Doors are the transitional pieces, the welcoming elements, the room dividers, the barriers against intrusion—be it weather or other diversions. A highly-crafted door is designed to function flawlessly and be in service for decades.
While chatting about the overall presence a home has—how it speaks to family, visitors, and neighbors alike—entry doors became a pointed topic. This sparked a more in-depth conversation with our fine woodworking division, NEWwoodworks general manager, Rob, and Jay, the team’s door guru.
Rob (left) and Jay (right) talk custom wooden entry doors.
Entry doors, barn doors, interior doors, flat track doors—NEWwoodworks crafts them all. What drives passion for wooden entry doors? Aesthetics, customization, tradition…Jay explained, “You can do a lot more with wood than you can with metal or fiberglass. Yes, they can at times be more expensive and may require more maintenance, but that door is going to be the first thing your guests will see and touch when you welcome them into your home. Wooden doors feel warmer, they shut with a solid feel, and there is so much more character and story in wood than any other material.”
I recently had the opportunity to chat with Richard Brown AIA, founder of RBA, about a newly completed project in Portland, Oregon. The modern, yet traditionally inspired design has a reclaimed timber frame core combined with stick built spaces. Nestled along the hillside with views of Mt. Hood, Richard explained that this will be the main home for a creative couple—a modern house with traditional queues. We conversed about this project and the broader driving forces behind his architectural creativity:
What can you tell us about this project’s build site? It’s a really beautiful site in Portland, which are getting to be rare in major cities as our population grows. This site had a home removed a few years back in anticipation of a development which never happened. There are great views to Mt. Hood and good access to sunlight. The homeowner is an avid gardener, so we intentionally sat the home into the shade away from where sun falls to leave space for gardens and a meadow area.
Leaving the world of party tents, awnings, and rough construction behind, Pete O’Brien joined our timber frame group finding the craftsmanship and finer work of traditional mortise and tenon joinery much more to his liking. In his opinion, handcrafting is second only to raising a frame.
We seem to be inundated with folks who love the outdoors so we were not surprised to learn that this timber framer likes hiking, kayaking, and frequents the Adirondacks. However, Pete admitted that he’s a gamer with a passion for racing and marksmanship games (cat’s out of the bag, sorry Pete!). On occasion Pete puts his kayaking skills to the test, participating in our local white water Wild Water Derby. After sitting down for this rapid fire interview, he regaled us with a few stories from the derby. Read on to learn more on this young craftsman (with author comments in brackets):
Pete’s favorite way to view the ADKs!
What’s your favorite word or phrase? Awesome. (Pete’s fellow timber framer and long-time member of the team, Jake, piped in saying to me, “That is for sure his favorite word.” Based on the grin he and Pete exchanged I suspected differently but didn’t press.)
We think this photo of Pete applying a chain saw texture is pretty awesome.
What’s your favorite time of day? Dinner. (Big smile from Pete with this answer.)
What’s your favorite truss or joint? A scarf joint.
Scarf joint assembly.
Favorite wood species? Oak.
What sound or noise do you love?
(A long pause here was punctuated by a good-natured verbal jab from a fellow timber who suggested the high pitched whine of the drill he was operating nearby was the sound Pete loves. Shaking his head and smiling Pete offered a different answer…) Water.
What sound or noise do you hate? Nails on a chalkboard (He couldn’t suppress a shudder and I grimaced with empathy for his reaction.)
Let’s move on…you travel to raise frames. What’s your favorite area of the nation? The Blue Ridge in Virginia – the views are amazing. (“Better than the Adirondacks you visit so much?” I asked.) Different. Less populated…
Not quite the Blue Ridge, but plenty of blue water for this lake home raising Pete was a key member of this Spring. (From the left: Pete, John S, and Mike G.)
What’s best about your profession? Crafting something unusual, something not many other people do.
Speaking of unusual, here Pete’s working some new joinery for 100+ year-old reclaimed agricultural timbers salvaged by our sister company, Pioneer Millworks.
What profession would you not like to do? Telemarketing. (Pete looked stricken by the very thought of having to cold call people.)
