Featured Project: A High-Performance Vermont Farmhouse 

An Interview with Bensonwood Client Stephen Ferber

Moving from a cherished mid-nineteenth century farmhouse, why did you decide to build new?
For the past 37 years my wife and I had been living in a 150-year-old Greek revival farmhouse on 40 acres. Retired now and in my mid-sixties, I wanted to downsize somewhat but wasn’t willing to compromise on what I had. Ultimately, three or four things came together in making the decision: First, I wanted to downsize to make it easier on myself. Secondly, I had made a deadline to retire from my job. Third, we wanted to move closer to family and my wife’s work: she works at Lyndon State College. Lastly, I wanted the new energy-efficient home to be a reward for all our hard work.

Why did you decide not to renovate your old house?
Our drafty old house cost $2,400 a year to heat, but that wasn’t the main consideration for building new. I had an energy audit done by the Efficiency Vermont folks, which showed us where the problems were, but I wasn’t willing to compromise the architecture by adding layers of insulating material over architectural features. I didn’t want to see beautiful Vermont granite block covered by insulating board.

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I know you were anxious to get into your new home as soon as possible. Did that affect your decision in choosing Bensonwood?
To be honest, I would have preferred the overall quicker turn-around that the pre-designed Unity Homes plans offer. We didn’t necessarily need a custom house designed from scratch, but we wanted more customization than Unity Homes could provide, so we went with Bensonwood. During the planning stages, we gave quick answers to questions posed by your architect Chris Adams and project manager Tony Poanessa in order to move the process along. We didn’t want one day lost.

Our old house had sold in four days, much quicker than we thought, but that meant we needed to rent while our new home was being built. Our old 40-acre property was deemed organic, which made it of special interest and why it sold so fast. The Jasper Hill Farm cheese people bought the home and property. Among the many renowned cheeses they produce is the organic Bayley Hazen Blue cheese you find featured on high-end restaurant menus.

So while the design process turned out to take a bit longer than we expected, the construction is going quickly and we should be in by the holidays.

What were your design considerations?
I wanted to start with a clean sheet of paper. I basically wanted to repeat my setup by building a farmhouse with a garage that looked like a barn. In my old house we had a four-bay garage and a large woodworking area. And while I wanted to recapture some of this space, I didn’t want my new house to look like a McMansion, with an enormous looking four-bay garage, that would stick out like a sore thumb in its rural Vermont setting. So we wanted the garage to look like a barn, with red-stained, rough-sawn, vertical siding—to make it look like two buildings with a connector.

In the broader sense, I have a real sense of place. We very much wanted to blend into the local vernacular. The home needed to look like an old New England farmhouse, not Adirondack style with orange stained siding—or modern looking, which might look fine in a lake or mountain setting, but not where we wanted to build. It had to look right in its farm setting. We didn’t want our new neighbors to be upset by what we built.

Given Vermont winters, what were your energy considerations?
Our new house, situated on 23 acres with a nice view, is in the middle of a field, with no trees so there are no shadows. We sited the garage due south, so putting PVs (photovoltaics, aka solar panels) on just one side of its roof will be more than adequate to supply all of the home’s electrical needs. We’re using a heat pump system for space heating and cooling and for hot water, with an ERV (Energy Recovery Ventilator) to recapture energy. I think the whole PV system cost $15,000 after tax credits. We had radiant heat tubing put in, just in case, but I don’t think we’ll really need it. The house, designed for Net Zero performance, is all electric—with the exception of a gas cook top.

What could Bensonwood have done better to improve your experience?
We felt we were flying half blind, not being able to walk through a Bensonwood home at the time, in order to say we like this room in this house, and that room in that house. We were shown many plans and pictures, so we knew the quality, but that’s not the same as actually standing in the home and getting a sense of what it’s like. I’m sure not everyone wants people traipsing through their homes. And I guess it’s not practical to have a model home near your facilities, but that might have helped.

On a related subject, how would you feel about your home being used as an example of state-of-the-art energy efficiency?
Situated where we are, within a mile of Lyndon College, with its degrees in Environmental Science and Sustainability Studies, and our proximity to the Fairbanks Museum & Planetarium, with its meteorological focus (they provide Vermont Public Radio’s Eye on the Sky weather forecasts)—I know there’s going to be a lot of interest in our high-performance home.

