Cordwood Construction Workshop at Kinstone, Wisconsin May 2013

The Cordwood Workshop on May 18-19, 2013 at Kinstone near Fountain City, Wisconsin was a rousing success. Sixteen wonderful people learned the fine art & craft of cordwood construction. The Cordwood Chapel is full of nature design motifs and the combination of an evolving permaculture site with stone circles and monoliths makes for some very powerful energy. There are more photos at www.permacultureproject.com and at www.cordwoodconstruction.org under What’s New?
Surveying the 3 completed Kinstone Chapel walls and looking to finish the next three.

Surveying the 3 completed Kinstone Chapel walls and looking to start on the next three.

I don’t know what it is about cordwood, but it draws out the very best people…we consider ourselves blessed to have met and worked side by side with “salt of the earth” types.

Classroom time is devoted to "Best Practices" with cordwood that have been hard won during 34 years of cordwood living, building and sharing.

Classroom time is devoted to “Best Practices” with cordwood that have been hard won during 34 years of cordwood living, building and sharing.

Hands on mortaring of a cordwood wall in a "learn it by doing" style is the best way to "cement" the tricks of the trade.

Hands on mortaring of a cordwood wall in a “learn it by doing” style is the best way to “cement” the tricks of the trade.

Design features like in the "fire wall" are made from serving bowls reclaimed from thrift shops.

Design features like in the “fire wall” are made from serving bowls reclaimed from thrift shops.

Learning to "screen" sawdust becomes a lesson in wind direction:0)

Learning to “screen” sawdust becomes a lesson in wind direction:0)

The Kinstone Academy of Applied Permaculture will be hosting many types of classes.  The facilities are outstanding and the food was most excellent. www.kinstone.com

The Kinstone Academy of Applied Permaculture will be hosting many types of classes. The facilities are outstanding and the food was most excellent. http://www.kinstonecircle.com

If I see it and do it, I remember.

If I see it and do it, I remember.

Good looking crew!

Good looking crew!

Making bottle ends requires concentration and Kinstone has hundreds of bottle ends. It is truly a work of art.

Making bottle ends requires concentration and Kinstone has hundreds of bottle ends in its walls. It is most assuredly, a work of art.

The shirt on Jarad portends the stones and the kinship feeling that permeates the environment at Kinstone.

The shirt on Jarad portends the wonderful stones and their stories and the feeling of kinship that permeates the air at Kinstone.

Sawdust and lime insulation is added and packed in the center cavity.

Sawdust and lime insulation is added and packed in the center cavity.

These pictures are all courtesy of Wayne Weiseman of http://www.permacultureproject.com   Wayne is a founding member of The Kinstone Academy of Applied Permaculture, along with “Rock Star” Kristine Beck and “Mr. Fix-it”  Jarad Barkheim.

When the mortar starts a flowing the wall starts a'rising.

When the mortar starts a flowing the wall starts a’rising.

Websites to find out more about Kinstone Academy,  Permaculture Project and Cordwood Construction.

  If you have any questions, please email me (Richard Flatau) at Flato@aol.com or go to my website http://www.cordwoodconstruction.org     You may also call with specific questions, from 9 AM to 6 PM  715-212-2870

Cordwood Castle in Maine

Alan Adolphsen built this absolutely beautiful small cordwood home in Hope, Maine in 2004. He describes his building adventure as an owner-builder. One with pluck and a good knowledge of construction. Here are a few words from Alan on how he decided upon cordwood and then tackled his project with gusto.

Alan's home under a soft blanket of snow.

Alan’s home under a soft blanket of snow.

“Deciding to build my own house was an easy decision for me. What was hard was waiting for the right time to tackle whatever it was that I came up with. The first thing that I wanted to build was stone. I have plenty of stone on my site so that was not a problem but it did seem a little too time consuming to do a stone structure. So my mind began to wander.”

Alan Adolphson Hope, Maine4

“I started looking for alternative methods for building. I have done a lot of modern conventional construction and I just could not bring myself to use these flimsy methods that would allow someone to virtually kick a hole through my house.
Dry wall, plywood and fiberglass insulation all send shivers of contempt down the back of my neck. They were all out of the question except perhaps the ever-useful plywood products that seem to keep getting better and better.”

With the walls under construction, a bleach water solution is applied to reduce the possibility of the log ends darkening.

With the walls under construction, a bleach water solution is applied to reduce the possibility of the log ends darkening.

