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Miscellaneous Questions about Cordwood |
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Q: I am about to start building a barn, and three of the walls will be cordwood. I need to know a good method of estimating how much wood I need. Is there a formula or is it just guess work. A:
Here is the formula I use. It seems to work very well. Q: I am thinking seriously about building a cordwood home in West Virginia and am thinking of buying your two books: "Complete Book of Cordwood Masonry Housebuilding: The Earthwood Method" and the newer "Cordwood building the state of the art". I also don't want to be throwing money away. Does the newer copy cover most everything in the older so I shouldn't buy the older one? A: I have been asked the question about my books a lot during the past nine months, so thanks for the opportunity to clarify this for the vast readership of this website. Complete Book of Cordwood Masonry Housebuilding (Sterling, 1992) was taken out of print by the publisher last year. I have a small number of copies left. Otherwise, you might find it hard to get. Cordwood Building: The State of the Art (New Society, 2003) should be around for many years to come and is the one we now use as a textbook at our workshops. Q: We have just purchased a beautiful cordwood masonry home here in northern Saskatchewan, Canada. My wife was concerned with the structure when she discovered (much to my dismay) that the logs appear to be a little loose in the masonry. Will this lead to moisture/rot problems? Should I try to somehow "fill" around the logs before we restain the building? A: No, the fact that you can move the log-ends within the mortar matrix will not cause rot or moisture problems. The long life of a cordwood wall has to do with the breathability of the wall. Ventilation has been called the best preservative for wood. Wood rot is caused by fungi, which need a steady damp condition, not present on a cordwood wall if basic good building practices are maintained, such as: (1) Keeping the cordwood clear of the ground, (2) Using a good overhang on the building , (3) Debarking the wood, (4) Keep log-ends from touching on the exterior, and (5) Use sound wood in the first place. Now, if there is quite a gap around all the log-ends, you may want to coat the entire mortar joint with a flexible log chinking product such as Perma-Chink or Log Jam(Sashco Industries). This will return a pleasing bright consistent color to the mortar and close off all the gaps, which are causing the movement you describe. Incidentally, I do not advise staining the log-ends. This makes a mess on the mortar and darkens an already dark medium, which is cordwood masonry, particularly on the interior, where you want to do everything you can to maximize light, especially in Northern Sakatchewan in the winter. And why get into a maintenance situation on the exterior? Let it weather. A: This project seems like it could be more trouble than it is worth. But, yes, it has been done before, and very attractively, with more traditional woods. As with a building, you need to keep the cordwood off the ground with a concrete or stone masonry foundation. If you are in a frost-free area, maybe 4" solid concrete blocks laid widthwise in the wall, right on the ground, would be sufficient. This would give a 16" wide footing, good enough for a wall width of 10 or 12 inches. Also, as you suggest, the cordwood wall will have to have some kind of "hat" to protect it. This can be tiles, large flat stones, or even a poured concrete cap. Whatever you use must have a good overhang so that the rain is not just running down the wall. It sounds to me like the first step is to try barking the wood. If it is absolutely impossible, you might consider building this wall with the bark on. Enter into this project with the knowledge that you are taking a chance on the success of the wall. Also, it will be a fairly time-consuming way to build a fence or a wall. Let me know how you make out. Q: I have a neighbor that is very interested in the cordwood designs. I have enough aspen trees to use for the size building that he would like to build. Can you give me a approx. cost for just the wood that would be cut and split when necessary. Perhaps a price on a fire or facecord. (4ft H x 8 ft. L x 16" W). His intention is to purchase the wood only from me, but he would like it already to use and begin construction. A: I have absolutely no idea what a face cord of poplar (quaking aspen) is worth commercially, even where I live, much less in an unknown part of the country. The wood should be barked, too, best done in the spring, in long lengths, soon after it is cut. With aspen, it is particularly important to store it in single ranks, top of the stack covered, but not the sides. Q: My husband (handy kind of guy, but age 74 and with severe arthritis in both shoulders plus artificial knee, but still works full time) has taken a wild hare, as we say in Texas, to homestead in the country. I'm 64, but still very healthy and active. All