Unity Homes Celebrates 2nd Anniversary

“The typical American home is a performance dinosaur, and is too much of a long-term burden for homeowners and society. Unity Homes aims to help make this species extinct.”     

Tedd Benson

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New Hampshire Governor Maggie Hassan (standing, center) visiting the Unity Homes production facility in October 2013.

On October 9, 2012, Bensonwood launched Unity Homes with the goal of making ultra-efficient, off-site-built homes affordable for the average home buyer. To date, Unity Homes have been built along the East Coast as far south as Asheville, NC and as far north as Montpelier, VT, and have been praised as possibly the “greenest prefabs on the market” by TreeHugger’s Lloyd Alter.

Designed to consume 50 to 75 percent less energy than standard newly-built homes, Unity Homes currently has four distinct 2 to 4 bedroom styles ranging in size from 1,028 to 2,450 sq ft. The home models are the Tradd (a classic tall cape), Xyla (an American bungalow), Värm (a Swedish contemporary) and Zūm (a passive solar optimized modern). All four of the highly-customizable styles have been built.

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Three interpretations of the Värm design shown here illustrate the highly-customizable nature of Unity Homes.

In the two years since its launch, Unity Homes has developed ways to raise the quality and performance of sustainably built homes while continuously trimming cost to make them ever more affordable. The company has already reached its original goal of trimming the typical build time to 30-35 working days for most projects and expects to get it down to around 20 working days in the future.

History

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Although Unity Homes first appeared in 2012, the seeds of the idea began much earlier. In 1991, Bensonwood began the long-term process of standardizing home production using computer-assisted design (CAD) software to optimize floor plans.

“I have long believed that the average American home should have a much higher standard of build quality, durability and energy performance,” Tedd Benson said in a 2012 Green Building Advisor article about the Unity Homes launch. After years of building a reputation for higher-end timber frame projects, Benson and the Bensonwood team wanted to bring his building innovations to the market-rate factory-built world.

There was also a philosophical element to Benson’s plan, describing the typical American home as a performance dinosaur, and too much of a long-term burden for homeowners and society. Then, as now, he wants to make that species extinct and transform the industry by offering an affordable home at a higher standard of efficiency.

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The LEED Platinum-certified, Net-Zero Energy president’s home at Unity College in Maine.

In 2008, Bensonwood received critical acclaim for its roles in fabricating the LEED Platinum-certified Unity House, a net-zero energy residence built on the campus of Unity College in Maine for the college president and his family.

The project was important, not only because the building was designed to maximize energy performance, but because it highlighted the Passive House standard for airtightness—the most cost-effective and easily achievable aspect of the Passive House standard.

Inspired by the project’s success and what the company learned from it, four years later Bensonwood launched a separate company producing high-performance prefab houses. The company was dubbed Unity Homes because it was thought the perfect name to express the democratic, egalitarian nature of these homes designed for the average American family.

Despite being in the throes of the worst housing crisis since the Great Depression, Benson realized that the company’s Bensonwood’s Open-Built® “operating system” capabilities and production capacity were being underutilized and warranted expansion. Tedd Benson also wanted to avoid reducing staff and a new division would allow the company to weather the housing downturn.

A 40-Year-Old Startup

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Building system team members assembling wall sections for an early Unity Home.

Unity Homes’ strategic vision began with a seemingly simple premise. “What if building only took 30 working days, all costs were known, the house quality was above anything the buyer had previously experienced, and the home could be net-zero-energy forever?”

For nearly a year, the entire Bensonwood team worked together to design and engineer the Unity Homes offerings and develop all the information, renderings and floor plans.

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An early Net-Zero Unity House planning session.

With no outside funding and many long hours, the company created a “40 year old start up,” Tedd Benson quipped at the time. In the end, Unity Homes was able to achieve both energy performance and price point goals with its high-precision panelized construction methods, keeping 60% of construction inside its production facility. Each home is organized into easily accessible “layers,” making for easier future upgrades and repairs.