“I eventually came upon cordwood construction. This method did not seem to be the complete answer, at first. I had a lot of reservations about the types of insulation to use and the inevitable shrinkage separation cracking that occurs when one stacks mud and wood in the same place. I put a lot of thought into this subject. I knew that there is no way to completely stop wood shrinkage from happening, but I was determined to at least minimize its negative effects.”

Alan Adolphson Hope, Maine 9
“After about 500 sketches of the ultimate house, I finally decided to look at what I really needed to accomplish. Living in Maine, I wanted first to heat as cheaply as possible, so big was out of the question. If the place was going to be small, by golly, it is going to be “cool.” This led to another 500 designs lying on the floor.

At this point the design process actually began to get more fun. It was time to go for a long ride. I drove all over looking at different shapes of houses. What I discovered with this trip, and many others, is that some builders had got it right with regard to house shape. I decided on squares and 45-degree angles. Luckily for me, cordwood lends itself to these shapes quite well. That is how I came up with what I built. I decided that I could live with a somewhat reduced version of my stone castle if I just incorporated some finite amount of stonework on the inside and the outside.”

Alan Adolphson Hope, Maine 1
“Castles have lots of arches, which frame the view and lend their shape to the observer’s peace of mind. So I decided that major design elements, like windows and doors, had to have arches over them. Arches, combined with squares and 45-degree angles, are what “makes” this little house visually. And arches have very real structural benefits, too. I looked for products that would let me build masonry arches. I thought of pouring them in concrete. I thought of lifting them, but then quickly decided on fitted wood.
A couple other details down the scale, from arches and the like, are the gable ends. They had to be continuous walls—bottom to top—and the arches were my rounds, so all the wood would have to be split at least once. There is, however, one lonely round log-end high in the wall.”

The house is now all finished, comfortable and gorgeous.

The house is now all finished, comfortable and gorgeous.

For information on building with cordwood construction you might wish to visit www.cordwoodconstruction.org and if you have a notion go to the menu on top and click on NewsArticles, Photos and Books for a visual feast.

The backyard BBQ is all set for grillin'.

The backyard BBQ is all set for grillin’.

German newspaper reviews Cordwood Construction

Over the past month I had the privilege to be interviewed by a Romanian newspaper woman (Nina May) about Cordwood Construction for the German newspaper Deutsche Zeitung.  The article covers existing cordwood in Europe and North America and its potential uses in Romania and Germany.   Nina was very perceptive about building techniques and was interested in translating the current cordwood craze in North America to her countrymen and women.     Here is the article in German and the fascinating translation is below.

Deutsche Zeitung article 4.21.2013

 

An eco-house firewood?

Aesthetically, solid, flexible and incredibly cheap – a nearly forgotten Civil Engineering conquered new territory

By Nina May    Sunday 21 April 2013   Who has not dreamed of in any phase of life, to build with their own hands a house somewhere in the countryside? Ideally, a spacious and comfortable family home, with rural charm and personal touch, warm in winter and cool in summer. Or at least a romantic summer residence on the lake or forest, a rustic mountain hut on a flower meadow … No? Then at least a tiny writers retreat in the far corner of his parents’ garden. Of course the dream house should also be as original! How about some grass and vegetation on the roof? Or with colored glass portholes?  And ecological materials are more and more coming: wood, clay, straw. In addition, it should be easy to implement, best known as Do-It-Yourself. For anyone who has been to engage in leisure the nerve to supervise a squad worker, or the money, a professional construction company? If you loaded with all of these criteria, surfing through the Internet, you quickly end up … in America! In fact, in Merrill, Wisconsin, Richard Flatau, teaches a construction technique which is called Cordwood. Both in Sweden and in North America in the 19th Century in parallel and developed without mutual influences method of construction is there for the “Habitat” exhibition in Vancouver in 1975 of a real boom because Cordwood houses not only meet all the criteria above, they are also aesthetically pleasing, have excellent thermal insulation properties, are relatively earthquake-proof, fire-resistant and suitable for all climates. than 1,000 magnificent Cordwood houses are to be developed in North America since then. Richard Flatau, builder and manager of some Cordwood building appropriate workshops, collects and documents all experience the same number of pages. Cordwood first attempts to find more recently in Europe: Sweden, Finland, England, France, Poland, Hungary, Russia. Most are even smaller huts with a few square meters – tentative steps on new terrain. Cordwood to Romania is not yet penetrated. About the idea of introducing this construction here, Richard Flatau, enthusiastically. principles for a solid home in America there are more than 100 years Cordwood homes that are still in perfect condition. Richard and Becky Flatau but only for 33 years living in their Cordwood home. The building has cost them two summers (1979/80) and $ 15,000 – a third of the price of a comparable conventional house, said Richard. Although known in the U.S. as “Poor Man’s Architecture”, it shows on its website a lot of examples for larger villas. Up to two stories can be built with Cordwood said Richard, if you follow a few basic rules irrefutable without a Cordwood house can quickly become a nightmare.  He explains in his 2012 book “Cordwood Construction Best Practices”.

