Who Knew Plywood Could Be Elegant?

October 30, 2019 to May 11, 2020:  I’d long admired the cabinets made by my friend Eric Wallner for his own home. The design is simple, functional, and inspired by the work of Frank Lloyd Wright. Just like at Taliesin and dozens of his Usonian homes, they are made of humble plywood. Doors swing from unadorned boxes by way of “piano hinges”—-full length strips of steel just like you’d see closing the lid of a piano. ericBuilt-ins like this were promoted by Wright as a way to save space and save money. Tucked along hallways, they became an integral part of his post-World War II design vocabulary. Now the “everyman” could afford a thoughtfully designed space—not just another cookie-cutter box. Plywood was celebrated as new and modern—an industrial material beautiful in its own right.  FullSize 1Like Wright’s, Eric’s design is constrained by the dimensions of a 4×8 sheet of plywood. Here is his initial sketch for two 48” wide x 24” deep x 72” high units. I needed a wardrobe for each bedroom and one for coats at the entryway. Plus a linen cabinet.  CCI_000002When I later asked for 72” long units—-48” for hanging clothes and 24” for shelves, Eric devised this pleasing asymmetrical scheme. He ordered 15 sheets of 3/4” thick 11 ply formaldehyde-free birch plywood and got to work. He promised that all that would be left on the shop floor would be a pile of sawdust.  20200421_090641I chose birch over a more exotic veneer because it’s super cheap. Birch plywood is considered “case grade”—meant to be used for cabinet backs and sides, not fronts. Look closely and you’ll see the telltale “footballs”. These patches are glued in at the factory to replace troublesome knots and are quite certainly not meant to show. We think differently.

Inexpensive stainless steel furniture legs from IKEA take the place of boxed-in toe kicks. Slender stainless steel handles take the place of knobs or latches for barrier-free accessibility.  Cabinet backs are dispensed with because painted drywall is fine. Butt seams are banished in favor of elegant offsets. 11 Edges are left exposed, not hidden behind a strip of veneer.  And every inch is lovingly sanded to baby bottom smooth. The wood grain becomes almost iridescent and the whole assembly is a pleasure.   Thank you Eric!12

Mud & Paint

December 27-April 14:  It’s a good thing that the dreary work of mudding & taping coincided with the dreary days of winter (and the better part of the shut down). It was 20 years since I’d last picked up my drywall trowel and unspooled a roll of tape, but the skills came back. I started in the attic to make sure. 

Drywall and the mud that makes it seamless are one of the few modern building materials that are relatively benign.  Drywall is approximately 75-90% gypsum (calcium sulfate), 10% cellulose and “trace amounts” of proprietary additives. Gypsum is considered an abundant resource and available worldwide. It’s most commonly extracted from vast open pit mines, manufactured in vast factories, and shipped in vast quantities. Mud (joint compound) in it’s conventional ready-mix form is 60% limestone, 32% water with the rest talcum, mica, perlite and a mix of proprietary ingredients including fungicides, preservatives, and polymers. The USG compound I used has been granted a Green Guard Gold label—a third party certification that tests for chemical emissions to the indoor environment (mostly VOC’s).

I could have made the more environmentally sound choice (were I willing to shoulder more work) by buying compound in its powdered form. This product has less packaging waste (all those 5 gallon buckets), transportation waste (all that factory added water), and doesn’t contain nearly as many mystery ingredients. I did order the bulk of my ready-mix in boxes (with plastic bag liners), not buckets. 

The drywall scraps (despite all efforts, there were a lot), got tossed to the edge of my property and covered with rotten straw. Gypsum is a good soil amendment when you want to raise the pH of your soil (to make it more alkaline). I chopped a few scraps and threw them in the hole where I planted a lilac bush. This unconventional solution may have raised eyebrows in the neighborhood, but saved me the expense and hassle of a dumpster.  lilac

For paint, I chose a soft white in a matte finish for its timeless appeal. An eggshell finish is more practical but I object to the shine and was worried that my mud job wouldn’t be up to the challenge. A flat or matte finish hides better.

