Process

updated 05-19-2002

previous info: pre 6-22-2001

We met with Lars Stanley on June 22, 2001 to present and discuss our design and to discuss moving ahead with construction.  Below are the schematic drawings and model.

Pre-October:

We have recently poured the concrete footings, which are 3'x3' spread footings with 8" dia. concrete piers.  There are 8 individual footings, one for each corner of the designed square (as seen in plan) and one for each midpoint of the edges of this square.  They were poured in two parts, initially the spread footing itself, with the piers poured after hardening.   Materials used include QuickCrete concrete, QuikTube concrete tubing, #5 steel reinforcement bars, and on-site collected rainwater.

In addition to the footings is the foundation for the central fire-pit.  It consists of  a 6'x6'x9" slab (#5 rebar @10"O.C.).  CMUs are being used to raise the foundation up to floor level.

8x10 steel I-Beams were chosen for the floor beams, with pressure-treated wooden sole plates and 2x8 floor joists @ 16" O.C.  See our nifty moment diagrams (AutoCAD 2000 file) for the calculations on the steel.

A supplier of straw bales has been chosen, now we must finish framing the floor and we will be ready to frame the walls and also to build the firepit.

Currently, we are working out a problem where our floor level drops on the NE quadrant.  Floor beams were initially designed as 2x12 lumber, but a switch to steel beams after having poured the concrete piers complicated the matter.  See the pictures of the floor framing and download the potential solutions (in AutoCAD 2000 format).

Oct 1:

Updated design drawings for wall section and plywood flooring.  Estimated 14 sheets plywood and 30 - 8' deck boards:

Nov 1:

Slowly but surely, we finished the flooring, no thanks to the extensive rain.  3/4" pressure treated plywood is used on the interior spaces with 6" deck boards on the exterior space.  Next we are working out exactly how we are going to do the roof.  Currently the plan is as designed above.  Like all things Benchley, it's subject to change.

December:

The structural portion of the walls has been designed and is being erected.  Composed of 3x3 structural steel tubes at the corners, an open-web steel truss spans the length of the wall (24 feet) and will act as clearstory windows.  The straw bales will be stacked up to the lower ledge of the truss.  These windows will be located on the east and north faces of the building, bringing in diffused northern light during the day and warm morning light from the east.  See the construction pictures for more info; design drawings to be posted soon.

January:

Structural portions of the wall are up, including the framework for the firepit, which will be fully constructed from steel.  Roof rafters are 2x6 SYP @ 24" O.C., resting on 2x4 top plates bolted to steel angles which rest upon the steel tubing posts.  The valley of the roof will be a steel truss, similar to the truss on the north and east walls.  Roof rafters will frame into a 2x4 top plate bolted to the top of this truss.  As always, the pictures show a lot.  We are also constructing a small CMU shed at the front of the property to house the existing gas tank and some other misc utility. 

February:

Roofing is almost complete.  On top of the rafters are 1/2" sheets of OSB (Oriented Strand Board, similar to plywood).  Then comes the asphalt impregnated felt (AKA tar paper), we used what we had already at the site, 30 pound and 15 pound (30 is thicker).  On top of that is the 1x4 nailers for the corrugated sheet metal.  

Where the chimney will emerge, we have created a plywood box for the rafter to tie into and the roof to rest on.  The chimney will come through this box.

A new addition to the design is a band of small horizontal windows beneath the main wall truss, framed in 2x6s.  These windows will slide open and aid in ventilation.  See the updated pics here.

Lars brought his new baby, a Case mini-dozer.  Clearance is being made for greater vehicle accessibility, a yet-to-be-designed alternative septic system, and general site flow.  Since the yaupon tends to take over the site, clearing it is virtually necessary for moving anywhere on the site.

Also, Saturday afternoon boredom created a new exterior firepit, one designed for cooking and general warmth.  This new pit is closer to the new structure, whereas the old pit (read: hole in the ground) was slightly further and partially in the circular driveway.  See a pic of it on the downtime page.

Straw bale walls will most likely be going up starting in early April, stay posted.  Logistics of how the straw is installed and secured will be posted here.

March-April:

Roofing is COMPLETE, excepting some flashing that will occur once the chimney is constructed and we bring it up through the roof.  Straw Bales were brought in mid-April, from supplier Ron Stehling in Fredericksburg.  Presently we are gearing up for the big day, May 4th, when we'll be stacking the bales and prepping for the plastering.  One year later and we're finally there (well, pretty darn close), and we're very excited.  Steel lateral bracing on the frame of the house is being welded into place while we also construct the wooden framing to house the windows within the straw.  All windows being used are leftover from who knows what, found in the little shed on the site. 

Currently we are making the final decision on how to brace the bales and tie them into the floor system.  Once that is decided, look for drawings here.  Consult the wall images page for a latest pic of the house, as of April 21.

May 4th:

Straw Bale Raising Party!

May Onward:

The Bale Raising Party was a huge success, thanks to everyone that came out to help!  The moisture barrier (felt paper) and the wire mesh started going up the day after the bale party, to protect the exterior faces of the bales from rain.  The paper/mesh is held in place with wire, needled through with the same baling needles we used to re-wire bales.  These needles thread wire through the bales, which you can tighten to hold them in place.  The first tests of stuccoing have begun, as well.  Stucco ties in nicely into the straw through the mesh, and works nearly as well with the moisture barrier behind the mesh.  Moisture barrier is used on exterior walls only.  This site will be moving to Lars Stanley's server soon.