By the time Benson announced the new company’s launch in an October 9 post on his blog site,The New House Rules,” Unity’s first two homes were already in production.

Montage: A Streamlined Process

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In Montage Building, pre-designed, high-performance elements can be easily reordered to fit homeowner budget, lifestyle or location.

The Unity Homes team sees these houses as more than another entry into the green prefab market, but rather as a complete rethinking of how houses are built. Many people in North America buy houses that might not last as long as they do; Unity houses, like the custom Bensonwood homes, are designed to last for generations.

Additionally, instead of prefab or modular, Tedd Benson prefers the term “montage” to describe the homes, which essentially means “assemble” or bring together disparate elements to form an integrated whole. That use of montage refers not only to the building process where panels are assembled at the home site, but also to a unique approach to vernacular design. The homeowner would not incur the cost of hiring an architect, nor would they be choosing from a limited product line as with most modular or prefab houses, but be allowed a range of customization to fit their lifestyle, budget and location.

Produced in Bensonwood’s Walpole, NH “studio,” the panelized wall, floor and roof assemblies are typically ready to ship to site in a few weeks. This work is concurrent with site prep and in parallel with other component fabrication such as the precision-cut beams and millwork.

The onsite assembly of the weathertight shell is usually accomplished in one to three days, depending on complexity and garage options. From there, Unity Homes can be finished quickly because of the open layout and packaging of systems, such as pre-assembled HVAC modules. While a standard new home takes 150 days to build, Unity Homes can now shave the building cycle down to as little as 30-35 days.

The Unity Homeowner Experience: “Rewarding and Fun”

Tedd Benson has always stressed the importance of owner involvement in the homebuilding process, but J.C. and Nancy Woodward of Fitzwilliam, NH, took it to another level. J.C. and Nancy initially came to Bensonwood looking for a custom home, but after several discussions with associates, architect Chris Adams suggested they consider one of the new Unity Homes about to be launched. The Woodwards were intrigued and chose the Värm style—J.C. also chose to act as general contractor to cut cost.

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An early Värm in New Hampshire was finished by the owners to reduce cost.

The site was prepped in late 2012, production began in February 2013, and by April the crew arrived with the home’s shell, which Woodward would finish out himself with help from some local subcontractors. Having built another house 25 years prior, he expected the typical chaotic construction scene with a host of endless problems to address. Because of the obvious attention to detail and quality, Woodward says, any problems that arose were small ones and easily solved.

J.C. was there from 7 a.m. until evening every day and was stunned at how quickly and smoothly the home came together. He was also impressed by how, “every person on the Unity team deeply cared about my project’s success.” From architect Chris Adams “wringing function from every square inch” to make the house feel a lot bigger than its 1,700 SF footprint, to project manager Tony Poanessa repeatedly “going the extra mile” to make the project run smoothly, Woodward describes the experience as rewarding and fun. In fact, he was so inspired he is now taking a CAD drafting course at Keene State College and hopes to work as a project manager himself someday.

High-Performance

The airtight homes possess many of the standards of passive house: optional triple-pane windows, high levels of dense-pack cellulose insulation (R35  OBPlus Walls® and R44 roof), buttoned-up building shells with a Passive House level of airtightness to 0.6 ACH @ 50 Pascals or better, energy recovery ventilators, air-source heat pumps and more to reduce energy use by 50% to 75% compared to standard new houses. The homes’ operational efficiencies with low energy loads mean less power use and smaller HVAC systems. They’re also capable of achieving net-zero energy if the owner decides to add a modest solar electric system.

Health & Comfort

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Stressing health and comfort as much as energy efficiency, Unity Homes are well-lit, quiet, draft free and moisture controlled.

In addition to the energy-saving features, standard specifications of the two- to four-bedroom homes include low-VOC paints and finishes, all-electric water heaters, Moen fixtures, EPA WaterSense toilets from Kohler, and high-quality woodworking and cabinetry.

In addition, they’re comfortable, light-filled and spacious, have great air quality and are fitted with high-quality materials, finishes and fixtures. Another less-considered element is that they are quiet—something too often missing in our homes. Silence is a feature increasingly accepted as vital to health and emotional well-being; and with doors and windows closed there are no traffic sounds from the street, airplanes overhead, barking dogs or noisy neighbors. Tedd Benson often refers to these as providing vital “sanctuaries or “sacred spaces” for family.