Just as I did for the exterior, I purchased organic, low odor, zero VOC paint from South Carolina manufacturer Ecos Paint. The paint is certified Red List Free (free of “worst in class” chemicals prevalent in the building industry).

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It’s non-toxic and biodegradable. It doesn’t contain any algicides, mildewcides, pesticides, herbicides, or fungicides. Ecos is one of few companies with a completely transparent label—all ingredients are listed. Their product is especially needed for those with chemical sensitivities and other vulnerable people.  

The paint covered well and was reasonably priced. I think companies like this who are striving to make a difference should be rewarded with our dollars.

Once the brushes and rollers were put away and the tarps folded up, I breathed a sigh of relief. I was finally able to enjoy the feel of my transformed space without scrutinizing every dip, drip, skip and bubble.

polished June 2020

OPEN HOUSE Saturday July 18, 2020

Saturday July 18 from 10 am to 5 pm:  Are you looking for something interesting to do this weekend that’s not too far away?  Why not stop by and have a look at Spring Green’s first net-zero energy home?  Construction is almost complete, except for a few finishing touches.  I now have 6 months of solid numbers on solar production—and if you ignore a few nitpicky details—Poem Homes is not just net-zero.  It’s producing twice the energy it consumes!  But wait, I’m not getting rich.  As of July 8, I’ve banked just $35.13 with the utility company.  20200609_074430Speaking of finishing touches, my favorite (so far) is the cedar window sills and the cedar door jambs.  What was in my mind’s eye has become a beautiful reality thanks to the careful attentions of Eric Wallner.  Check out the patio door jamb, a real Frank Lloyd Wright move the way it goes from outside to inside with seemingly no break (but there is).

When you visit, you’ll find masks and hand sanitizer at the door.  Outside, we can be more free.  I look forward to seeing you—and it doesn’t matter whether you’re thinking of buying or building or remodeling.  Poem Homes is all about learning and conversations, the exchange of ideas and contacts, and being grateful for the chance to fashion a way to live more sustainably. 20200713_195123

 

OPEN HOUSE Saturday June 13, 2020

Saturday June 13 from 10 am to 5 pm:  Are you net-zero curious?  Stop by today and check out our 7kW solar array and learn how it powers this super-insulated all-electric home.  Equipment is installed and we now have modern conveniences like bath vents, AC and lights.  Super energy efficient, quiet, LED, and dark-sky friendly of course.  Flush toilets are nice too—especially at 1.28 gpf (gallons per flush).  Cabinets, countertops, and other finishing touches are going in, all vetted for ultra-low chemical additives like formaldehyde.  Notice too the features that make this home barrier-free.

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Because of Covid, I’ll be asking all visitors to wear masks and use hand sanitizer upon entering—both of which I’ll have on hand for your use.  Outside, we can social distance.  I’m looking forward to seeing you!

OPEN HOUSE Saturday February 15, 2020

Saturday February 15 from 10 am to 5 pm:  Stop by today and see what we’ve done!  Drywall is up and mudding the seams is “in process”.  Over the next few months, finishes—from paint to cabinets to counters—will be installed, all vetted for their ultra-low or non-toxic properties.  Ask me anything you want about the construction so far—like how to source healthy materials, what makes it super-insulated, what makes it low-carbon footprint, and what makes it zero net-energy.house

A beautiful, sparkly snow fell on Sunday.  It shut down solar production for the day and the next and the next.  That’s the downside of a roof-mount install.  A ground-mount (on a rack) could be swept clean.  My low pitch roof (3:12) doesn’t help.  Snow would slide off a steeper roof faster.

How do I know when the PV (photovoltaic) system is working?  The easiest way is to look at the meter on the side of the garage.  If the arrow is pointing toward the street, I’m sending kWh’s to the grid, and getting paid.  If the arrow is pointing toward the house, I’m buying from the utility.  Of course, it constantly varies depending on sun and clouds and whatever equipment I might be running.  I’m paid 3 cents/kWh for my production.  When I buy, it’s at 12 cents/kWh.meter

There’s also an app for that.  I can look at my phone to find out exactly how much the panels are producing, hour by hour.  Last week a clear day with no snow netted me 31 kWh of electricity.  That’s equivalent to running an efficient refrigerator for 19 days.  It’s also equivalent to the greenhouse gas emissions of driving a car 53 miles.

