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:
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 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.
This fall, our friends at the Timber Framers Guild will raise the new Gateway Community Visitor’s Center in Schuylerville, NY. The new timber frame building will be constructed at the site of General Burgoyne’s surrender in the Revolutionary War and will serve as the starting point for tourism of historic sites in the upper Hudson Valley. From September 5th through the 15th, instructors will work with more than fifty students and volunteers to process approximately 24,000 board feet of locally sourced white pine and red oak timbers to form the community center.
Mike Beganyi, our New England representative and timber frame designer for the Schuylerville Community Building Project, and Timber Framers Guild Project Manager Neil Godden have incorporated characteristics of the Dutch barn frames native to the area into the Gateway Community Visitor’s Center plans.
“The timber frame is a modern take on a traditional Dutch style barn that was common in the Hudson Valley”, states Beganyi. “The traditional design has been adapted to meet program requirements for a visitor center which will house interpretive displays rotating exhibits, and host community events.” Large anchor beams with thru tenons and celebrated joinery will tie the frame of locally harvested pine and hardwoods together.
A community hand raising of the Gateway Community Visitor’s Center frame will take place on September 14th and 15th.
Since 1988, the Timber Framers Guild has collaborated with communities to create over seventy-five timber frame structures. Throughout their time, they’ve worked in the US, Canada, Suriname and Poland and have built timber frames for bridges, market pavilions, picnic shelters, park structures and house frames for a Habitat for Humanity affiliate.
When the lot faces south and the view is of Mount Hood, only great design should result. The 3,600 square foot home encompasses one floor living with a tower room for getting away and a garden level for guests. Natural material, intimate volumes, and local craftsmanship make living here easy.
Jim and Pam, the homeowners, wrote:
“It has been a great ride! Once we got into the timber raising, your crew showed their colors. They were fun to watch and talk to – a great bunch. What a good adventure for us…wow, it is a real cool house. I will cut this short since I could go on and on – thanks for your passion and help and guidance.”
Read the entire case study on Cascade Range Outlook here.
Photos by Loren Nelson.
Home & Design featured one of our East Coast timber frame homes in a recent edition of their magazine. Architect Mark Kohler ‘went out on a limb’ and purchased five acres of land in Woodbridge, Virginia after visiting a client’s job site in 2001. The Kohlers envisioned a rustic retreat crafted from natural wood, stone, and glass. When Mark’s drawings were near completion, he reached out to us to supply Douglas fir timber framing and reclaimed antique heart-pine flooring (from Pioneer Millworks) for the house. Mark stated,”You associate timber framing with vacation homes in Colorado. It adds to the character and warmth.”
Read Home Design’s take on the project below.