well and good, but I am confronted with problem of building a house on a very tight budget. No choice but do it ourselves. I foresee your website is going to be the answer to a prayer. A: (Kelly) Building a house, no matter what the technique be, is lots of work...but this can be enjoyable, especially if done so that there is no urgency about moving into the new house. Give yourselves plenty of time to do only as much as you really want to at any given time. And choose a technique that you know will be manageable by the two of you, with some occasional help. I especially like cordwood since it can be done as "infill" under a post and beam roof which will satisfy your local building department and give you protection from the sun and the rain as you proceed. Also you end up with a well-insulated home that requires no maintenance or further finishing inside or out. Q: Is it ok to chicken wire the outside and stucco the cordwood? I was leaning to the Spanish style appearance. Would there be problems down the road? A: I recently saw a beautiful cordwood home in Ontario where the inside was plastered. The outside was left as cordwood. I think you could "stucco" the outside, after the wood was dry; that is to say, little or no sap moisture still trapped in the cells. The chicken wire might help with the bond. To be honest, this is an area where I am not experienced, so you have to take responsibility. But I have heard of successful plastering done to cordwood exteriors. I'm just unsure of the best way to do it. We would welcome comments from any readers who have experience in plastering cordwood masonry Q: I am interested in building a double stackwall cabin in the North Okanagan of British Columbia. The inside of the cabin would only be 14' X 20'. How much wood am I looking at to need here? A: There is not enough information in your question to come up with the wood quantity. I need to know whether you are doing stackwall (crisscross) corners or are doing cordwood masonry infilling within a post-and-beam frame (my recommendation). In either case, I need to know the height of the walls. If you are building within a P & B frame, this would be the height to the underside of the girt (or plate beam.) Finally, I need to know the thickness of both the inner and outer walls. In general terms, anyone can figure out how much wood they need if they follow these steps: (1) From the plans, calculate the square footage of the cordwood walls themselves. Don't count windows, doors, and heavy posts and beams that are a part of the wall. (2) Divide the square footage by 32. This yields the number of face cords needed to fill the space earmarked for cordwood masonry, if you were to stack the wood without mortar. A face cord is 4 feet high by 8 feet long by whatever length you are cutting the wood (12", 16", 24", etc.) (3) Take 80% of the figure derived from step (2) and this will be the number of face cords you will need for your project. You will have enough to reject pieces you don't like. This step takes into account the mortar, which tends to "swell" the face cord. Any leftover wood will help to heat you the first winter in your cabin. As an example, if step (2) yields 10 face cords, take 80% of this - or 8 face cords - and you will have plenty. Q: We would like to build a 14' x 14' cordwood root cellar as a stewardship project for a school in New Hampshire. I know this may sound big but we may be up to 80 students in a few years and need to prepare for this size population. I am told by a long time resident that if the cordwood structure is properly sited on the north side of a hill and in the shade, there will be no need to excavate to maintain a temperature between 40 and 60 degrees year round. I am not so certain that I agree. I believe that even with a living roof there will be a bit too much fluctuation in temperature. I think we probably need to dig it into the hill on three sides. Any wisdom you can give is much appreciated. A: I agree with you. A cordwood building on the north side of a hill, in the shade, without a source of heat, will not maintain 40 degrees Fahrenheit in the winter, especially in New Hampshire. The interior will freeze, and severely. Similarly, I think the interior will eventually get to ambient temperature in the summer, possibly in the 70's. Your idea of digging it in on three sides is a good one. I am not too wild about using cordwood masonry below grade. It can be done, but must be done very carefully: dry cordwood, parge the outside smooth with two coats of plaster, apply a waterproofing membrane and use good drainage. Frankly, as much as I love cordwood masonry, I would personally use surface-bonded concrete blocks for this root cellar. Use cordwood masonry on the one exposed side. And, no, the earth roof, while helpful, is no panacea, unless it is very thick, placing the whole building, effectively, deeper into the ground. Structurally, that becomes expensive. An extra inch of extruded polystyrene is as effective as an extra foot of earth, in this regard, and a whole lot easier and