Update on the First Complete Cross Laminated Timber Building in NY State

Enclosure, mechanicals, and moving in. What’s the latest with our CLT build?

tomorrowland CLT building exterior NEW web

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. Progress since May has included:

Wood fiber installation, another product which is new to the US. Also referred to as “out-sulation” since it is installed on the outside of projects, the Wood Fiber panels offer 3.5R per inch, are FSC (Forest Stewardship Council) certified, and are a carbon sink – for each 1 m3 used, up to 1 tonne of CO2 is bound within the product. Made by Steico, we found this product installed with a fair amount of ease and is performing well.

Will G Steico DSCN2802

wood fiber install tomorrowland clt new energy works

The custom CNC cut corner tree received a coat of stain and is now sheltered behind glass.

tree paint new energy works clt building

CLT tree cut out night shot new energy

Siding, including shiplap Shou Sugi Ban Color Char by Pioneer Millworks.

shou sugi ban color char siding by pioneer millworks on clt building

siding tomorrowland

Shou Sugi Ban is an ancient Japanese technique of burning wood as a preservative treatment for exterior siding. The process gives Pioneer Millworks Larch a dark, slightly iridescent look. We anticipate that in this exterior use it may change over time, depending on its exposure to the elements.

Lights! All LED lighting combined with the natural light from the clerestory make this a very bright space. Our fine woodworkers are clamoring to move in for the lighting alone!

LED lighting CLT building new eneryg works

Concrete – what a BIG pour! Lots of man power and man hours. Concrete was flowed over radiant heat throughout the shop.

KB Masonry's team handled this big pour.

KB Masonry’s team handled this big pour.

wet concrete

Concrete complete and set! Photo by Scott Hemenway.

Concrete complete and set! Sprinkler lines run…lights to come. Photo by Scott Hemenway.

Mechanicals, such a sprinklers, and duct work. Steve and Ed our maintenance duo have been hard at work installing duct work/dust collection alongside a few of our trusted partners who handled the sprinklers and other mechanicals.

Ed and Steve talk connections for the dust collection ducts.

Ed and Steve talk connections for the dust collection ducts.

Ed is a bit camera shy and did well hiding behind the pipes.

Ed is a bit camera shy and did well on the man lift hiding behind the pipes.

Mechanical room.

Mechanicals room.

Amenities including the break room and bathrooms are underway.

rooms in tomorrowland

rooms framed in

Plumbing and electric are in. Next: doors.

In use: Pioneer Millworks has begun using their storage and shipping space at the back of the building. What once seemed to be a cavernous 8,000 sq ft is filling up quickly with custom orders that are ready to ship and other weather sensitive products.

PMW storage tomorrowland

We’re on schedule to move all of our fine woodworking shop to their new space in mid-August. Check back for information on our ribbon cutting this Fall. And visit our previous blog post for more images, videos, and details of this project.

About CLTs:
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.

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.

Wood where the elbows are: Celebrating the Table.

Dining, meeting, drafting, sewing, displaying—the table is one of our most versatile pieces of furniture. They range in size, use, and style—across cultures and materials. Small functional bedside tables, wide ornate coffee tables, grand formal dining tables: each personal and flexible to nearly any imaginable design.

In this New York home, two wide reclaimed Elm thresher boards were bookended, butterfly joined, and place atop a custom fabricated metal base.

In this New York home, two wide reclaimed Elm thresher boards were bookended, butterfly joined, and placed atop a custom fabricated metal base.

For over two decades our fine woodworking group, NEWwoodworks, has been designing and crafting all varieties of tables, working out nuances and integrating creativity with functionality. Wood is this team’s preferred medium, be it antique reclaimed, live-edge, or newly sawn. Celebrating the beauty of the wood is instinctual with these craftsmen.

Headed for its new life as a bar height community table this creation has intentionally selected planks from original Foundry Maple flooring with a resin pour finish atop a powder coated custom steel base.

Headed for its new life as a bar height community table, this creation has intentionally selected planks from original Foundry Maple flooring with a resin pour finish atop a powder coated custom steel base.

Completed last week, this boat-shaped conference room table has a top crafted from Reclaimed Settlers’ Plank Mixed Hardwoods and a base of what we like to call “Toasted” Oak. Also integrated into the top are three power tilt-ups.

conference table reclaimed hardwoods newwoodworks custom reclaimed hardwoods conference table newwoodworks
Working alongside our Architectural and Interior Designer, Andrew, the NEWwoodworks craftsmen recently made two tables for our showroom remodel. Both are intended to provide additional work surfaces and meeting spaces for clients and co-workers alike.

A modified “waterfall” effect has the reclaimed Tropical Hardwood Mix of one of the tables dripping over the edge towards the floor:

reclaimed exotic hardwoods waterfall table newwoodworks

The original stamps marking the approval of this wood for overseas use via a form of kiln drying.

The original stamps marking the reclaimed exotic hardwoods are pest free.

Not to be missed is the “suspension” table, an idea that has been percolating in the NEWwoodworks group for some time. Crafted of mixed oak with a dark wash stain, the deep wood color draws attention to the metal suspension components:

suspension oak table by newwoodworks

Live-edge tables are always intriguing with their organic edges and truly one-of-a-kind shapes. Several tables designed by Rob, manager of our NEWwoodworks group, celebrate live edges and “x” bases in a Kentucky farmhouse:

The root burl of a large walnut tree was carefully maintained to create a live-edge end on this farmhouse table.

The root burl of a large walnut tree was carefully maintained to create a live-edge end on this farmhouse table.