Adaptability

Heavily influenced by the thinking of John Habraken and Stewart Brand, Benson and associates developed the Open-Built platform to allow simple modification of structures as occupant needs change. The central idea behind Open-Built is to “disentangle” the building’s interior and exterior systems into separate, functional layers, which improves the efficiency of the construction process. That disentanglement also allows for long-term access, meaning homeowners and professionals can accomplish changes, upgrades and renovations with less demolition and rework.

All systems within the Unity Homes will be continually scalable, with most mechanical and space upgrades able to be accomplished by the homeowners.

Cost

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The ultimate goal of all green prefab manufacturers is to get the quality control and efficiencies possible in a factory at an affordable price. A common complaint is that Unity Homes and its peers are not affordable when compared to conventional stick-built housing, despite the fact that these are not conventional houses.

In truth, cost for this “beyond code” design and performance is competitive with current on-site, building-code-based construction when all factors are considered. These include: resale value, energy bills, maintenance and repairs, health effects and remodeling cost.

Nevertheless, driving down cost is a top priority in the Unity Homes mission. Unity plans to broaden the market for their homes by continually reducing cost to match the cost of conventional building, which varies widely between geographical regions. The company has already achieved this in many areas of the Northeast.

Eventually, Benson says, as more builders use and demand high-performance products, competition will increase among manufacturers, creating a virtuous cycle of improved performance and lower costs. He is emphatic, “Americans deserve better homes, and the industry has the capacity to build them, we’re just not doing it on a consistent basis. If this type of building was industry wide, the costs would drop for everyone.”

Future

OPTI_MEIR-AUER-5June-2013-001Tedd Benson is pretty clear about his future plans for Unity Homes: expanded production facilities across the country to lower shipping costs, continual improvement in the production process, and lower cost.

Eventually, Unity Homes wants to merge its current panelization process with modules that would allow Unity to complete mechanical rooms, bathrooms and kitchens at its facility, and leave only 20% of the building process for on-site construction.

Last, but not least, he wants Unity Homes to stand as a sustainable model for the industry, and with that to change how Americans view homebuilding from something to be dreaded and endured to something that is rewarding and even fun. In the end that will be a source of healing not only for future homeowners but for the planet.

Unity Home Pioneers: Part of a Greater Movement

Unity Homes TraddFor those wondering if the green movement in homebuilding is on track to address personal and environmental needs, that train has already left the station. New-home buyers wanting to be part of the larger movement towards low-impact, healthy living while at the same time moving towards F3 (fossil-fuel-free) energy independence, have taken a hard look at Unity Homes’ family of high-performance, customizable homes—and decided to invest in the future.

In the two years since launching in 2012, Net-Zero-ready Unity homes have sprouted up in three regions of the country (the northeast, southeast, and mid-Atlantic). Moreover, their owners, green home pioneers and early adopters of the new homebuilding technologies, have selected homes from all four of Unity’s design platforms—Tradd, Xyla, Värm and Zūm: an architecturally diverse collection of homes—customizing them to their personal lifestyle preferences.

So, who’s buying these highly versatile, architecturally diverse homes, and what’s motivating them to invest in a low impact, high-performance lifestyle? To answer that question, let’s visit a few recent Unity homebuyers, all of whom coincidentally (or possibly not) are related to the health and wellness industry.

Downsizing in Southern Vermont: A Nurse/ Midwife Customizes a Xyla 212

Unity Homes Xyla elevationsHow did Laurie Coursin, a Certified Nurse/Midwife and mother of an Antioch University student and pottery maker, come to discover Unity Homes? In her words, “The stars just all lined up.”

Elaborating, Laurie continued: “ For the past 14 years, I’ve been living in a timber frame home Tedd Benson built 30 years ago in Gilsum, New Hampshire. I am actually the second owner, so I had had no direct experience building my own home, or working with Bensonwood. I’ve loved the quality of the home and wish I could keep it, but I needed to downsize and wanted to be mindful of the latest advances in sustainable, energy efficient living. So, I wanted to build a mini-version of my home, but the whole process seemed overwhelming to me.”

