy timber framing and solar panels. On April 26th, 2017 outside of New Energy Works SE Portland Studio in Oregon, a couple of our timber framers raised heavy timbers crafting an 18 foot by 10 foot carport structure.

Quinn, Darren and Mike finishing up the frame.

Quinn, Darren, and Mike finish 
up the frame.

Zero nuts, bolts and screws. Just wood joinery.

Zero nuts, bolts and screws.
Just wood joinery.

 

 

 

 

 

 

 

 

 

After completing the frame, our colleagues at Syncro Solor came by and attached four, 345 watt,
solar panels to the top. Synchro Solar is a locally-owned, full service solar energy contractor serving Oregon and Southwest Washington that specializes in the design and installation of completely custom solar electric and solar water heating systems.

4 solar panels atop Douglas fir timbers

4 solar panels atop Douglas fir timbers

The event was from 2 – 4 pm. Our guests were a range of architects, builders, and artisans. We shared information about timber framing, cross laminated timber, the environment and what New Energy Works is all about.

Jonathan Orpin presents to DWP guests about timber framing.

Jonathan Orpin presents to DWP guests about timber framing.

The morning had started out a bit rainy, but the sun broke free of the clouds and we ventured outside to have a closer look at the carport and the timber framers manipulating timbers.

Checking out the timber frame as a group.

Checking out the timber frame
as a group.

Darren using a large drill into Douglas fir timber.

Darren drilling into a Douglas fir timber.

 

 

 

 

 

 

 

 

 

We’re excited to send all proceeds and donations from the event went to Community Energy Project. With hundreds of trained volunteers, they reach low-income households, providing life-changing services to thousands of diverse clients. They offer free community workshops that teach practical skills to make homes safer and more energy efficient as well as in-home services to weatherize and repair homes for people in need. To further help support Community Energy Project buy tickets to their spring social event here.

Community Energy Project's booth at the event.

Community Energy Project’s booth at the event.

Our thanks to everyone who attended and our friends at Synchro Solar and Community Energy Project, for joining us on this venture. As well as a special thanks to Cascade Wester Representatives for all of their help with equipment and supplies.

Nestled in Vermont

vermont timber frame rendering apr 2017

In our experience, homes are most successful when they adapt, age, and grow with their inhabitants. It’s always pleasing when we can plan ahead for changes, such as transitioning a weekend vacation space to full-time home. Hank and Julie have given us such an opportunity. The couple has a delightful build site in Fayston, VT and enlisted our team to design their vacation home, which will eventually become their full-time retirement retreat.

Sublime views of Slidebrook Basin between north and south ski areas of Sugarbush Resort guided the overall home orientation, and specifically the great room layout, for Hank and Julie’s project.

view of sugarbush

Careful consideration was also given to the traditional Vermont farmhouse vernacular. The design acknowledges this aesthetic with a main gable roofline that intersects with an asymmetrical salt box gable roofline. It incorporates the couple’s desire for mountain-rustic style with mixed exterior materials and subtle timber elements. The corner of the home’s “L” shaped layout is defined with a stair tower that has evenly stacked windows and will feature shou sugi ban siding.

The stair tower anchors the corner of the home's "L" shaped layout.

The stair tower anchors the corner of the home’s “L” shaped layout.

With a combination of woodlands and open agricultural space, the site will allow the home to be set partially within the trees at the end of a curving drive through open land. A banked garage is angled into the hillside, giving the front of the home a modest street-side facade.

Phippen_ericfraser1509.rvt_2017-Feb-08_02-29-00PM-000_3D_View_9

Meeting individual needs is always a design driver which, for this project, lead our team to incorporate a craft room on the lower level walk-out. This space was a must-have to support Julie’s non-profit and grassroots organization, Sewpportive Friends. The group creates kits vital to feminine hygiene for young girls and women in Zimbabwe; a necessity for both health and education. We can’t tell the story as well as the Sewpportive website and blog. Julie will be headed back to Zimbabwe with a team this July to distribute to more schools and villages. We’re excited for their continued success.

sewpportive web

Hank and Julie are avid outdoor enthusiasts leading to another need: storage. Large storage on the lower level will be used for housing/maintenance of skis, hiking gear, canoes, snowshoes, and other equipment. Walk-out access eases the transition to/from nature with or without gear.

Phippen LOCAL1

“We are having a very enjoyable time working with Ty, Pete, and the rest of the NEW crew. Their focus on creating a relationship with us, rather than making a transaction, is evident in their overall approach to the design/build work: from their site visit to our VT property, our trip to the NEW facility in Farmington, NY, and all additional communications. They are inspired, honest and professional. They understand that attention to what WE want in our house is of utmost importance, and are happy to share their knowledge and experience by providing creative ideas that we could explore or not.” – Hank and Julie.

An overall open floorplan ensures a relaxed, easy, flow when family and friends visit to sample local Vermont brews and views. It also allows for commanding views of the surrounding landscape from all common spaces.

Phippen LOCAL - 3D View - 3D View 14

We sat down with Pete, lead designer for Hank and Julie’s home, who explained that a key to open floor plans is accentuating areas with details, often flooring or in this case, with timber. Overall the timber frame directs views and differentiates spaces. In Hank and Julie’s home, two keyed beams flank the dining room and kitchen island (image below). This change in ‘ceiling’ visually separates the spaces from the great room which features canted queen post trusses with curved bottom chords (image above). Pete continued to verbally draw the home, describing flitch beams, a combination of steel and timber, used in the lower level to create a larger clearspan while defining the circulation of space from the family room. Moving up two levels, he noted that guest rooms have bunk loft beds over the closets, a fun feature that will likely be a fascinating novelty for kids and adults alike.

Phippen LOCAL - 3D View - 3D View 12

Other build details include roof SIPs (Structural Insulated Panels) and our Matrix Wall enclosure. We’ll be raising the frame this summer and working with Brothers Building of Waitsfield, VT to complete the project.

The home will include a master suite, craft room, great room, game room, and ample storage. 5 bedrooms and 3.5 baths.

The home will include a master suite, craft room, great room, game room, and ample storage. 5 bedrooms and 3.5 baths.

Many thanks to Hank and Julie for the kind words and for allowing us to be part of your project!