A Passive House Design (with a Few Curves Thrown In)

passive house designUnlike many panelized home builders who enclose their home shells using standard XPS and EPS foam core SIPs exclusively, Bensonwood builds many of its own structural, insulated wall and roof panels to realize the visions of its in-house design team and outside architects alike, while reducing waste by eliminating cutouts for doors and windows, which are not recyclable and end up in landfills.

Our walls feature dense-pack cellulose for insulation (a renewable, recycled product), and can be easily upgraded to extreme R-Value and air tightness for Passive House levels of performance. They also incorporate our Open-Built® chases for easy access to wiring and plumbing.

passive house curvesPerhaps best of all, our custom panels can accommodate curved walls and join complex, compound roof pitches to realize the contemporary designs of even the most innovative architects. One such Passive House design, by Jonathan Knowles and Laura Briggs of Briggs Knowles Architecture + Design, is a strategically sited home on a wooded lot in the Hudson River Valley of New York. Passive House is a rapidly emerging standard requiring that buildings use extremely small amounts of energy for heating and cooling.

The striking 3-bedroom, 2.5-bath house re-imagines the often utilitarian designs of the Passive House vernacular with its own unique curvilinear aesthetic, open space plan and multi-level views.

passive house walls panelThe first-floor plan includes a living area with a wood stove and screened porch, a separate kitchen and dining area, 2 bedrooms, 1.5 baths, a mechanical room, and a polished concrete floor. The dining area and one of the bedrooms are built into the curvature of the outer wall design, creating interesting interior spaces and angled wall partitions.

The second-floor plan has a generous, curved master suite complete with a large walk-in closet, sauna, bamboo wood floor, balcony, and dramatic, cantilevered porch. Rounding out the second floor is a large playroom open on one end to the living area below.

Bensonwood delivered and rapidly raised the home shell in the middle of winter, with R-49 roof panels and R-35 wall panels pre-installed with Zola triple-glazed windows. From there, the on-site builder, John Hommel of Ashley Homes, added additional layers of insulation to easily bring the house up to Passive House levels of performance.

A Classic Barn for a Classic Car Enthusiast

elevation of classic car garageAre you one of those people who owns a classic car and longs for an appropriate place to keep your dream machine? That was the impetus behind one car enthusiast’s desire to physically connect his passion for collectible automobiles to his existing 1930s Delaware residence. The owner, who has an existing garage for his family cars, tools around in a ‘76 Triumph TR6 and hopes to acquire more vintage cars once his new timber frame car barn is completed next month. The result will be an architecturally true barn and connector addition that can drive home, literally, his automotive passion.

The barn and connector were designed by Patrick McDonough, of John Milner Architects, to integrate and reflect the style of the existing main house while adding to the majesty and proportion of the façade.

classic car garage elevationBensonwood was hired by the owner/builder, a repeat client, to fabricate and raise the free-standing timber frame barn shell. The lengthy connector joining the house with the barn will be site-built by Dewson Construction Company, a Delaware-based general contractor and construction management firm.

The car barn, with four bays and an epoxy-painted concrete floor to showcase the vehicles, will be a traditional design, with a single, 28-foot-long glulam girder to achieve a post-free opening to the shed bump at the rear of the building. Roof trusses on either end of the barn will have straight bottom chords, with three arched glulam bottom chords on the trusses in between, defining the vaulted space. The structure includes a central king post with decorative and structural steel reinforcement plate custom fabricated by Bob Taylor of Alstead, NH. A multi-purpose loft with ladder at one end of the structure will add useful square footage to the plan.classic car garage interior rendering

CAD DRAWING vintage auto barnTo integrate the architectural style of the barn with the main house, an eight-sided “lantern” cupola will be stick-built atop the barn by a local company to match the cupola on the main house. In addition to its unifying aesthetic, the copula will allow in natural light to illuminate the timber frame interior and future car collection. Dewson Construction will then finish the barn with a brick exterior to match the main house.