Dense Pack: Take 2

December 16-January 16:  Nothing is more motivating on a building project than knowing you have put 100% into a task, that it is done, and you are now free move on to something new. As if it were Christmas, I tore open 4 boxes of plastic MemBrain vapor retarder and began hanging it like a curtain on my walls. Of course, it quickly became another labor of love and laborious. Each electrical wall outlet and switch, each wire and pipe, each window opening had to be carefully lapped around and caulked before I could confidently call in the drywallers and the insulators.

I explained the necessity and benefits in my previous posts “The Whys & Hows of Vapor Retarders” and “Hanging the Lid”, written after I’d draped and drywalled the ceiling.

Just as before, the vapor retarder hung long and the drywall stopped short at the edges. Running along the ceiling perimeter and under each window was a 6” gap—just enough room to stick in the insulation hose.

My crew from Accurate-Airtight Exteriors arrived with a box truck fitted with a hopper and assortment of hoses, and a trailer full of bales. They were eager to see how my house was coming along. Last time they were here was in June, when it took them 3 days to pack the ceiling. This trip, they’d need 4 to pack the walls. A lot of their work is retrofit and crawling around in attics and basements. My house was going to be a nice break in the routine, easy—even a little boring.

My walls are 11-3/4” thick. The north wall is 13′-6” tall and 56′ long, with few windows. The bales were slit open in the garage and slowly fed into the hopper. The hoses were draped through a window and down through each frame cavity. Cellulose—non-toxic, biodegradable, and 100% a byproduct of the paper mills up in the Fox Valley—trickled out. It was going to be a slog. Wallace Kennedy and son Nicholas took it in stride, and were a delight to have around.

There are many ways to build a super-insulated wall. My goal was “double Code minimum”—about R-38 to R-45. Here are the basic options I considered:

MANUFACTURED COMPONENT

  • SIP’s(structural insulated panels)
  • ICF’s (insulated concrete forms)

FRAME WALL WITH EXTERIOR INSULATION

  • 2×4 or 2X6 with sheet foam or sheet mineral wool
  • 2×4 or 2×6 with I-joist exoskeleton with fiber insulation

THICK FRAME WALL

  • 2×6 with horizontal or vertical strapping with fiber insulation
  • 2×4 double-stud with fiber insulation

All are interesting and have their advantages. To decide, I turned to my most trusted source for practical advice and solid building science, Green Building Adviser. What method—for my situation—would be the most build-able, affordable, least toxic, and have the lowest carbon footprint? I settled on a 2×4 double-stud wall with dense pack (not loose fill) cellulose, for an R-45.  I’d be happy to talk with you in more depth about the options, pro & con.

bottom plate

Double 2×4 Wall

The house was, of course, noticeably warmer by the time my crew left.  On sunny days, I can turn off the heat and coast on passive solar energy.  Next step: mudding & taping the drywall.

 

 

Mind the Gap: Take Two

December 10, 2019:  Finally, it was time to find out how well I’d done. In the last few days, the electrician had made a lot of holes. Had I followed up with each one? Did they all get hit with caulk or tape?

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Subway Station, somewhere in Great Britain

The energy rater who is shepherding me through the process of getting the house certified through Wisconsin’s Focus on Energy’s New Home Program was arriving with his blower door kit. This was going to be my second of three tests—and the most important. The drywallers were due in a week, and this was my last chance to make things right. I really, really wanted a good number. My goal was a “1”.

An airtight building shell is essential for the kind of house I’m building, and a blower door test is the only way to know for sure you have it. Jim Kjorlie of Kjorlie Design Services has tested hundreds of homes in the Madison area. The best result he’s seen is 1.2 ACH (air changes per hour)—literally how many times the volume of air in the home is changed out with fresh air from leaks in the building shell.