Then, a bit of serendipity happened, according to Laurie: “It was at this time, that a pediatrician in the Keene, NH area told me about Unity Homes, so I gave them a call, and from that time on, it seemed like it was meant to be. From the start, I met with Unity sales person, John Dunbar. As it turned out, I had helped deliver one of his babies! So, from the outset, the Unity folks felt like a family to me—so supportive—and they’ve made the process so hassle-free. Beyond that, John showed me how high-performance homes like Unity were the wave of the future.”

And in order to live as lightly on the land as possible, Laurie also wanted the perfect location for her new high-performance home. Again, in her words: “I had become interested in an intentional community, Putney Commons, just across the Connecticut River in Putney, VT, and found an 11-acre parcel of land, with 6 existing homes (mine would be the 7th of 9 planned) that would be perfect for me. In addition to investing in sound land stewardship, I would be able to walk to the Quaker meeting house I frequent, as well as to the co-op and the library. And I’d be part of a like-minded community!”

UNITY HOMES XYLA FLOOR PLANAs for green energy, Laurie plans to buy into a solar farm (Soveren Solar’s Vermont Community Solar program), to power her home’s high tech HVAC system, with Air Source Heat Pump and HRV (Heat Recovery Ventilation). And since the intentional community doesn’t permit wood burning, she plans to use a small, gas-fired Yodul stove to replace her old fireplace, for the warmth and ambiance it provides.

Regarding the ability to customize her Xyla 212 plan, Laurie was able to extend the garage to add a special pottery-making room.  “I wanted to build a pottery studio for my son while he’s away at college;” Laurie said, adding, tongue-in-cheek, “It may be the only way I’ll get to see him.” Her design also includes a custom connector between the house and garage that incorporates a bath, laundry and entry. To further illustrate the flexibility of the Unity Homes platforms, when it was determined that the original site would have some site preparation challenges—leading to higher than anticipated costs—an alternate lot was selected and the original floor plan was modified to fit the new site without significant changes to the shell components.

Summing it all up, Laurie took a longer view: “At the end of the day, I want to be a responsible home buyer and citizen, so I can have some impact on the world my son, and his children, will inherit.”

 A Unity Tradd Rises in Central Vermont for a Young Doctor’s Family

Unity Homes TraddWhen Kimberly White, a homemaker and mother of two children, now aged 4 and 6, and her husband, Joshua, a medical doctor moved east from Minneapolis, Minnesota, they bought a plot of land in picturesque Barnard, Vermont and rented a basement apartment in a commercial building while researching high-performance home builders.

In Kimberly’s words: “We really wanted to be self-sufficient, and build a beautiful, healthy, solid house—and one that’s also good for the environment.”

They had learned from experience, Kimberly indicated: “I was pregnant with our second child at the time we came east. We had moved from an 80+ year-old stucco house in Minneapolis, with drafty windows and doors and gas heating, to a dank apartment with few windows—a space that was hard to keep warm enough for two small children—so building a tight, energy-efficient home was at the top of our list as we began looking for high-quality, green home builders.”

Regarding their insistence on quality, Kimberly offered: “My husband is very forward thinking. After we had done a lot of soul searching, at one point he said, ‘This is going to be our home—our life!  Where our kids will grow up. It needs to be a healthy, comfortable environment. And with the way the economy is going, the price of energy is going to be a major factor when considering a home’s design.’”

vermont xyla unity homesOn how they found Unity Homes, Kimberly said: “My husband is an avid researcher. He began looking into quality builders in the area and Bensonwood and Unity kept coming up. So we visited their New Hampshire facilities, and then took a tour of a nearby Unity home. What really struck us besides the overall quality,” Kimberly said, “was the tightness and even temperature of the home. The homeowners said that they often had to crack a window when they used the fireplace. That really spoke volumes about the quality and tightness of the house,” Kimberly noted.

The White’s bucolic wooded property, up a steep, winding road, has a couple of ponds and nice views, the perfect setting for their new Tradd 123, a 3,084 SF classic tall cape with 3 bedrooms, and 2.5 baths, plus a walkout basement that will be living space in the near future. The home will be rapidly raised and finished this fall, in time for the holidays.

