The second *official* week of our icehouse rehab project has come and gone. Please excuse the tardy week-in–review. Better late than never! (Did you miss last week? Here’s the link: “Icehouse Rehab 01: The Ice Hook“.)
The idea behind these weekly updates, chronicling our progress on the icehouse rehabilitation project is multifaceted (ie. muddled and evolving.) As I recap the second week, here are few of the underlying objectives:
recognize/celebrate our distributed team (Trello to coordinate, @rosslynredux to showcase, rosslynredux.com to chronicle, etc),
transparently map our rehabilitation process, accounting for the ups and the downs without “airbrushing” the journey (rehab inside out)
document our fourth and final historic rehabilitation project at Rosslyn,
inspire others to undertake similarly ambitious and rewarding rehab adventures, ideally with an eye to adaptive reuse of existing structures,
and leverage this current experience as a way to revisit and reevaluate our previous sixteen years of Rosslyn rehab ad infinitum.
Overview
Code officer and carpenters troubleshooting (Source: R.P. Murphy)
In broad strokes, the week started with a site visit from Colin Mangan, the Town of Essex Code Enforcement Officer, included a site visit from John Bean, the sales rep for Windows & Doors By Brownell (who is coordinating new windows and doors), and ranged from prepping foundation for concrete forming and pouring to refastening the existing cladding (two layers s) to the studs. Also lots of small projects and final materials estimates for insulated panels, replacement clapboard, etc.
In addition, Hroth was able to begin work first finisher/refinishing lumber that we will be using in the project.
Garapa Re-Milling
We have begun re-milling and re-planing garapa decking salvaged from Rosslyn’s summer 2022 deck rebuild. These sample boards are among the many weathered specimens carefully removed this spring and summer prior to rebuilding Rosslyn’s deck substructure and re-decking with new garapa. Hroth’s patient. Hroth’s patient exploratory experimentation is the first phase in our effort to adaptively reuse this character-rich material in the icehouse. Still preliminary, but exciting possibilities ahead!
https://www.instagram.com/reel/Cj4hbRIAFlh/
Homegrown Lumber
Another exciting milling and planing project underway is looong overdue. Rosslyn’s carriage barn is stocked floor to ceiling with years and years of lumber grown, harvested, milled, and cured on our property. Two local sawyers, Mark Saulsgiver and Andy Vaughan, labored over the years to transform trees felled by storms (and for reopening meadows) into finish lumber. Well cured and stable, ash and elm is now being planed and dimensioned for use inside the icehouse. That’s right, it was grown, harvested, milled, and dried on site.
Thank you, Hroth, for painstakingly preparing and analyzing this beautiful material to help plan icehouse rehab.
Columns in previous owner’s workshop, present day dining room (Photo: Geo Davis)
It’s time for another architectural salvage update, this time focusing on the Greek Revival columns that we salvaged from Rosslyn’s future dining room back in 2006 in the early days or our renovation project. Let’s dive right in with that photograph above, but first a quick semantic note. For the sake of this post (and others) let’s assume that “adaptive reuse” and “repurposing” are sufficiently equivalent to be used interchangeably. There are those who restrict use of the former for buildings and use the latter for both buildings and materials, design elements, etc. I use the two interchangeably, not limiting “adaptive reuse” to buildings.
Some of you may recognize the photograph at the top of this post as the workshop of Rosslyn’s previous owner, George McNulty. Others of you know this same space — originally a pair of parlors and later dining rooms when the property was operated as the Sherwood Inn — as Susan and my principal dining room. (To avoid confusion, the qualifier is intended to distinguish the space from our front parlor which we use as a smaller dining room and the morning room or north porch which we use as our informal dining room.)
Deconstruction & Salvage
Although similar to the photograph above, this next set of visual benchmarks were made about half a year later. In the first photo the well equipped wood shop was still ready for creative carpentry and historic preservation, active pursuits of the previous owner for decades. But in the photograph below renovations are well underway and this room is virtually empty and deconstructed to the studs and brick.