The classic car barn, currently in fabrication at our Blackjack Crossing facilities in Walpole, NH, is slotted for a September 15 raising, with the complete weather-tight shell installed within a week’s time.

Contemporary Polynesian Pool House on the Charles

polynesian pool house

Photo by John Linden

A young couple with children asked Charles Rose Architects to design a “contemporary Polynesian hut” for their property southwest of Boston on the Charles River.

timberframe pool house roof

The design called for indoor and outdoor sitting and dining areas; kitchenette; stainless steel outdoor shower; bath/changing area; 1,500 SF deck with in-ground hot tub; and a fire pit with built-in seating. The architect carved out one corner, creating a covered, but open and airy, outdoor lounging area.

Everyone agreed that the new pool house should be wood construction — primarily to match the look and feel of an earlier project the architects designed for the clients, a wood-clad “play barn” with two large rooms, divided by an outdoor space framing views of an adjacent pond. That’s where Bensonwood came in.

pool house interiors

Photo by John Linden

pool house timberframeOur timbered Douglas fir frame supports an asymmetric hip roof whose peak is pulled off-center so that the pool house subtly connects with the geometry of the existing play barn. Our timberframer C.J. Brehio was the job captain, and did a masterful job executing complex compound joinery. Custom concealed steel connections were also used throughout the building. Western red cedar lends rich, warm hues from exposed beams, custom doors and millwork.

complex compound joineryThe stainless steel shower structure was was a built by Alstead, NH welder and metal sculptor Bob Taylor and has a unique sand blasted finish and unique hardware such as flush mounted tapered screws and a big piano hinge for the door.

Other wood used includes: mahogany for the windows; ipe (pronounced “ee-pay,” aka Brazilian walnut); and bamboo. See more photos on our Houzz page here.​

charles river pool house

Photo by John Linden

Aquatic Dreamhouse Required Fluid Construction Strategies

Pool-Centric Vision Posed Technical Challenges

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Faced with a significant technical challenge, Alfandre Architecture, PC and its construction company, EcoBuilders Inc., teamed up with Bensonwood to fabricate and install the large-span glulam timbers and insulated shell of this spectacular 6,000 SF timbered dream house — all built around a large 2,000 SF indoor pool — for their client, a retired couple in Putnam County, NY.

pool house living areaThe challenges included engineering the long timber spans of the pool room, humidity control and the sensitivity of the rocky build site, to name a few. Here, Bensonwood’s expertise in timber engineering, off-site fabrication of panelized assemblies and rapid on-site installation was instrumental in realizing the ambitious project with minimal disruption to the ecology of the home site.

The house, recessed into the bedrock of its 15-acre site, was designed by architect Rick Alfandre to complement its natural setting, with the pool room both anchoring the design and providing the homeowners with the physical, social and emotional benefits of their daily one-hour swim. To add to the ambiance, the light-drenched, four-bedroom, five-bath home has over 70 triple-glazed windows to draw the surrounding landscape into its interior.

pool in upstate ny dream houseGC and local construction company, EcoBuilders Inc. (owned and operated by Rick Alfandre) completed the foundation and walkout walls, first floor system, infill, window installation, mechanical systems, and finishes.

From this project, Bensonwood went on to contribute the timberframe and roof panels for Alfandre Architecture’s offices across the Hudson River in New Paltz, NY, for which Alfandre is seeking LEED Gold certification.

For more photos, visit our Houzz Page.

On the Boards: Cape Cod Pool House

cape cod pool house

In keeping with this month’s “Everyone into the Pool” theme, here is a charming little pool house we are helping fabricate on Cape Cod.

Designed by Rebecca Elsy Ribeiro of D. Michael Collins, Architects, the energy-efficient building features classic colonial carriage house styling with cupola and a sheltered overhang.

Bensonwood is crafting the timberframe, insulated wall and roof panels, and installing the Marvin Ultimate windows and a Marvin outswing bifold door. The timberframe consists of Douglas fir glulam timbers for the main structure and for the exterior timbers​.