The home’s standard open living plan has exposed timbers and the first floor includes the living, dining and kitchen areas, a powder room and a laundry room. Upstairs are the master with bath, and two additional bedrooms with shared bath. An unfinished walkout level rounds out the space plan. Because Unity floor plans are highly customizable, the second floor was flipped so that the master bedroom could take advantage of the views. Lastly, for outdoor living enjoyment, the home has a 287 SF porch and deck. An elongated, freestanding, 581 SF 2-car garage will accommodate their tractor.

Besides the reconfigured floor plan, the Whites opted for several upgrades, including an ERV (Energy Recovery Ventilator) air handling system to complement the standard air source heat pump.

In concluding, Kimberly re-emphasized: “It was really important to us that the home not only be healthy for our family, but healthy for the environment as well.”

A Retired Doctor & Teacher Retire to a Unity Xyla in Southern Connecticut

Unity Homes Xyla RenderingWhen Nikki and Joanna were contacted for the purpose of this interview, they were flush with excitement and anticipation after having just viewed their completed weather-tight Xyla 212 shell rise as if by magic, within a week’s time, in the coastal Connecticut town of Guilford.  Nikki, a retired family doctor, and her partner, Joanna, a retired teacher and practicing artist, were drawn to Unity Homes for a variety of health, environmental, and aesthetic reasons, but seeing the home materialize so quickly was a real thrill.

Not long before, the two weren’t sure a high-performance home was even achievable within their means. As Nikki explained, “Though we were familiar with the passive solar standards out there, and wanted to live lightly on the land, we didn’t think we could afford an environmentally-advanced home.”

Unity Homes XylaThen, describing how they discovered Unity, Nikki continued, “We were originally involved with a co-housing group in Bethany, Connecticut, but we were concerned that things were moving slowly and that, at our age—in our early sixties—getting a truly sustainable home was going to take too long. Sensing our frustration, a builder who had previously recommended Unity Homes to the co-housing group, directed us to the company website.”

According to Joanna, “One of the primary reasons we came to Unity was how well the homes were constructed, with large sections finished in the factory, unexposed to the damaging effects of weather. Our present home is a 50-year old house, with drafty windows and doors and a gas furnace. We thought of retrofitting it for energy efficiency, but it was totally impractical, if not impossible. With our new home, we want to reach Net -Zero energy, so we plan to add PV (photovoltaic) panels to our Xyla.”

The couple wanted a large master bedroom, a yoga studio, and a home office/studio. To achieve this within the Xyla 212 platform, a master bump-out was added to the plan and interior partitions were reconfigured—all while retaining the core volume and window configuration.

On the ease of achieving their wish list, Nikki had this to say: “The Unity model was a great combo, where the design is already set, but the space plan had the flexibility to meet our needs. For example, we wanted a larger master bedroom, so they put the whole team on it—you know, in-house designers, engineers. They ended up taking a master bedroom from a larger Xyla and added it to the Xyla 212 plan. We also really liked having many of the design decisions pre-set, while at the same time, having the flexibility to change the floor plan.”

unity xyla barnard vermontIn addition to the master bump-out, they did specify a number of finish choices to make the home uniquely theirs, like a special Japanese Shoji screen pocket door, a screen porch and cedar siding on the exterior to better weather the shore climate.

On the style of their Xyla 212, Joanna had this to say: “We really love the design. We find it organic and aesthetically pleasing, and we love the post and beam, the exposed timbers. We also really like the low profile—it being built low to the ground, which will make for easy, single-floor living as we get older.”

Summing up, Nikki spoke of the growing movement towards green living: ”It seems like everyone we’ve talked with in this area, even people overhearing our conversations and joining in—a waitress, a real estate agent, a cop—they were all interested in environmental building…in what we’re building. They all wanted to know what we were doing.”

Nikki then added, “We get the sense there’s a real movement building towards green living, and for Joanna and me, it feels really good to be out ahead in that movement.”

 

 

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.