Cordwood what does it really mean? To Germans “cordwood” betrays the concept already the most important basic substance: Firewood! Peeled firewood – one basic rule – because the bark would attract moisture and insects! Whole tree slices and split logs of ideally 40 inches long, possibly in different sizes, such as high masonry bricks, the ends protrude inside and outside of the wall. Under no circumstances should you remove them or plastered with conventional materials because the breathable fibers of logs act like straws that exude the moisture out of the house, said Richard.

A Cordwood house therefore always offers rustic look. then he reveals two basic rule: soft wood has to be, because hard wood swells when it rains too much, and can burst the walls. Suitable cedar, spruce, poplar, pine or fir. As dry as possible, because otherwise arise during subsequent drying cavities, which can, however, easily repaired. As a mortar, he recommends five variants of strictly natural clay-straw-sand (Cob) or lime-sand (lime putty) mixtures on newsprint borax, lime sand, cement-lime-sand sawdust and cement newsprint sand compositions , all touching in a certain ratio with water.

Swede Olle Hagmann, who has built a writers cabin in the woods, has tried all the variants themselves. He had very few cracks in the sawdust mixture and absolutely no paper with the cement composition. His house 3×3 meters of spruce and aspen cost him 500 euros. ”Until now it is tight, no mold, no mice,” says Olle. ”If we had not already a sauna, I would build one from Cordwood, because the technique is particularly suitable for this, especially when clad the interior of the fire with clay,” says the retired professor, who wants to be necessarily informed once in Romania the first Cordwood experiment running! Although suitable for humid climate, river and lake regions Cordwood houses, have direct contact with water – Principle Three – to be avoided, warned Richard. This means a slightly higher plinth of stone or concrete and an overhanging roof, which should be before the walls of the walls. The best is erected a wooden pier construction and then backed up between the posts. So round constructions can be realized as easily as square. For earthquake zones Richard recommends additional cross braces. For the future installation of windows wood frame must be supported as a wildcard.

Cool in summer, warm in winter The excellent thermal insulation properties, which were detected by the University of Manitoba (thermal resistance of a 40 cm wall: R = 24), Richard explained by the high thermal mass the logs to prevent temperature fluctuations. But also the technology that helps Bricklaying: The logs are only connected at the ends with a dab of mortar. Into the cavity between sawdust comes to insulation. therefore A Cordwood wall contains much less mortar than it visually gives the impression. How thick or thin plotting the mortar layer is a question of the desired look. To protect against insects and fungi can mix the sawdust in the insulation space with slaked lime or treat the wood logs with borax. With old wood to build, was not a problem, says Richard. Never, however, already infested wood may be used. Olle Hagman has opened another technique in his research in Sweden and Norway (1870-1930), in rectangular pieces of wood – such as brick walled with a clay-straw mixture – the operation of sawmills were. Cordwood walls that are even fireproof, shows an experiment at the University of New Brunswick. Five hours held the test wall was a fire, the wood charred only at the ends.

A personal piece of art you can let off steam yourself artistically in the Cordwood same technique in several ways. Firstly, by the shape and arrangement of the logs. In a project for the head of the bear clan in Ojibwa Indian Reservation Bill Paulson realized a stylized bear paw as a personal trademark. But are also attractive walled with glass bottles in all shapes and colors that provide charming lighting effects. shells, beads or stones can be pushed into the mortar, or applications of clay attached. If you like it very rustic, gnarled trunks can use for the base construction. A Cordwood wall can easily be adapted to uneven interfaces. Shelves or niches if you include long timbers that protrude inward or outward from the wall. ”A Cordwood house provides a lot of decisions before,” says Richard Flatau. Although, as he says, not much can go wrong, it takes a little courage. So, who dares? ——————————————–

“Cordwood Construction Best Practices” by Richard Flatau, as an e-book at www.daycreek.com/dc/html/paypal_flatau.htm available. More info under www.cordwoodconstruction.org and www.daycreek.com

Cordwood Construction on the Black River

[If you wish to enlarge this article, press Ctrl and + at the same time and the screen will enlarge.]