Kenneth Vona Construction, a company that very much shares Bensonwood’s values, will be the builder. KVC is not only one of New England’s oldest and most respected custom builders, it is also one of the greenest.

pool house elevationsTheir ideal six-sided building envelope is one that breathes, insulates against losses, sheds water away for sustainability and remains energy efficient and reusable. Like Bensonwood, KVC believes a commitment to environmental responsibility results in immediate payback and comfort.

timber frame design for cape cod pool houseD. Michael Collins, Architects is a small, but high-quality design firm established in Natick, Massachusetts, in 1987. They specialize in new custom homes, additions and renovations, small scale commercial, institutional and historic restoration projects.

Most of the firm’s projects are located in Massachusetts, but they also have projects in Maine, New Hampshire, Vermont, New York, Colorado, Florida and the Caribbean.

We’ll profile more design-build collaborations with D. Michael Collins, Architects and Kenneth Vona Construction in the months ahead.

Customized Unity Xyla 212 Sits Softly on the Land

xyla 212

Artist’s rendering of our standard Unity Homes Xyla 212.

Dan Farrell and Melora Kennedy have long been interested in nature conservation. So when they wanted to build a healthy, comfortable, energy-efficient home — close enough to town that he could walk or bicycle to work—a friend, builder and energy consultant, Mark Snyder, suggested they call Unity Homes. Dan works for the Vermont Chapter of the Nature Conservancy as their Conservation Information Manager/GIS Analyst. Melora teaches preschool and kindergarten. The “GIS” in Dan’s title stands for Geographic Information Systems: a science which lets us visualize, question, analyze, interpret and understand data to reveal relationships, patterns, and trends. In the conservation context, GIS would come in handy in evaluating the impact his new home would have on his sloped, 8.9 acre parcel of land, with its old field species and natural plantings — some edible — as well as diverse wildlife crossings.Screenshot 2014-06-23 10.06.14 Unity’s low-waste off-site fabrication and rapid on-site assembly — coupled with its natural materials, extraordinary energy efficiency, and energy-sipping mechanical systems — will all help to reduce the carbon footprint on the sensitive landscape. Their Xyla 212, customized for a walkout, is heated and cooled with an air source heat pump and an optional ERV (Energy Recovery Ventilator) to condition air with minimal energy loss. Both HRV (Heat Recovery Ventilator) and ERV systems are vastly more energy efficient than plain ventilation systems or exhaust-only systems with no heat or energy recovery. Despite its higher up-front cost, Dan chose an ERV system for its edge in operating efficiencies, air filtration, degree of comfort (through greater humidification/dehumidification control) and environmental impact.

air pohoda ashp

The Air Pohoda ERV used in the Farrell home in a special housing devised by our Building Systems team.

Unity’s standard HRV system is designed to recover approx 80% of the heat in the air that is being exhausted from the house, while the ERV (Energy Recovery Ventilation system) is expected to recover over 90%. Given the ERV’s added efficiency, there would be a relatively short payback period on its premium cost over the standard HRV system. In comparing the ventilation systems, the ERV units are expected to save about 1315 kWh per year over the HRV system. At $0.15/ kWh, that comes to almost $200 per year at the current electric rate, with those savings continuing to rise as electricity rates increase. The Return On Investment calculator projects an 11-year payback on the $3,000 additional investment over the cost of a comparable HRV system.  (Source: EPA Greenhouse Gas Equivalencies Calculator.) IMGP7792But for Dan and Melora, it wasn’t just a matter of dollars and cents. Framing it more in conservation terms, the 1,315 kWh per year saved by their ERV over the HRV, is equivalent to 102 gallons of gas, 97 lbs. of coal or 21 barrels of oil. Saving that energy would be the carbon equivalent of 23 tree seedlings grown for 10 years or 0.75 Acres of forest grown in one year. The 2-bedroom, 1-bath Unity Xyla, with its super-efficient 1,028 SF first floor space plan and optional 939 SF walkout level, celebrates the lagom values at the heart of all Unity Homes. Roughly translated, lagom is a Swedish word meaning “not too much, not too little —  appropriately balanced.” The home is neither too big nor too small, but just right perched lightly on its steeply sloped site and in-balance with its surroundings. work in progress Xyla 212Entry is from the up-slope side (and future patio) directly into the living area, which is open to the eat-in kitchen and second bedroom. Down a short hallway and adjacent to bedroom two is the master bedroom and common bath. Dan and Melora plan to leave the ground floor, with its separate down-slope entry, unfinished for the time being, but it will eventually have a rec room and second bath. With the home fabricated off-site and assembled on-site over late spring/early summer, the Farrells expect to be in their home by mid August.