cheaper to do, because of the high cost of the structure to support an earth roof on a 14-foot span. Q: I was reading your book about the round cordwood house you built, Earthwood. I'm not asking anything about the cordwood, but I'd really like to know how the sod roof has held up through the years and if any moisture problems or maintenance occurred. A: We love the earth roof and it has performed very well for 25 years now. We had a small leak in the membrane the first year, the result of bad edge detailing and some tenacious carpenter ants. We had to dig up a section, repair the leak, and improve the drainage detailing. Then, no problems for over 20 years. In December of 2004 we had another leak, this one in the bathroom. Again, ants seemed to be the culprits, eating up from some wane in the 2x6 T&G planking and through the membrane. Christmas Day was warm enough that year to give us a narrow window of opportunity to quickly pull up the earth and the insulation, repair the leak, and rebuild everything before the dark and cold returned. Took us about four hours. No leaks since. Our new Stoneview Guesthouse at Earthwood is an octagonal post and beam frame, with the eight wall panels made of cordwood, a door, and windows. The living roof was a very successful experiment making use of just 3.5" of earth, planted to sedum, chives, and other drought-resistant plants. It is the most beautiful roof on campus. We have improved our drainage detailing, too involved to discuss in this reply, but my new book, Earth Sheltered Houses, covers this thoroughly in a designated chapter. Outside of the two small leaks mentioned, we have had no problems with Earthwood's roof. We agree with Mac Wells that Americans are paving and roofing certain parts of the country to death. The earth roof has energy, environmental, and esthetic advantages and, if done right, is the longest lasting roof you can build, because the substrate is protected from the negative effects of erosion, freeze-thaw cycling and UV deterioration. Earth roofs also provide protection from sound, tornados, fire, and radiation. Q: Hi, am really excited to start building...but I am in the midst of nay-sayers who are concerned about the problem of termites in the Dallas, TX area. How do we go about building the foundation for the cordwood and leave these little pests hungry and wanting? A: I know of only one instance where termites attacked a cordwood wall. (There may be others I have not heard of, so, readers, let me know!) In this case, the owner/builder, in southern Georgia, had had no problems with termites for several years. Then he installed an air conditioner in one of the windows. Due to less than ideal detailing, condensate poured down the wall, keeping it constantly wet. Despite being built mostly of cypress and red cedar, fungi began to grow. Termites ran up the wall to harvest the fungi, for there was no metal termite shield built into the concrete slab foundation. After a while, the termites destroyed a fair amount of cordwood under the window, but there was no damage anywhere else. A: In answering your question, I am keeping in mind your goal of a 10-year structure, with no heat. My suggestion is that you use 6x6s to frame the building, get a roof on it and then start the cordwood. You don't say what kind of pine you've got, but most pines are less troublesome than the other woods you mention, which are all hardwoods. So use the pines on the first course, at least, and then mix the hardwoods in on succeeding courses. With 6" walls, you will need to go with a solid mortar joint as there is no room for insulation and you are not worried about heating the structure, anyway. Q: How do you correct what Malcome Wells calls an "energy nosebleed", something about not wanting to have direct conduction of heat from the inside of the building to the exterior? What is this thermal break in the framing system to prevent condensation? How do you create this thermal break? A: Thank you for a good question. Softwood timbers on side grain, such as the posts and girts of a post and beam frame, have an R-value of between R1.0 (red and white pine) and R1.5 (white cedar) per inch of thickness. So an 8x8 post has a total R-value of between R8 and R12, hardly an energy nosebleed. Compare with a thermalpane window at R2. I have never seen condensation on the inner surface of any heavy timber frame building, and I have seen a lot of them. Q: Could you suggest one or two definitive books for someone looking to build a cordwood home? A: The basic textbook we use at our cordwood classes at Earthwood is Cordwood Building: The State of the Art. The CoCoCo/05 Collected Papers has the latest developments. Cordwood and the Code is good ammunition if you anticipate a battle with your local code enforcement officer. Richard Flatau's Cordwood Construction: A Log End View is also good, and is the least expensive at $20. All are available from Earthwood at out website, www.cordwoodmasonry.com , although Richard's book is not listed on the order form. Just add it on at $20 and include $2 