Tarp House starts to become Sunnywood

Because it's important for the lime-putty mortar not to cure too quickly, we had tarped each panel as it was completed, to protect it from sun wind. So as far as the neighbors could tell, despite all of our building efforts, we still had just a tarp house.

Today we removed the tarps from the panels that we had completed 30 or more days ago (time enough for initial curing): a total of 5 panels. Even though these earlier panels, as the "learning walls," incorporate all of everyone's mistakes, they are still awesome. I can't wait to live in this house.

Trapped in cordwood

Our long silence does not mean that we've finally mortared ourselves into our walls! We're just in a building frenzy, trying to complete as much wall area as possible before the calendar puts an end to it. After that we'll update this blog with detail and process notes and photos.

We finished the 8th panel on Saturday the 12th. We could move in for the winter with 8 panels, as that would give us three "bays" closed in, if we install a temporary wall at the west end of the completed panels. But we made so much progress on the 9th panel yesterday (we're getting better at this, and faster*), that we are now considering the possibility of a 10th, which would give us 4 bays---all of our living area except the utility and project rooms.

See the rough floor plan below. The gray exterior border represents the 18" cordwood wall. The small black rectangles are posts; there are a total of 14 cordwood panels between the posts. We have completed the panels bracketed with red: three on the north, three on the south, and the two large east panels. As of yesterday, we had about a third of the cordwood done on the 9th panel (the next south-facing panel). If we complete another north panel, making 10, we can move our temporary wall west by an entire set of posts.

We've extended our "stop" date to the 19th, which is surely pushing it in terms of approaching frosts. What do you think: is it worth taking a chance that frost might affect the set of the lime mortar?



*Joe and I, working alone, mixed and laid up six batches of mortar, in addition to cleaning some logs and sifting some sand.

Working on panel 6!

Heidi, beginning the sixth panel:

Our post and beam, shed-roofed, 43' x 25' design has 14 infilled cordwood panels between the posts. The minimum number of filled panels we need to be able to live there during this winter is eight: this would give us the kitchen, bath, one bedroom, and a bit of living area. But we can only lay cordwood until about mid-September, because lime-putty mortar doesn't set up well in really hard frosts. So our goal has been 8 panels by mid-September. Looks pretty doable at this point (maybe we can fill 10 panels, which would give us more living area and the other bedroom!).
The following pictures show the fifth panel, which is actually the center panel of the three well-glazed south-facing living-room panels. This went fast because the window frame took up so much room.
Here are Isaac and Heather, completing the top of the center panel. Note Joe's homemade scaffolding:


Check out Isaac's under-the-window cordwood pattern!


Laying a bottle end:



Joe is sitting in the window well. 18-inch-thick walls make window frames with a lot of options! (You can see one particularly bright turquoise bottle end as well.)

What a crew of six can accomplish

TWELVE batches of lime-putty mortar. That's what Isaac, Heather, Joe, Ian, Heidi, and Holly mixed and laid up today.




Wha' da ya know? It's raining! Boy, we really needed that!!!



Isaac, Ian, and Joe built and set the front kitchen window frame while waiting inside behind the tarp for the monsoon to end.

Life can sure change all in a moment

So . . . we've lived in our current house for almost exactly a decade: longer than either of us has lived anywhere else in our adult lives. It's where our youngest daughter spent her high school years, and where our youngest son has lived since he was nine. We had planned to try to sell it, when our cordwood house was nearly ready to move into. But life has a funny habit of not working out as planned. Our house has been---unexpectedly---sold, to the satisfaction of both seller and buyer. Now all we need is a place to live!

We had planned to start laying cordwood last spring. We worked on painting and repairs in our current house, so that when we were ready to sell it, it would be ready to sell. We enjoyed the activities of our youngest child's senior year in high school, and concentrated on college preparations for him.

We were ready to start laying cordwood. Then the rains hit. As I write, it has been raining pretty steadily, with few breaks, for about two months. No one around here has ever seen anything like it.

We have 14 panels to fill in with cordwood---although we could probably move in with just eight panels and a temporary wall. But we have to stop laying cordwood no later than mid-September, because the lime-putty mortar won't set up properly in a hard frost.

We have already been blessed by "help from the sky." Isaac and Heather have been awesome!!! Karen and Clive!!! Ian!!! However we are here to say that if any of our readers have the slightest interest in learning how to build with cordwood, NOW IS YOUR TIME!!! We stand ready and waiting to teach you everything you would ever want to know (as well as stuff you wouldn't). Come on out and experience the zen of cordwood . . .

30 batches of mortar later

We had our two days of summer, and it's raining again. We have managed to make a bit of progress, though.

Laying cordwood at last

Rain be damned---we are laying cordwood! And very glad that we decided to build a timber frame with cordwood infilling, rather than building load-bearing cordwood, because we have a roof to work under. The folks in the Daycreek forum---particularly Bruce and Nancy---have been most helpful and we have achieved very good LPM (lime-putty mortar) mixes, with the help of some bagged dry sand. When the mix is good, you can feel it and hear it while you're mixing.

We are using 18" log ends, and following Rob Roy's suggestion, going with approximate MIM (mortar-insulation-mortar) widths of 5"---7.5"---5" (to leave a half inch for log-end relief when pointing).








The corners around the posts are kind of funky: we use 6" log ends on alternate courses. From the outside there is no difference: we just need to remember to leave room for insulation on the inside.

Splooty mortar, and the cordwood learning curve

You can read all you want about something---and trust me, we have---and you can try to learn from the example of others---we took Rob Roy's cordwood course---but nothing can prepare you for actually doing something, other than . . . DOING it.

We have opted to use lime-putty mortar rather than a Portland cement mix. It is time-tested (the Romans used it) and doesn't have the embodied energy of Portland (cement manufacture produces huge amounts of carbon dioxide). So last week we cracked open some of the 100 bags of Type S builders lime we'd purchased, and hydrated it to make a lime putty, using a recipe from New York cordwood builders extraordinaire Bruce and Nancy: 13.5 gallons of water, 3 50-lb bags of lime, and 1/2 cup of dish soap. This mixture is WORK to mix, even with a paddle mixer attached to a power drill. We covered the putty with a film of water and plastic, and let it sit for a bit more than the required 3 days.

Yesterday we tried our first mortar mix: 2 1/2 parts sand to one part lime putty. However, here in Maine we have had a freakishly wet spring---we had five inches of rain just between June 19 and 21, and it's been raining all month---and our sand, despite our best efforts, is pretty moist.

The resulting mortar was overly moist. Cordwood guru Rob Roy says that a ball of mortar, when tossed three feet in the air, should NOT go "sploot" when it lands. All I can say is that ours was pretty splooty.

We tried laying up our first bit of cordwood with our too-wet mortar, rolling up one of our tarp "walls," but the rain and wind began again as soon as the tarp was up. We were forced to give up after half a batch of mortar, which is probably just as well. We were in a hurry to lay our first cordwood after all of the preparation, and forgot everything we'd read about technique and "mortar, insulation, wood" cadence. Looks like we'll need to wait out the weather, settle down, and try again.

"Pretty splooty"