Wisconsin’s Uniform Dwelling Code allows a new home to be as leaky as 7.0 ACH, though studies have shown that the average new home here tests out at 4.0 ACH. Some neighboring states mandate 3.0 ACH. Some really meticulous builders are hitting 0.5 ACH or less. Is all that caulking and taping worth the extra cost? I’d argue that a well-sealed home insures against more than high utility bills: it insures against moisture, mold, mildew, and insect problems. Even so, out of curiosity I ran the numbers on my house through a modeling program called REM Design:

 

Poem Home @4.0 ACH = $908/year heating costs @0.12/kWh
Poem Home @0.6 ACH = $630/year heating costs @0.12/kWh
YEARLY SAVINGS = $278

Jim set up his equipment by propping open the front door and replacing it with a fan attached to an adjustable shroud. The fan slowly depressurizes the house to simulate a 20 mph wind bearing down on all sides. Drafts that normally aren’t felt are suddenly amplified. My friends Eric and Lew stopped by to see how it’s done, and thanks to their sleuthing, we found two major leaks.20191210_133505

Cold air from the mini-split was pouring out the narrow gap between the unit and the drywall. We later found out that the installer hadn’t sealed or insulated the line set connecting the outdoor unit to the indoor unit.  I can stuff this with fiberglass.

The second leak was at the fixed panel of the patio door. A steady draft was easily detected by waving a hand over the crack between the frame and the sash.  I can caulk this.

So how did I do? We got a 1.0. Yeah! “Don’t celebrate yet, Amber” is what Jim didn’t say but implied. He’ll be back for a final test when the house is complete.

Mechanicals

October 14 to January 7:  Now we punch holes. After all the careful air-sealing, after all the work and worry with caulk guns and rolls of tape and spray-foam—it was time to make intentional holes, lots of them.

ELECTRICAL  My electrician got started by extending the service from the panel in the garage to the far corners of the house. I got to help, drilling holes and running wire. It was all new to me, and interesting. Bob Rowen of Rowen Electric insisted on straight runs, artful bends, and minimal slack.

The installation required a few extra steps and probably more wire compared to a conventional home, but in several ways is more environmentally friendly. Most critical is the extra attention paid to air-sealing. Each line coming in and going out is sealed with flexible silicon caulk or flexible tape. Electrical boxes have integral gaskets that compress when drywall is attached. And the vapor retarder was taped to the gasket, providing both a continuous air-seal and vapor-seal.

In other posts, I’ve extolled the virtues of a slab-on-grade home, but here I have to admit that it made running mechanicals harder. In a conventional home, you run freely through wall and ceiling cavities but on this job site they are “Sacred Space” reserved for insulation. You also run through the attic (none here), the basement (none here), and the floor cavities (none here). Instead, I built a chase on top of the loft floor, tucked along the back wall and out of sight from the living room below.

The electrical runs are attached to the loft flooring, covered by a plywood lid that can be flipped up for service at any time in the future. The plumbing pipes are above. Future plans call for a cushioned bench built over top and running the length.crop

LIGHTING  Everything is LED (light emitting diode)—-no incandescent, halogen, or CFL (compact fluorescent lights). LED’s use about 10% of the electricity of incandescents and about half that of CFL’s. LED’s don’t contain the mercury that CFL’s do—and supposedly no hazardous chemicals—but do contain small amounts of heavy metals that can be recycled. I have yet to find a recycler. Do you know one?20200206_105258

LED’s are not only cheap to use, they are cheap to buy. The first bulb I ever saw—just a few years ago–was proudly displayed by a friend who dropped something like $50 on it. For the garage, I chose simple porcelain sockets fitted with 25 cent LED bulbs that are expected to last 22 years, at a cost of $1.20/year. Thank goodness for those “early adopters” who purchase by purchase spur technology along—-but I’m not one of them.20200109_140028Outside, I chose “dark sky friendly” light fixtures. Any fixture that casts light downward instead of upward or outward is good. To be sure, you can look for a compliance label when shopping. For everything you need to know, check out International Dark Sky Association.

A personal pet peeve and (as I learn more), harmful to human and animal health are LED bulbs that cast an eerie, unnatural brightness. It’s the same “blue light” our phone screens give off that we know disrupt our circadian rhythms. When used in outdoor lighting, they brighten the night sky more than other light sources do and effect the survival strategies of nocturnal animals.dark sky KelvinIt doesn’t have to be this way. Look for “warm white” bulbs in the 2700-3000 Kelvin range and a CRI (color rendering index) of at least 90. Notice the difference between my house and my nearest neighbor.

HEATING & COOLING  Building an all-electric, fossil-fuel free home in our northern climate would have been a laughable proposition just a few years ago, but is now possible with the latest “mini-splits”. You’ve probably seen these devices installed in a room addition, office, or small apartment. The indoor part looks like an oversized through-the-wall air conditioner, and the outdoor part looks like a rectangular version of an air-conditioning compressor. The technical name is Air Source Heat Pump (ASHP). I chose the simplest version: single-zone and ductless.

These super-efficient appliances are also super-affordable. Where a conventional house might spend upwards of $20,000 on a heating and cooling system, mine came in under $5000. Of course, this is possible because my house is wearing a thick down parka on top of a wool sweater and a turtleneck—not a sporty spring jacket.

A conventional furnace is overkill for a small, super-insulated house. Ductwork is cumbersome, expensive, often poorly sized, and can harbor dust and allergens. With an open floor plan, and for families who can tolerate some temperature differences from room to room— a single mini-split can work. Daily modifications may be needed, like closing and opening doors for better circulation and closing and opening curtains for better temperature control.20191106_163035The Mitsubishi unit went in mid-October. By mid-November outdoor temperatures were dropping and snow was flying.  Reluctantly, I turned it on. The ceiling was insulated, but not the walls. We were still wiring and willing to work chilly, but the water was on and the plumbers were coming. As it turned out, 2 months would go by before wall insulation went in. I dreaded looking at my electric bill. Good news: those two months of heat were “paid for” by my solar production in July.

More good news: since I broke ground and tapped into the grid (November 2018) until now, I’ve produced more electricity that I’ve consumed. So far, my construction project is “energy net positive” by 2782 kWh. That’s a “carbon dioxide equivalent” of the carbon sequestered by 2.6 acres of forest/year OR the greenhouse gas emissions from 4881 miles of driving.

VENTILATION  People ask me, “Isn’t it true you can build a house too tight?” In a word, no. A conventional house gets its fresh air through cracks in the windows and electrical boxes and random places. That “fresh air” is pulled through dusty crevices and frame cavities and in most homes, formaldehyde-laced fiberglass batts. Along the way, it’s depositing moisture—creating a breeding ground for mold and mildew.

A super air-tight house shuts down random leaks and instead relies on a mechanical system that brings in filtered fresh air. I looked for a system that could dial up or dial down depending atmospheric conditions and how many people and plants and cooks I have over.

Condensation on window panes is the bane of Northern Homeowners and a sign of too much moisture. Stuffiness is unpleasant and a reminder that “indoor air pollution” really is a thing. Damp, stagnant air is more likely to harbor and spread disease. Effective ventilation that dries and dilutes indoor air can limit bacteria, viruses, dust mites, and mold—and prevent allergies and asthma according to the American Lung Association.

Finding the right appliance turned out to be the biggest headache on my “build a house or bust to-do list”. The answer is what’s called an HRV or ERV (heat-recovery or energy-recovery ventilator). Most HRV’s on the market are sized for larger homes or commercial spaces and require complicated ductwork and expert commissioning. They’re not yet common. Contractors I contacted seemed unfamiliar with them or unable to answer my questions. I poured over manufacturers specs and called distributors who could point to a specific unit but not installation details. I finally settled an innovative, ductless, through-the-wall product called Lunos from 475.com  My electrician gave his tacit assent.