Similar to the dining table, walnut end tables have one-of-a-kind live-edges in this Kentucky home.

Similar to the dining table, walnut end tables have one-of-a-kind live-edges in this Kentucky home.

Figured cherry maintains a live edge with a low height traditional for coffee tables.

Figured cherry maintains a live edge with a low height traditional for coffee tables.


Reclaimed wood
lends other interesting character marks and hard-earned patinas to any fine woodworking project:

Old French white oak and domestic barrel/vat staves were repurposed into a pier table off the kitchen island, ideally situated for family meals.

Old French white oak and domestic barrel/vat staves were repurposed into a pier table off the kitchen island, ideally situated for family meals.

Incorporating our torsion box design and a mixture of reclaimed hardwoods, Parsons-style tables offer space for patrons of a Florida-based bank:

reclaimed hardwoods box communal tables

In another commercial space, Kindred Fare, a large walnut table with contrasting butterfly joinery and a trestle base (crafted of reclaimed Hemlock) seats 10+:

custom walnut table kindred fare by newwoodworks

An extra large, curving edged Settlers’ Plank reclaimed oak conference table easily seats 20+ as demonstrated by some of the NEWwoodworks team:

nww crew at SP table

As we find with any fine woodworking, so much is in the details. Custom designs are made better with detailed execution and specific attention to each wood plank’s grain and character, to overall dimensions, to what base material and style fits best, to the shape of an apron (or not having an apron at all!), to what joinery is applied, to the finish, and much more.

In the details: A reclaimed beech table with thru-tenon aprons and pyramid pegs.

In the details: A reclaimed beech table with live edge, thru-tenon aprons, and walnut pyramid pegs.

The more challenging and more unique, the better for this team. What table is in your imagination? Let us know – we can help bring it to life.

A well-loved 'timber' table in the NEWwoodworks showroom celebrates live edges and original mortise pockets suspended from heavy Douglas fir timber legs.

A well-loved ‘timber’ table in the NEWwoodworks showroom celebrates live edges and original mortise pockets in its top, all suspended from heavy Douglas fir timber legs.

 

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.

Building the First Complete CLT Project in New York State

first-clt-building-in-nys-new-energy-works-timberframersWe’re excited to announce that we’re building the first complete Cross Laminated Timber (CLT) building in New York State on our campus in Farmington, New York. Cross Laminated Timber (CLT) construction is an economically and environmentally conscious alternative to steel and concrete construction. The new building will house or fine woodworking division, NEWwoodworks, and offer storage/shipping space for our sister company Pioneer Millworks.

“We’re extremely excited to bring this alternative building method to New York State. We see CLTs as the wave of the future and are investing in our Western New York campus to better position the region and our industry to ride the wave,” states Jonathan, our Founder and President. “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.”

clt-exampleCLTs are large wooden panels, typically consisting of 3, 5, or 7 layers of dimensional lumber, oriented at right angles, glued together. This results in exceptional strength, dimensional stability, and rigidity. The pre-fabricated wall, floor, and roof panels can be installed quickly with little job-site waste. European countries have been utilizing the panels for multi-story buildings with great structural, financial, and environmental success.

timber-frame-of-tomorrowland-new-energy-worksCombining the strength of timbers and CLT panels, the building will utilize a timber frame wrapped by CLT walls and topped by CLT roof panels. The panels will be pre-cut for windows and doors and will arrive by cargo shipment to Farmington NY in early January 2017. Both the timber frame and the panels will be raised in January 2017.

“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,” explains Jonathan.

In February of 2015, our fine woodworking division, NEWwoodworks located in Shortsville, NY, suffered a catastrophic event as half of the roof collapsed over their 70-year-old building (no one was injured). The CLT project will be a 21,000 sq ft, single level building, to house both NEWwoodworks and provide storage/shipping for Pioneer Millworks reclaimed wood products.

An example of a CLT project built in Washington DC earlier in 2017.

An example of a CLT project built in Washington DC in 2016.

NEWwoodworks’ manufacturing equipment and craftsmen will be entrusted with 13,000 sq ft while Pioneer Millworks will utilize 8,000 sq ft for reclaimed wood storage and shipping. We broke ground for the foundation on November 15, 2016 behind our timber frame shop.

close-up-fiber2017 will start off with the timber frame raising followed by raising of the CLT panels (walls and roof). We’re also examining a wood fiber insulation which is more environmentally friendly than the majority of alternative options. We’ll share more as progress continues. Contact us with any questions or for a schedule of events: events@newenergyworks .com

Case Study: Lakeside Charm on the Cliff

Years of dreaming and planning culminated in Tom and Maureen’s lakeside home. Situated on a steep slope, down a drive with several switchbacks, the site was both challenging and exciting to our construction group. Porches and decks welcome family and friends to enjoy lake views from outside, while reclaimed flooring from Pioneer Millworks and custom cabinetry by NEWwoodworks offer warm elegance inside. The design takes advantage of the site with large windows and walk-out lake access on the lower level.

Location: Naples, NY
Architect/Builder: New Energy Works
Size: 3,320 sq ft

View the entire case study here.

lakeside_charm_exterior

The porte cochère of Tom and Maureen’s home has become a popular gathering space during parties and large family functions.

canandaigua_lake_home_great_room_timber_truss

Inside the home, the great room offers intimate volumes while capturing views of the trees and lake outside.

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Crafted by NEWwoodworks, the cherry cabinetry will continue to deep in tone and character as it naturally ages.

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