Texas Prefab Lake House

austin texas lake house 1 An admitted This Old House fanatic, Matt Risinger had grown up watching the PBS television series when, in 1989, a program aired that would change his life. The Wickwire Barn Series—the second time Bensonwood had appeared on the long running home improvement program— featured Tedd Benson and an old barn being converted to a new house: a project Matt had dreamed of building for himself someday. It became the seminal moment in his decision to become the best builder he could be.

Mette Aamodt AIA and Andrew Plumb AIA

Mette Aamodt, AIA & Andrew Plumb, AIA

Fast forward nearly two-and-a-half decades, and architect Andrew Plumb of award-winning Aamodt / Plumb Architects in Cambridge, Massachusetts, is looking for a builder to help assemble and finish out a highly custom modern timberframe ranch home he designed for a special client he has known for years. The lakeside projectTEXAS PREFAB, expected to approach near Passive House standards, would have an aggressive build schedule of one year, and it needed to come in at a fixed budget—so Andrew knew it had to be done right. His first thought was to call Bensonwood for its expertise in the sustainable fabrication of high performance homes, and his second thought was to call green builder, Matt Risinger, now of Risinger Homes, to say Tedd Benson’s company would be fabricating and installing the home’s shell. With the name “Benson” still fresh in his mind after a quarter century, Matt jumped at the opportunity. The home plan, viewable on the Aamodt / Plumb website, is a interpretation of the Texas Ranch vernacular, with two gabled buildings joined by a light-filled entry hall. Designed for a young family, this prefab home strives to create a relaxed, contemporary feel through the use of natural and reclaimed materials, ample daylighting and a thoughtful relationship to the site.

MATT RISINGER

Austin, Texas green builder Matt Risinger

“We sought to create a warm modern atmosphere through the interplay of simple forms, materials and natural light,” says Plumb. The play of the modern and rustic is achieved through material choices and elemental forms. Japanese (Shou Sugi Ban style) charred wood siding, mesquite and ash flooring, and an oversized FireRock masonry chimney and fireplace add a dramatic touch both inside and out. texas green prefab architects renderingThe light-filled open interior, with its elegant but simple timberframe, richly-finished flooring and high-end fixtures, perfectly complements the striking exterior while framing the surrounding views. Matt Risinger asserts that, “The most sustainable house is a pretty one. Architect-designed houses will be loved and cared for because they are beautiful. Ugly houses will fall into disrepair and be torn down eventually.” fireplaceBeyond the aesthetics, this house was designed to coast through the hot parts of the day with little need for air conditioning. This is achieved through rigorous attention to air sealing and our panelization process using super-insulated walls. All the exterior claddings are installed over a rain-screen air gap. The roof, wood siding and even stucco have an air gap behind them so that the potential for water intrusion over the life of the building is minimized. Risinger installed super-efficient mechanical equipment to make the best possible use of the resources consumed. 95%+ efficiency gas equipment, super high-efficiency AC, Ultra-Aire Split Dehumidifier prevents mold and allows the owners to keep thermostat settings high when the building is unoccupied.YOUTUBE TIMELAPSE IMAGE You can watch Matt Risinger’s YouTube video of the home being assembled here. Once the project is completed and finish photos become available, we will revisit this home to detail its space plan. Stay tuned.