shipping. We have a 3-1/4 hour Complete Cordwood DVD which we sell at a reduced price of $44 (including First Class Postage). Although you indicate that you are not interested in attending a workshop, it is a great place to meet other people in the same situation. Very often, students get together and help each other on their individual projects, a networking benefit of workshops that is often not considered. Q: I am working on a small cordwood cabin (16 ft internal diameter, circular). It has taken me 4 days to locate, collect, debark, and cut enough wood for one face cord. I am using hardwoods as this is all that is available in my location. I am a novice builder who is new to cordwood building. I have plenty of wood available in my lot, consisting mostly of the scrap from a logging operation, and I'm a student which means I have almost every day of the summer to work on this. My question is about the amount of time I should expect the project to take. I would like to have the building enclosed, including the roof, before November, if possible, and I am wondering if this is a reasonable timeframe? A: The only "truth" I have managed to come up with in 60 years on this planet is this: "Everybody is different." I have seen people who would do the project you describe in 3 weeks, others would squander away 6 months. It seems to be taking you quite a while to gather the wood. Depending on doors and windows, and height of wall, it seems as if you will need 6 or 7 face cords of wood. At 4 days per, this looks like 24 to 28 days of work just to get the wood prepped. Perhaps you will gain speed with experience. Once you have the wood, it should be possible to do a 16-foot diameter cabin in 30 days of cordwood laying. Then there is the foundation, the roof, and other details which you don't discuss in your letter. I think you could do it by November, but, then again, "Everybody is different!" Go for it! And best of luck to you. Q: My husband and I live in Nova Scotia, Canada. We have decided to build our dream home using cordwood. Can you tell us what would be the best wood and supplies for this area? What would you use for interior supplies (wiring, plumbing, windows, insulation etc)? What would we have to look into for building permits? And are these types of home easy to get home insurance for? A: I cannot be familiar with woods available in all the various regions of North America. Please read my past replies to others, wherein I describe the importance of using light and airy woods (which are more stable and have a higher insulation value), as opposed to dense woods with poor insulation value and a greater tendency to swell and shrink. There really is no difference in "interior supplies" (wiring, plumbing, windows, insulation), to use your words. The wiring of the cordwood walls is a little different from the other non-cordwood interior walls, but this is covered in detail in a couple of articles by Paul Mikalauskas and Michael Abel in my book Cordwood Building: The State of the Art . It is not possible to rehash those comprehensive articles an this type of column. It is rightly said, "A little bit of knowledge is a dangerous thing." You need to find out what the local jurisdiction to get a building permit. It could be town, county or province. You will apply to the code enforcement officer or the building inspector, two names for the same person. There is an excellent document now available called Cordwood and the Code , which can smooth the way with the code official. I have never had any trouble insuring cordwood homes, and we have had four of them. In all of the hundreds of cases with which I am familiar, I have only heard of a handful where getting insurance for a cordwood home has been a problem. Some people have had to try several companies, but eventually one comes through. The books cited are available at our Earthwood website, www.cordwoodmasonry.com Q: How are cordwood homes affected by termites, or other wood boring insects, or pack rats? A: I have only once seen a cordwood home attacked by termites, in Georgia. Actually, it was fine for many years. Then the owner installed an air conditioning unit in a window, and it was not detailed properly, so condensate ran down the wall, a constantly damp condition. Fungi began to propagate and, next thing, termites started scrambling up the wall to harvest the fungi. After a while, they had eaten a fairly large hole in the wall. The best protection against termites a "termite shield." This is a piece of metal, like flashing, that extends out from the foundation, six inches or so off the ground, but below the cordwood. The termites have to build their tunnels around the shield if they want to get to the wall. (And they don't like endgrain of wood, anyway, unless laced with fungi!) You just walk around the building once in a while and look for signs of activity and kick any mound construction down before it reaches the wall. If you live in a termite area, ask the local building inspector or go to the local building supply yard. They should be able to advise