What’s your dog’s name? No dog, I have a cat. His name is Porter and he’s…awesome. (Another grin spread across his features. I have to admit appreciation for Pete’s sense of humor and overall affable nature.)
(Follow the pink arrow to Pete)
How about theWild Water Derby? This was my first year participating. Bruce, Jason, Matt, and a few others – we formed a team using an old wooden raft some of the… (he paused, sending a quick glance at Jake) …more seasoned guys raced a few years back. Things were going well until we started taking on water. (“Really?!” I asked and Pete laughed.) Really. The rapids were splashing up and tossing us around. We were using our hands and a bucket we had in the boat to scoop it out between bouts of rowing. It was epic. We all made it out fine and we got a wooden oar award too! I’d like to do it again next year.
We 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
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.
The 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.
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.
A blustery, snowy day in upstate NY.
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.
We 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.
A tree for a mass timber project? What started as an idea branched into reality as our team selected a west coast Broad Leaf Maple tree to be a central post in our Cross Laminated Timber project. Mike W, one of our timber craftsmen and an avid nature lover, applied his skills and artistic eye from unloading the big Maple in Oregon to hand-crafting the joinery and leading the raising in New York. Along the way he formed an attachment to this “post” and named it ‘Atlas’. He shares his adventure with Atlas below:
This tree had a purpose, a destiny even. The 60-year-old Acer Macrophyllum Big Leaf Maple was selected by my co-workers Randy and Noah (from Randy’s land) for its particular size, shape, and branch structure. It would become a load-bearing post and not just any post – it will support a 30,000 lb gravity load and an 84 foot glulam beam line in our new Cross Laminated Timber (CLT) building in Farmington, NY (the first complete CLT building in New York State!).
Using some experience from previous projects, the support of my colleagues, and a little book knowledge I picked up at the Timber Framers Guild conference, I got started.
First, I snapped out the reference lines – this would orientate the precise position of the beam pocket and base cut (where all the pressure is). Second, I set the tree onto sawhorses and played with the overall shape. This was my favorite part because it is all about balance and feel. This was where I got to imagine how the piece I was working was going to orientate when it was done. I had to get high over the tree and observe its relationship with the lines I snapped. I even laid down and looked at it from the side, imagining how it will look as the post I wanted it to be.
Once I was set on the position of the tree in relation to the joinery I began to mark my datum lines and started layout of the beam pocket. One thing to mention is that plans were for the beam pocket to be made up of two upright co-dominates. (Co-dominate, in this case, refers to how the main trunk splits and becomes two. This is a fun thing I learned from our newest addition in the timber frame shop, Noah Mize. He comes from an arborist background and is very knowledgeable.) I got out the laser to guide my cuts, after all it is the 21st century.
A little customization on the joinery. According to Mike, it represents “With love from the west coast to the east coast.”
The chisel work was a true joy. The chisel seemed to glide effortlessly allowing me to really push for precision, without losing sight of efficiency. That was the first upright. The second proved to be much more difficult. Long story short I had to tap out the lap joint all upside down and overhead. I had to squat on a block of wood 7″ off the ground while operating my chisel at shoulder height to make a flat which was facing the ground. Awkward, to say the least. To add to the difficulty the location of the work was right near the union, or point where the trunk splits into two. Needless to say the grain got harder and ran in all directions at once, or so it seemed.
The time for the post bottom cut was upon us. Randy brought in his O44 chainsaw with a 42″ bar to preform this work. We made a couple test cuts and away we went. The final cut was cleaned up with a 12″ planner to flat with the layout marks re-written on the fresh surface.
Our McMinnville and Portland OR teams, as well as our Farmington NY teams, signed the base of Atlas prior to raising.
With the base cut done this was no longer a tree; it was a post. I could imagine myself as this post, holding my arms out wide supporting the timber [much like Atlas]. I can truly say it was my honor to pour my love and energy into tree. It was my privilege to be part of giving this tree to its new life, a post at the heart of our new fine woodworking shop.
Mike was a key part to raising Atlas earlier this week. The post is now in place and connected to the frame, supporting substantial glulam timbers. More CLT panels are going into place and will shelter Atlas for decades to come. A video and photos of the raising are below: