“An Engineer should design a structure that an Architect should be ashamed to cover up.”

Design priorities for this structure were:

Thermal-Bridge-Free Load Transference:   In accordance with the Passive House method, absolutely zero conduction of thermal energy occurs between building structure and earth or outside air.

Exceptional Strength:   Built to withstand a 250+ mph sustained wind.

Cradle-to-Cradle Approach:   Utilize only materials that were post-consumer or post-industrial recycled, salvaged from the original home or from former projects.

Non-Toxic Materiality:   VOC-free construction throughout, from adhesives bonding exterior insulation, to finish paint.

New materials used were:

Company	Role	Description
	ICF	Concrete forms made of slag, recycled wood pallets, and insulated with rockwool form the extension’s reinforced concrete structure on South and portions of the East elevations.
	Rigid Insulation	Made entirely out of aerated recycled glass, Foamglas is a rigid insulation we used below slabs and around footings.  It entirely clads the envelope & forms a vapor, fire, termite, radon, and thermal barrier.
	Floor Structure	Lightweight temporary steel floor structure eliminates the need for extended forming and greatly reduces lumber used in construction and allows column-free interior spans. Our particular installation borrows from suspension bridge design and allows for a “springy” luxurious residential feel while providing thermal and structural benefits of reinforced concrete.

Reinforced, Insulated Concrete Wall – Home Addition

Pictured is cantilevered flat roof, Durisol ICF block, Steel bracing, and Foamglas exterior insulation (applied with VOC-free adhesive instead of mechanical fasteners).

Reinforced concrete lintel formed within cradle-to-cradle ICFs and with recycled steel rebar.

Recycled steel rebar within insulated envelope.   Such strong corners allow for superior wind resistance.

Reinforced, insulated concrete wall.   Steel reinforcement and heavy concrete are both within insulated envelope.

Column-free Concrete Floor Structure – 2nd Floor Addition

We chose the early fall to pour concrete slabs in order to maximize cure time and eliminate the need for toxic antifreeze in our mix.

Rebar from reinforced concrete wall was intertwined with reinforced concrete flooring to substantially increase building strength over traditional construction methods.

Hambro flooring system allowed the use of scrap plywood for framing the concrete floor & borrowed lockable bracing bars (returned to manufacturer) once concrete cured.

The result is a column-free concrete span and substantial thermal mass totally within the thermal envelope.   Living spaces encased in concrete creates a very peaceful interior.

Steel Reinforcement and Bracing – Throughout Building

72 pieces of structural steel were strategically placed to brace and reinforce:

1) The wood structure,

2) The reinforced concrete structure, and

3) Roof and floor structures

Connection between old and new home

View of steel being added while existing home is rebuilt.   Note framing of new window, with presence of old bathroom window (not yet removed).

Foamglas-clad Durisol block, framed openings for new windows, steel bracing.

Steel framing for entrance foyer.   Future entryway is supported by bar trusses.

Original block foundation is salvaged, and integrated with Durisol block foundation wall.

Wooden floor joists placed within steel structure.

Salvaged original timber braced by new structural steel.

Spliced structural steel column supporting eccentric load in all directions.  Note reclaimed lumber used in new structure.

95% recycled steel structure is thermally broken from the ground, and resting on a pad of Foamglas rigid insulation.

Woodframe Structure – Existing Building Retrofit

Photo depicts original block foundation meeting new Durisol foundation, atop of which are staggered studs to avoid heat transfer from front & back of assembly.   Note reclaimed/salvaged studs.

Use of double 2×12’s as floor plate.  Note staggered reclaimed studs.

Window lintels are separated front to back to eliminate thermal bridging

Scrap lumber reclaimed from site used as blocking to give exceptional strength to 2×6 stud walls.

Expert integration of steel and wood framing.

Scrap lumber reclaimed from site used as blocking to create an extra-rigid floor diaphragm with 2×12 floor joists.

Reclaimed 2×8 lumber used as nailers for 2×12 floor structure.

Reclaimed 2×8 lumber used as nailers for 2×12 floor structure.  Note 2×12 floor joists used in 8-inch steel perimeter.

Reclaimed 2×8 lumber used as nailers for 2×12 floor structure.  Note 2×12 floor joists used in 8-inch steel perimeter.

Reclaimed 2×8 lumber used as nailers for 2×12 floor structure.  Note 2×12 floor joists used in 8-inch steel perimeter.

Salvaged 2×12 used to reinforce steel joists, while steel columns are enmeshed into triple-stud wall assembly made of both salvaged and new FSC-certified lumber.

 

Adding roof rafters made of 2 x 12s.

Reclaimed subflooring and salvaged 2x4s used in construction.

Reclaimed studs, mix of old and new, steel bar joists, and Foamglas layer under new concrete slab in existing cellar.

Reclaimed sub floor, reclaimed studs, and steel-reinforced bracing.

Reclaimed wood seen framing out new voids for high-performance windows.

Hambro, steel, and lumber work together to form the building superstructure.

 

We staggered the studs in the woodframe portion’s triple stud-layer to minimize thermal bridging.

We fabricated and inserted steel framing within the existing woodframe structure.

Steel reinforces and stabilizes the structure enabling the building to withstand powerful storms.