you about the termite shield. It is also a good idea to keep vegetation, including grass, at least two feet back from the wall. I do this with plastic or landscaping cloth, covered with two inches of crushed stone. If any readers have additional experience with termites in a cordwood wall, please write. Pack rats? You mean like the Roy family? Can't help you on this one! Q: I have been wanting to build a cordwood home for 8 years. I live in Sewanee, TN. I am having issues with the bank appraisal, they don't know how to determine it's value. I thought they could use log homes to compare it for value. I keep running into dead ends. Do you have any advise? A: Your attempt to compare it with log-building was a good idea. Too bad they didn't go for it. My advice to people building of cordwood is to do it within a strong timber frame (post-and-beam) structure. This affords the luxury of working under cover, generally makes the building inspector happy, and you should be able to pass the project off as a timber frame structure. The cordwood infilling, in this case, could be cordwood, straw, light clay, cob, zucchinis, almost anything. (Well, I probably wouldn't use the zucchinis.) Q: We own a cordwood home in Francy Gap, VA and use it as a second home. The house was completed in 1984 and the walls are 12 to14 inches thick. Two weeks ago, we were checking on the property and found a faucet had frozen during a 5 degree cold snap and it looked like a fire hydrant when we walked into the home. We estimate that water ran for two or three weeks within our home. Overall it is in pretty good shape because the stone fireplace and the concrete slab absorbed most of the water. The remaining water ran out under the logs. The water restoration company has had dehumidifiers and blowers within the house for eight days and the inside of the logs are showing being dry with a moisture reader. The concrete slab and stone fireplace are dry as well. The outside of the logs are still showing higher moisture content and you visually can see the wetness. The logs that are still showing dampness are the bottom section and just where the faucet was located within the inside. I wanted to see if you have any suggestions on how to get the logs dry on the outside during winter or if this is something that will dry in time . My concern is mold or even rotting. A: Wow, what a nasty surprise to come home to! It is very difficult for me to evaluate the situation from a distance of 800+ miles, so I must issue a disclaimer with my answer: Advice is worth what you pay for it! But, nevertheless, my strong feeling is that the cordwood wall is going to dry out over time and be okay. Fungi will not begin to propagate in the cold, and by the time it gets warm, the wall should be dry. Hopefully, the fungi will not get a foothold. It would not be a bad idea to run an electric fan directed on the very worst area, maybe one inside and out, a few hours a day while you are there. The insulation in the first course - and you don't say what kind - will take the longest to dry out. Let's hope it was sawdust with lime, which will set up with the moisture like a beadboard insulation product. Q: My husband and I live in Dutch Harbor, Alaska, a windy, treeless, beautiful volcanic island. We want to build with local materials, and have decided that driftwood is the most available "green" resource. After researching a number of options, we are pretty sold on the idea of building a cordwood home, with a Mongolian yurt shape--and have just ordered your book. From what we've read so far, we think this would be a good fit with our climate of high winds, rain, and snow, and almost no sun -- but moderate temperatures. We get 100 or even 170 mph winds, which, of course, can cool a house down quickly. Also, living so far away (800 miles from Anchorage), we want to cut down on or eliminate the cost and energy consumption of shipping materials, and two resources that aren't available locally are the cement (we do have sand, though) and sawdust. With these concerns in mind, do you have any advice for us? A: Wow, you and your husband are certainly hardy types! Driftwood can be used for cordwood masonry, and has been before, although I would be hard-pressed to locate an example. I remember one being done with driftwood from the Mississippi River. Make sure your sand is washed and not salty. You want sand that is some distance from the shore, where it has had a good rinsing from rain. Salty sand makes poor mortar. Maybe lime putty mortar would be good for you. The lime bags are lighter, only 50 pounds instead of 94 pounds for Portland. And all you need is lime: no Portland, no sawdust (for the mortar), no cement retarder. The downside might be, for you, that lime putty mortar requires a couple of weeks of frost-free conditions to set without damage, whereas the Portland mix needs to be protected from frost for just a couple of days. For insulation, an absolute necessity for you, you could bring in any sawdust, or bales of cellulose, which fluff up nicely. You mention a yurt, which