The units look simple and unobtrusive, were easy to install, and have the best heat recovery efficiency and noise ratings I found. Working in synchrony, each Lunos (1 in each bedroom, 1 in the living room, 1 in the loft) push stale indoor air out through a ceramic core, heating it up. After 70 seconds, the fans reverse direction. Fresh air is pulled through the ceramic core—and a filter—to deliver a stream of clean, warm air to the room.

lunos crop

Lunos Vent (left of bedroom window)

To meet the high CFM ratings required by Code for year-round bathroom ventilation, we installed ultra-quiet Panasonic fans above each shower.

panasonic

Panasonic Bath Fan (screwed to loft floor)

The Code is silent on kitchen range hood ventilation. I plan to install a high quality ductless hood with carbon filter. For the laundry, I plan to install a ductless condensing dryer. So altogether, we avoided 2 holes (range hood, dryer) but punched 8 big holes (4 Lunos, 2 bath fans, 1 plumbing vent, 1 line set sleeve for the ASHP), and dozens of small holes through the thermal, vapor, and air barrier that is the wall.  There are none through the roof.

Is it really possible to survive winter without burning fossil fuels? I’ll keep you posted on how everything mechanical goes once the house is up and running and occupied.  If you have any questions or can recommend something, please let me know!

 

 

 

 

Inground Gutters

September 30-October 4: Gutters are a maintenance headache and generally, pretty ugly. I decided to try “in-ground gutters”.

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BEFORE: EROSION & SPLASHING

My excavation crew laid down a 12″ deep layer of washed river stone in a landscape-fabric-lined-trench under the eaves.  The trench prevents erosion at grade and splash-back on the siding.  Rainwater flows freely through the gaps in the stone, seeps through the fabric, and drains away into the native sand below. The fabric prevents the underlying sand from working its way up through the river stone and clogging the works.

If I had a basement to keep dry and/or heavy clay soils, I’d need a more robust solution. It would include plastic draintile (slots up) laid within the river stone and run downslope to daylight.  This strategy would serve the same function as downspouts with extenders—to get the water away, fast.

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Shawn & Tyler of Slaney Landscaping & Excavating, Dodgeville

Ringing a house with stone like this is fairly common, and usually done to make mowing easy. Most installations include black plastic bulb-style landscape edging but I decided to take my chances without. It seemed like another maintenance issue (they have a tendency to pop up) and I visualized a “naturalized” edge where stone and grass meet. So far, I’m pleased with the look but worried about future weeds until a friend gave me a tip: “hit ’em with a blower torch”.

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AFTER: IN-GROUND GUTTER—SOUTH OVERHANG

 

 

 

Building a Loft out of a Pine Tree

August 5-October 4: The loft is the most unique feature of my design and so far, the most fun to build. I ordered a 4×8 Douglas Fir beam from the lumber yard, and it arrived in pristine condition—28 feet of straight, clean, perfectly milled wood. I called in Mike & Nino, the two strong guys from Wood & Stone to set it in pockets they had framed out a few weeks earlier.

While sturdy on its own, the beam would need support to carry the weight of the loft. My design called for threaded rods, similar to what you’d find around here supporting the hay mow of a “hung barn”. Just like a farmer who wants a wide open milking parlor, I wanted a large living room free from posts. 3I turned to my friend Bob Rowen, a master electrician who also happens to be good at solving any sort of mechanical problem. He tinkered with wood scraps and presented me with a mock up that we then took to a local machinist to weld up from steel rods and plates.  Thinking ahead, Bob built two wood boxes reinforced with steel channel and installed them between pairs of trusses. At the design stage, I had coordinated with the truss manufacturer to factor in the point load on these trusses, which came with an engineered pattern of webbing & steel plating, along with an extra-wide 2×6 bottom chord.

My worries about drilling the holes and having them come out straight were found-less—Bob devises a jig for everything he does and has a clear road map in his head for each step to be taken. The beam was hoisted up and down several times with block & tackle as we tested fit.

When the last bolt was turned tight, I masked the area with paper and tape and spray painted the steel matte black (note: the spray paint came straight from the hardware store, not vetted for low VOC or other chemical emissions). We think the rods turned out pretty handsome, with their extra-wide bottom plates and over-scaled double nuts.

