The final (final!) Cross Laminated Timber (CLT) panels have been installed on our CLT project. Forming the front corner of the building these panels represent a piece of the flexibility of building with solid wood panels and speak to our passion for planet, forest, tree, and wood.
Our fine woodworking division, NEWwoodworks, used ingenuity, software, and CNC tooling to draw, layout, and cut the “tree” design. Our timber frame and construction teams, including Jason, Kevin, and Jim, installed the panels on a chilly Monday morning. Roofing and final enclosure, including wood fiber insulation, are underway.
Residents of Indiana, Doug and Tammy have called Grand Traverse Bay, Michigan their second home for 18 years. The site they’ve enjoyed over those years includes lake frontage and views worth talking about. (Mike W captured the panoramic above from the peak of the frame on crisp day.) The couple frequented several timber home shows where they met New Energy Works Drake Ambrosino, and we’ve helped them bring it to reality this Winter.
We were told the weather is usually great in Grand Traverse, but that lake-effect snow is no joke near the water. While Darren, Mike, Anthony, and Noah were raising the frame, some tough weather hit the site. For nearly two weeks the temperatures ranged from just above zero into the teens with daily snow. The flakes didn’t diminish the team’s energy as they joined the custom stained Douglas fir main frame, front porch, and rear balconies.
T&G of the same species and finish was installed over the main frame, followed by SIP roof panels. Mike W told us, with a quick chuckle from behind his hearty beard, that high winds were ‘a challenge’ for the SIP panel installation in particular.
Porter Builders from Kewadin, MI will be completing the home throughout 2017. Points of interest within just an hour of this project include Charlexoix, Petoskey, Traverse City, Torch Lake, and many ski areas.
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.
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.
The challenge was set: take a well-loved 1980’s family home and transform both aesthetics and functionality. Our design and build teams embraced the challenge with gusto. Ty Allen, head of our Design/Build groups and our in-house Architect, gave us the cliff notes.
During the first site visit Ty and team captured this image of the home’s roadside facade.
The homeowners built their family lake home over 25 years ago. They raised their children and made countless memories. Yet, the 1980’s contemporary design was no longer meeting all of their needs and had become dated in style. We were building a new timber frame home on a neighboring lake and we’re told that project was part of the inspiration for couple to join our community and incorporate timber framing into their lives.
Ty explained, “I think 80’s contemporary homes are the best type of existing home to transform. They are often a clean slate with open volumes and simple details.” Remodeling requires balance – the changes for this home would be bold. “We wanted to respect the integrity of the existing home, using what was already existing as a springboard to modernizing how the home looks, feels, and works.”
The original roadside facade (above) and with updates (below).
“A good example is the porte co·chère,” continued Ty. From the road it was difficult to tell what the structure was particularly as the roof flowed down from the house as one mass over the car port. The existing porte co·chère was removed and re-imagined, presenting a gable end on the roadside facade. “Rotating the roof lines defined the porte co·chère and allowed it to have impact. It is the primary focus the facade while maintaining the original purpose of the space.”
Tear off of the original car port.
The naked timber frame of the new porte co·chère.
Rotating the roof lines to present a gable end on the roadside facade redefined the car port as a focal point while maintaining function.
Under the new carport a custom door from NEWwoodworks welcomes guests.
A major new functional improvement: a three car garage. The home’s original single car garage was ideally situated for transformation into the transitional space (mud room) from the new garage into the home. Our team had several visits to the build-site to stake out the garage addition. While accommodating set-backs and other regulations, they worked to get the angle, the flow, of the new structure to fit best with the existing garage, house, and driveway and be considerate of lake views. “We wanted to create a courtyard effect with easy access to the home so the setting of the garage was key. The mud room offers the first glimpses of the lake as you transition through it from the garage or as visitors move down the drive in front of it.”The lakeside facade had a large span of roof and large windows which allowed harsh western sun into the home. “We were deliberate about the fenestration [window placement]. The placement and scale of glass needed to lower solar heat gain was carefully balanced with taking in lake views.” The new fenestration, updated Marvin windows, breaks in the roof lines, and an expansive covered porch improved efficiency and style. Covered space on the lakeside not only provides more enjoyable year-round shelter from the elements for the homeowners, their family and friends, but for the home as well.
The lake side of the home before (top) and with the remodel nearly complete (bottom).
Inside the home timber elements were added to the great room and entry. Beginning at the porte co·chère entry, the same truss style flows through the central great room and back outside to the lakeside porch. What’s next? An interior timber ‘bridge’ is on the list. It will replace the current loft-bridge to connect the bedrooms on the upper level.
Interested in seeing more of our projects? See our website galleries. Want more images of this lake home remodel? See the below photo collection:
Updating the lakeside facade and a glimpse of the back of the new garage.
The home’s boat launch also features timber framing.
Jim & Rebecca came to us with a dream for a timber frame barn that would be a centerpiece to their hilltop property in Castle Rock, CO. What a spot to call home! Our timber frame team arrived from Oregon to spend three weeks on-site raising the frame and enclosing the barn – all while soaking in the scenery.
Over the next few weeks, the team learned that Jim had fallen in love with timber frames in Ohio and made it a goal to call one his own. That’s our kinda’ goal; our thanks to Jim & Rebecca for enlisting us to build this 80′ by 32′ rough sawn Douglas fir timber frame barn.
The barn doesn’t use any true trusses, but has plenty of traditional mortise and tenon joinery crafted in our McMinnville, OR shop by Darren, Mike, Jimmy, Todd, and David. A clerestory brings light into the structure while a ‘tower’ adds dynamic space.
Dynamic = dramatic, right? With regular wind gusting upwards of 120 mph on the hilltop, the team tells us (with their usual aplomb) there were a few interesting days. We can only imagine that flying structural insulated panels (SIPs) to enclose the frame while the wind whipped was quite a challenge. Extra straps, extra patience, and extra vigilance were certainly required. The SIP walls are 6.5″ achieving an R value near R28 while the 10 1/4″ roof SIPs achieve R42. Overall the enclosure is rated to handle those +120 mph winds.
On a free weekend, Mike, Darren, Todd, and Jimmy visited past clients in Estes Park, CO.
We know it can be hard to turn these congenial guys away, and John & Cindy went beyond to welcome them. They were even treated to a tour of the home and the entertainment of local wildlife.
An unexpected drop-in was met with smiles, snacks, and a tour of John and Cindy’s timber frame home. (Gosh we have wonderful clients! Or, as Mike described them, “lovely folks”.)
Back at Jim & Rebecca’s the team finished the enclosure, complete with gable walls that extend higher than the roof, and give the barn a distinct look. The barn will function as part garage, part housing, with a full in-law suite on the upper level.
We’re looking forward to visiting Jim & Rebecca in 2017 and we’ll be sure to grab some images of the completed barn. We’d also like to note that the design for the barn was done by Kathy Eichelberger Jones, AIA of ArchStyle, Inc.
Mike models a Superman t-shirt, a fun gift from a vendor, while installing t&g on the barn roof.
The crew arrives on site during a foggy morning.
The pre-assembled bents sitting on the barn foundation give a sense of just how large the structure will be once raised.