requires a tension ring around the outside of the top of the wall. I do a lot of round cordwood buildings, and I always use a center post to support the inner end of a radial rafter system. This prevents outward thrust on the wall, so that you don't need the tension ring. The wind should move quite nicely around your round building, particularly if you don't spoil the aerodynamics by plunking a mudroom or some other appendage onto the side of it. If you must have a mudroom, keep it inside the building, as we have done at Earthwood. Q: I have read several books on cob/strawbale/cordwood building and would love to build a sauna. I live in Interior AK, so have special building considerations. Most notably earthquakes (we had the world's largest a few years ago), permafrost (my house foundation is telephone poles because of this), need to use vapor barriers/mold worries in walls, and extreme cold (-50 will happen every year). I also live on a creek, but flooding concerns are rare. Because of these needs, I've had a hard time reading between the lines of non-Alaska publications to see if a cordwood (or other natural building type) sauna is appropriate. Many natural buildings seems to have very heavy floors, yet my foundation will have to be elevated due to permafrost. And what is appropriate for sauna, where things will get both wet and hot? What is appropriate for earthquake-proofing (e.g. need timber framing for cordwood walls, and can you still use a living roof)? A: I do not see why a cordwood sauna will not work for you, just as it does for us in our cold climate. With respect to your special concerns, you do not need or want a vapor barrier; unnecessary with cordwood masonry. Yes, most probably you will need to build off the ground with your permafrost situation. I suggest frequent pillars or posts, using standard building procedures for your area. With cordwood walls, you will want a substantial perimeter girt system joining the tops of your pillars, probably 8 x 8 girts with no more than a six-foot span between them. Yes, you need to do timber framing as protection against earthquake damage, but I do not see why you cannot support a reasonable living roof of 6" of soil or less. The thermal mass in a cordwood sauna works to your advantage in a sauna. Q: I live in Eastern Tennessee. I have purchased several 40' steel shipping containers with the intent of converting them to a house. I am wondering about building cordwood walls around this strong exterior structure to provide thermal mass, insulation and improved aesthetics. My thought is to build a concrete block footer to get the logs away from the most soil. The container would be on piers, providing an open crawl space underneath. Is there a method you could recommend to anchor the logs to the steel skin and frame that would not require a timber frame? A (Kelly): I think that what you propose is entirely feasible and practical. Such an external cordwood shell would definitely help insulate the metal container in very aesthetic manner. It would add some thermal mass, but not a whole lot. The cordwood walls would really just need to be self-supporting, since they are not necessarily part of the structural integrity of the building. It would not require much of an attachment to the container, only enough to connect the two together, and this could be accomplished with periodic metal bars (angle iron, etc.) that was welded perpendicular to the container wall and imbedded within the cordwood. You can actually stack cordwood at the corners in such a way that they interlace directions and are self-supporting. There are some fine examples of this at http://www.midcoast.com/~adolphsn/alan . Whatever roof structure you devise would obviously need to extend over the cordwood walls. Q: What about carpenter ants? We do see them quite frequently here on PEI, Canada and in fact had to battle to get rid of an infestation in our white cedar log house. A: We have twice (in almost 30 years) had to get rid of carpenter ants at our Earthwood home. Both times, they were up in the tongue-in-groove ceiling, but, once, they migrated into the cordwood wall and we had to poison them. The problem only lasted a day or two. Q: People asked me if can you put electrical in the cordwood wall as you build them, either by using conduit or UF wire, and also possibly plumbing and radiant heat. If this could be done then I would only have to stud the interior walls and save more this way. A: As for the electrical part, you can use either of the methods you suggest. For duplex receptacles (plugs, required every 12 feet around a room by code), you can run a course of conduit at about 14" or 16" off the floor. (Code does not specify the height of receptacles off the floor, but 14" to 16" is the convention.) Run it right in the insulated space between the inner and outer mortar joints. Boxes can be installed on the sides of posts, laid up in the wall like small log-ends, or - as one friend did - inserted in routed spaces on large log-ends. |
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