Road trips to Timbergreen Farm became our pleasant distraction over the next week. Just a few miles up the road, consulting forester Jim Birkemeir runs a milling operation and solar kiln. His stash of lumber from the Driftless includes white oak, red oak, black oak, hickory, black walnut, ash, cherry, and other hardwoods but I had my heart set on pine. Humble, easy-to-work-with, aromatic pine. He had just the thing: rough planks harvested from a stately White that had stood strong in the Village for a hundred years. He agreed to mill it for me. 9

Our first haul included 2×8’s for ledgers and 2×6’s for floor joists. We sorted for warp, wane, and knots. We accepted some scant thickness or width and agreed that skips (saw marks) added character. Pieces that had pronounced staining or dark streaks were pronounced “uglies” and went in the mechanical room. Working with minimally processed wood takes a different mindset. You have to love the fresh smell and slight stickiness, the lack of conformity, and the limits of band saws. The payoff is rustic charm and knowing that this is about as low-carbon footprint for a building material as you can get. 10

People are surprised to learn that you can build with “unstamped” wood—wood that doesn’t come from a lumberyard and doesn’t carry a grade stamp. The Wisconsin Uniform Dwelling Code allows it, but downgrades it to #3 (most framing lumber is #2). My joist spans are short (under 10′), and the design load is low (“attic with storage”—not “habitable space”).

Just as we did for interior walls, we installed vapor retarder and drywall before attaching the 2×8 ledgers in place. We lag-screwed the ledgers to the inner 2×4 wall and set the 2×6 floor joists temporarily with scraps of plywood. 11

The original plan was to support the floor joists on a 2×2 nailer but a mock-up looked clunky. I also considered decorative joist hangers, but they looked busy. Bob had a better idea. Why not use an angle iron? He ordered it up from a local shop (raw steel for the kitchen and stainless for the bathrooms) and we spent several days laying out a pattern of holes and patiently drilling them out. I helped, then set up an ad hoc assembly line to spray paint the dozens of washers and bolts we’d need to attach the angle iron to the ledger and the joists to the angle iron.

Finally, each joist was top screwed into the ledger, blocking, or the beam via a concealed pocket hole.

Our next foray to Timbergreen was to pick up full 1” thick pine flooring, milled from the same tree. Jim had neat piles ready for us which we sorted for width and quality. As before, the best stuff went to the kitchen. Never mind the discoloration from where straps held bundles together in the kiln and unevenness from thickness differences and skips. My job was a hands & knees operation up in the loft—running the air nailer—while Bob manned the saw below.

The loft is a storage loft. By Code, it’s an “attic”. It doesn’t qualify as habitable space, because the ceiling is less than 7′ high. The advantage is that I don’t need to install a guardrail, and I don’t need a proper stair to it. In lieu of a basement, I at least have some space for junk but am still forced to downsize. The disadvantage is that it’s not really convenient, and you can’t really stand up.

The loft is also a mechanical chase way. The electrical runs are now in place along the back wall and plumbing will come next week. Tucked along the back wall, the chase isn’t visible from the living room. 20

The idea of the loft took shape in the design phase as I settled on a shed roof (facing south) for the PV solar panels. But even if I kept the slope as low as possible—3:12 for a metal roof is pretty much the limit—I’d still have a lot of space above the bathrooms. Frank Lloyd Wright did it, but I didn’t want a 13′-6” high ceiling in my bathroom. I like vaulted space but I also like cozy. Having a wood trellis-like or pergola-like structure overhead was appealing, and having a low entryway give way to a grand space as you turned the corner into the living room seemed like a better way to channel FLLW. 19

The raw and rustic nature of the loft will animate the more contemporary forms and materials I’ll use elsewhere in the house. It will bring my affinity to nature indoors, and restore my spirit especially over the long and drab Wisconsin winters. Research shows that nature-connected design makes people healthier. It improves our emotional state and reduces our blood pressure, heart rate, and stress level. It increases social interactions and creativity. But architect Frank Lloyd Wright said it better:

“Wood is the most humanly intimate of all materials, and the most kindly to man.”