Ed and Julie McAllen built a gorgeous cordwood home near Galesville, Wisconsin by the Black River.   They built it for $23,000 because they recycled, scrounged and did most of the construction themselves.  The following article is used with the permission of the editors at New Pioneer Magazine.  It comes from their 2o12 issue #155.

New Pioneer article page 1

Ed and Julie lived in an old cabin while they constructed their dream home. By looking around for bargains and throw outs, they were able to build a home for the price of a modest new car.

New Pioneer article page 2

Bottle ends and special log ends are placed in the walls that detail the families journey to home ownership.  There are deer antlers for coat hooks, a bottle end Big Dipper and deer mounts on the walls.  With cordwood there is never a problem finding a place to pound a nail.

New Pioneer article page 3

Ed and Julie built a root cellar for storing their home canned food. They have access to the Black River and acres and acres of public land.

New Pioneer article page 4

[If you are interested in reading the article press Control and + and the screen will enlarge each time to press those keys.]

For more information and to see the latest literature on cordwood construction visit www.cordwoodconstruction.org   

If you need more information send me an email at richardflatau@gmail.com  

Minnesota Cordwood

Minnesota is home to not only strong Viking ancestors, Lake Wobegone and the Spam Museum (the canned meat), but also to a number of beautiful cordwood homes, cabins, cottages and saunas.   Here is a cordwood sauna being built near Tower, Minnesota by Paul Harney.   Paul has so many friends of Finnish descent that they have nicknamed him Harney-maki and encouraged him to love sauna. [These pictures are all courtesy of Paul Harney.]Paul Harney cordwood wall 6

The building is post and beam framed with the roof installed before the cordwood. This insures a place to keep materials dry and it allows mortaring to be completed in inclement weather.

Paul Harney cordwood wall 5   This portion will be the sauna and the other side will be the changing room. 

Well organized mortaring station2aPaul has a well organized work station for his mortaring.  Bags of cement and lime are under cover, there is a screen for sawdust, scaffolding is at the ready and the cement mixer is close at hand.

Paul Harney cordwood wall 2After mortaring for the day, Paul would tightly cover his days work.  This helped the mortar to slowly set and cure.

Tuck pointing 1aHe used a 1″ putty knife, then the convex side of a spoon and finally a paint brush.  He did a very nice job of tuck pointing and his walls look clean and finished.Paul Harney cordwood wall 4

Not quite finished,  Paul has been sharing pictures on the www.daycreek.com Forum.  His pictures and thoughts are under the title “A Cordwood Blessing.”

If you are interested in more information on cordwood construction go to www.cordwoodconstruction.org or visit my Facebook page at www.facebook.com/cordwoodconstruction/

You can also email me (Richard Flatau) at Flato@aol.com or richardflatau@gmail.com is you have any questions.

Cordwood Sauna in Givens, West Virginia

Patrick sent some wonderful pictures of his family building a cordwood sauna in the hills of West Virginia.  Since my wife’s family is from WV, it piqued my interested.  Then Patrick told me he was Finnish (I lived in Finland from 72 to 74) & I was hooked.

Kish 1

Since he was building in an area with a great view, but no access to a concrete truck, he decided on a post and pier foundation.  Cordwood is rather heavy (500 pounds per lineal foot) and so Patrick beefed up everything to handle the weight.

The post framework, using pressure treated posts is buried well below frostline and anchored with a concrete slurry.

The post framework, using pressure treated posts is buried well below frostline and anchored with a concrete slurry.

The family has taken their first saunas (if you know anything about Finn’s you know a sauna is a very important ingredient in producing a happy Finlander:0)   Here are a few photos of Patrick and his clan on this St. Patrick’s Day!

Katy is an enthusiastic cordwood mason and has the next log end ready for Dad to mortar.

Garnet (Katy) is an enthusiastic cordwood mason and has the next log end ready for Dad to mortar.

Patrick was kind enough to send me a little history of his family.  Nothing like a family project to bring the brood together.  The changing room is next in line for cordwood infill.

An outer and inner row of mortar and sawdust insulation down the center.  This sauna is gonna keep its heat inside!