Bensonwood Featured in “The New Net Zero” by William Maclay

the new net zeroThe New Net Zero: Leading-Edge Design and Construction of Homes and Buildings for a Renewable Energy Future

Bensonwood is featured prominently in a new book on Net Zero building by renowned architect William Maclay. We collaborated with Maclay Architects as a member of the team which designed and built the award-winning net-zero Bosarge Family Education Center at the Coastal Maine Botanical Gardens. The LEED Platinum-certified center was Maine’s first net-zero institutional building.

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WILLIAM T. MACLAY, AIA, NCARB, LEED AP

The new threshold for green building is not just low energy, it is net-zero energy, and in The New Net Zero, sustainable architect William Maclay charts the path for designers and builders interested in exploring green design’s new frontier—net-zero energy structures generating as much energy as they use while remaining carbon neutral.

Since traditional American buildings account for roughly 40 percent of our total fossil energy use, the significance of net-zero building is growing increasingly important—among designers interested in addressing climate change as well as homeowners concerned about energy efficiency and long-term savings.

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The Bosarge Family Education Center at the Coastal Maine Botanical Gardens. Photo by Robert Benson

Maclay, an award-winning net-zero designer whose buildings have achieved high-performance goals at affordable costs, makes the case for a net-zero future; explains net-zero building metrics, integrated design practices, and renewable energy options; and shares his lessons learned on net-zero teambuilding with like-minded companies such as Bensonwood.

The comprehensive overview is accompanied by several case studies, which include institutional buildings such as the Bosarge Family Education Center, commercial projects, and residences.  Both new-building and renovation projects are covered in detail. Unity Homes is profiled in the book, as is our multi-layered Open-Built® system.

The New Net Zero is geared toward professionals studying net-zero design, but is also suitable for laypersons seeking inspiration and strategies for beautiful and renewably powered net-zero options.

Our Building Systems Flawless in 3rd Party Inspection

2014.01.16_Panel shop (25) - Copy Four times a year, TR Arnold, a respected third-party “in-plant inspection agency,” or IPIA, is authorized by us to conduct unannounced inspections at our Blackjack Crossing production facilities. In voluntarily submitting to TR Arnold’s findings, our intention is to ensure that construction standards (state & local code, as well as our own stringent standards) are consistently adhered to.TR Arnold

Essentially, TRA inspectors go through each of our work stations inspecting up to 120 certification elements. As part of this quality control process, TRA inspectors are authorized to, “…reject non-compliant units, to withhold labels and to inspect all finished units produced and labeled prior to a unit found deficient and subsequent to the last unit inspected at the station where the deficiency occurred.”

One such audit has just concluded, and we’re pleased to report that of the many assemblies inspected, no non-conformance issues were discovered and we were found to be in complete compliance.

According to Building Systems specialist, Scott Bosworth, “This is really a big deal because of our building techniques compared to other, very different kinds of prefab home builders. For example, with “Double-Wide” manufactured homes that travel down the highway in halves, there are only two certificates required: one for the left side of the house, and one for the right side. With our many panelized assemblies (that are later raised at the build site), there are 120 or more certification elements that can be inspected prior their leaving our production facilities.”2014.02.07_Panel shop (8)

As Scott elaborates, “And because of the kind of closed-panel, or closed-cavity assemblies we fabricate offsite, building inspectors at the home site appreciate seeing certifications created by independent, in-plant inspectors who have seen the panels come together at the point of manufacture. Therefore, getting a full compliance report from a third-party administrator is huge,” adding, “A perfect score from a company like TR Arnold not only helps affirm our own quality control efforts, but in some cases, having the certificate can also help reassure a local on-site building inspector regarding enclosed areas he or she cannot readily see into.”
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According to Bensonwood/Unity Homes production head, Kevin Bittenbender, who is in charge of compliance control and was instrumental in setting up independent plant oversight, “We’ve been building to the highest quality standards for years. It’s just what we do. It wasn’t much of a change in our process, or product, to meet TR Arnold’s standards. We simply had to clearly explain and document our product, and how we work. Our standards are higher than what is needed for code, and receiving positive results from their inspections is a nice confirmation that we are successfully building to the highest standards in the industry.”

Customized Unity Xyla 212 Sits Softly on the Land

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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.

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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.