Rooms Take Shape-Interior Framing

July 18-October 10: People seem to like big, open, vaulted spaces and many a visitor has “oohhed” and “aahhed” over the barn-like quality of my Poem Home. I almost hated to call in the crew to build out the interior rooms, but it was finally time. The first step was to install the missing strip of drywall at the ceiling. That’s the 12” gap down the length of the building where the insulation crew accessed the ceiling cavity just a few weeks earlier. 2Once sealed up, top plates were screwed through the drywall into blocking between the roof trusses and studs were dropped down to bottom plates anchored in the slab. At exterior walls, the framing was held 3/4” shy and the last stud left loose, so I could slip in drywall later.

This isn’t the usual sequence. Conventional practice has all the framing done before drywall shows up. But for a super-airtight house like mine, you take extra steps to shut down air movement. In the same way that you want your down parka to cinch up at the wrists and waist when you venture out in sub-zero weather, you want your exterior walls to block drafts—-whether those drafts come from outside or from the volume of air inside the building. Insulation works best in a dead-air cavity—-in my case 12” of it sandwiched between plywood and drywall. 7

To maximize space for insulation, and to save on the cost of wood, the interior walls abut “ladder blocking” instead of doubled-up or tripled-up studs. The crew from Wood & Stone got the interior walls up in just 2 days. Fitting sections of vapor retarder and drywall between the ladder blocking and the new walls was my job, and that took longer.

Here’s are plan-view sketches that explain why I took this extra step. In conventional construction, interior walls are attached directly to the exterior frame. The first sketch shows that when built this way, air can pass from an opening in an interior wall (like an electrical outlet) into the exterior wall. Even when packed with insulation, air can move through and carry with it warmth and moisture—wasting energy and risking condensation within the colder outside wall. In the second sketch, a continuous vapor retarder and drywall is in place before the interior wall is permanently attached, blocking air movement.

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In this house, the drywall serves an additional function. Just as I did for the ceiling, I need to have drywall in place before the insulation crew shows up next month to blow the walls. Conventional batt insulation (like pink fiberglass), can simply be placed in an open cavity but blown-in insulation like cellulose needs an enclosed cavity. One way to do that is to staple a fabric across the wall studs. But my crew asked for drywall, promising it would make for a better job and save money. I’ll need to leave them a 6” gap at the top of each wall and at the bottom of each window so they can access each bay with their tubes.

For the plumber, I built a half wall inboard of a section of drywall at the laundry so his pipes don’t use up space in the exterior wall better left for insulation. This also eliminates any risk of freezing and makes the plumbing accessible for future repairs or replacement.

Next, I installed 3/4” plywood blocking between studs wherever grab bars might be needed in the bathrooms. The blocking runs horizontally behind the toilet and continuously through the walk-in shower. Plywood also covers the 6 foot high shower wall on both sides, for vertical and/or horizontal applications.

It was Bob Rowen’s idea to secure the shower wall with a section of square stock. He sketched out a 5 foot long bar with metal plates and had a local shop weld it up out of stainless steel. It’s bolted through the end studs and to the loft floor above with T-nuts.

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While the walls went up fast, the details took time. Fitted out, the rooms have each taken on their own shape, and they feel right. The size and proportion of the bedrooms is pleasing, and the bathrooms work. The “great room” stills feels big, and with the loft in place (see next post)—still feels like a barn. And that’s a good thing.

OPEN HOUSE Sunday November 24

Sunday November 24th from 10 am to 5 pm:  Turns out, we got slammed by freezing temps early this year. But not before this stunning rock retaining wall got in the ground, thanks to my friend Lew Lama and his crew at Wood & Stone. Come see it and explore it in all its sublime charm. 20191114_142803It all started when a dump truck off-loaded a few boulders from a farm in Ridgeway.  Then, smaller stones of mixed provenance snagged on the cheap as overage from Lew’s other projects. These were sorted & stacked as bottom layer, middle layer and cap layer.  Loads of crushed limestone, washed river stone, and assorted fill material stood at the ready.

The wall rose steadily, battered back and keyed together, to reach the string line set to house grade.  Mike & Nino set the biggest, baddest bolder at the Southeast corner.

When filled with topsoil, I’ll have a level vegetable garden right outside the door.  Please join me on Sunday to talk nice about local materials, craftsmanship, and energy-efficient building.

 

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