An outer and inner row of mortar and sawdust insulation down the center. This sauna is gonna keep its heat inside!

When you bring home a truckload of sawdust for the building of the sauna, what better way to sample the wares:0)

When you bring home a truckload of sawdust for the building of the sauna, what better way to sample the wares:0)

Karen and Everett dig into the mortar bucket to get the next handful of mud.  Playing in the mud is so much fun!

Karen and Everett dig into the mortar bucket to get the next handful of mud. Playing in the mud is so much fun!

In Finland everyone has a "sauna aika" or sauna time, who wouldn't want to be splashed with water, switched with birch branches and loofa-ed to clean the pores.  While you're at it throw a "makkara" (sausage) on the hot rocks for feasting after cleansing.

In Finland everyone has a “sauna aika” or sauna time once or twice a week and seriously, who wouldn’t want to be doused with water, switched with birch branches and loofa-ed to clean the pores. While you’re at it throw a “makkara” (sausage) on the hot rocks for feasting!

While you're at it, when life gives you a 2 x 4 and your Irish, Finnish and Hungarian, why not play a little air guitar in between batches of mortar?

While you’re at it, when life gives you a 1 x 4 and your Irish *by name), Finnish and Hungarian, why not play a little air guitar in between batches of mortar?

I’d like to thank Patrick and his family (Karen, Garnet & Everett) for allowing me to share their cordwood sauna journey.  Here is a little more of Patrick’s heritage.

“Grew up in  a the small Lake Erie town of Fairport Harbor, Ohio which was predominantly Finns and Hungarians.  Mom (Koski) Was Finn and Dan (Kish) was Hungarian.  My Great grandparent on my mothers’ side immigrated to Fairport from Toysa, Finland in 1920.  I spent endless hours in the sauna located in my great grandmothers basement while the warm nissu bread she made awaited our exit. The summer months  as a child where spent visiting Finnish relatives at their cabin on LakePenage in Ontario where the joys  of the rustic backwoods sauna on a cold lake where learned.  As the only one in the family that didn’t have a sauna , Karen and I decided to step it up and are pleasantly pleased, to say the least, we as a family (Me, Karen, Garnet and Everett) have put built  so far. Hungarian heritage isn’t so bad either especially when it comes to the food (chicken paprikash and Hungarian goulash)”

If you are interested in learning more about cordwood construction please go to www.cordwoodconstruction.org

Cordwood Cottage Garden Shed in Green Bay, Wisconsin

Tom & Mary Barchacky built this wonderfully attractive cordwood shed in the city of Green Bay, Wisconsin.  It is a building that was an idea that morphed into a project that became a work of art.

Tom and Mary Barchacky built a beautiful cordwood shed in Green Bay, Wisconsin.

Tom and Mary Barchacky built a beautiful cordwood shed in Green Bay, Wisconsin.

The building is made from all repurposed and recycled materials. The door was made from used lumber, the window was found in an alley in Milwaukee, the shingles are recycled and reused.

The arched door was hand built with recycled lumber and the cordwood was infiled around a temporary "bent" board.

The arched door was hand built with recycled lumber and the cordwood was infiled around a temporary “bent” board.

The cordwood infill is red heart cedar and was free for the taking from a neighbor who does tree pruning.

Red heart cedar has a beautiful undulation to the perimeter of the log and the center has a reddish tinge.

Red heart cedar has a beautiful undulation to the perimeter of the log and the center has a reddish tinge.

Tom used a block and tackle “truss derrick” to raise his top plate and roof trusses.

Tom used what he terms a "truss derrick" to place his top plate and trusses on the framework.

Tom used what he terms a “truss derrick” to place his top plate and trusses on the framework.

The building has a pleasant appearance and blends in well with their property.

Nicely done!

Nicely done!

Backhome Magazine published an article on this wonderful garden shed and now they use the cover for advertising.

The cover of Backhome Magazine about the Barchacky Cottage Garden Shed.

The cover of Backhome Magazine about the Barchacky Cottage Garden Shed.

The article is published on my website www.cordwoodconstruction.org  Go to Articles on the menu bar and then to Cottage Garden Shed from the drop down menu.

Hope you enjoyed this article.  If you liked it please visit my Facebook page and website.  

Richard Flatau
Merrill, WI  54452
Flato@aol.com
715-212-2870
“A house built of logs will look like none other, for it will glorify the stick.”  -Frank Lloyd Wright