Soon-to-be repurposed column during September 2006 deconstruction in Rosslyn’s future dining room (Photo: Geo Davis)
All of the trim in this room had already been meticulously documented by McNulty, but we salvaged everything that we could for reuse and to template from in order to bring this room back to its previous condition. It’s worth noting that we originally had hoped to be able to minimize repairs to this room, but it turned out to be a sifting sand trap. Each element we tackled revealed two underlying problems and so on. The floor was failing, the ceiling was failing, the fireplace was failing, the columns and beam which separated the space into two rooms was not original, and there was a window — bricked up and concealed within a closet — that was begging to be opened. Needless to say this room, our future dining room, was one of many that mushroomed in deconstruction and rehabilitation. The scope of work dilated day after day after day for weeks and then months and eventually years. But, I’m getting ahead of myself.
To refocus on the columns, lets start by taking a good look at the southern column (above) and the northern column (below) and then let’s get a little boost from the good folks at Britannica on the anatomy of a Greek column.
Soon-to-be repurposed column during September 2006 deconstruction in Rosslyn’s future dining room (Photo: Geo Davis)
The simplicity of these columns, only minimally embellished, lead me to consider them of the Doric order. And the following overview serves us well with one subtle revision. Both in their original location and in their future icehouse location, these repurposed columns will rest on the floor. In other words, the floor serves as the stylobate.
There are many separate elements that make up a complete column and entablature. At the bottom of the column is the stylobate; this is a continuous flat pavement on which a row of columns is supported. Rising out of the stylobate is the plinth, a square or circular block that is the lowest part of the base. Atop the plinth and forming the remainder of the base are one or more circular moldings that have varying profiles; these may include a torus (a convex molding that is semicircular in profile), a scotia (with a concave profile), and one or more fillets, or narrow bands.
The shaft, which rests upon the base, is a long, narrow, vertical cylinder that in some orders is articulated with fluting (vertical grooves). The shaft may also taper inward slightly so that it is wider at the bottom than at the top.
Atop the shaft is the capital, which serves to concentrate the weight of the entablature on the shaft and also acts as an aesthetic transition between those two elements. In its simplest form (the Doric), the capital consists (in ascending order) of three parts; the necking, which is a continuation of the shaft but which is set off from it visually by one or more narrow grooves; the echinus, a circular block that bulges outward at its uppermost portion in order to better support the abacus; and the abacus itself, a square block that directly supports the entablature above and transmits its weight to the rest of the column below. (Source: Britannica)
You’ll be quizzed on this later. Maybe. Or not.
Repurposed Columns
Now armed with some targeted vocabulary we can fast forward to about a week ago when Pam, Hroth, and Tony extracted the columns from the hay loft of the carriage barn where they’ve been stored for about sixteen years. I won’t pretend they’re tidy, but they’re intact, well preserved and ready for repurposing as a whimsical-but-structural design element supporting the new icehouse loft.
Hroth surveying soon-to-be repurposed columns from carriage barn hayloft to icehouse (Photo: R.P. Murphy)
In the photo above we’re looking over Hroth’s shoulder at the soon-to-be repurposed columns. Yes. Big. Eight feet from the bottom of the plinth to the top of the capital. Hroth’s a tall fellow, but these stately columns tower above him. I’m bringing this up to allow for critics to suggest that these columns just *might* be out of scale with the diminutive icehouse. It’s a reasonable suggestion. But we’re not undertaking an historic preservation. Instead we’re rehabilitating a utility space, a once-upon-a-time storage barn for ice, into a contemporary mixed-use office, studio, lifestyle space. Relevance is driving the program and adaptive reuse with a whimsical nod to the past is guiding the design choices. There are some incongruities baked into the vision for sure, but we’re gambling that they’ll prove charming rather than unsettling. Fingers crossed!
Hroth transporting repurposed columns from carriage barn hayloft to icehouse. (Photo: R.P. Murphy)
After a decade and a half of dusty hibernation in the carriage barn’s hayloft, these artifacts of once again seeing the light of day. Tony (upstairs, inside) and Hroth (outside) tenderly liberated the columns from the veritable warehouse of architectural salvage — windows, doors, moldings, trims, shutters, fireplace surrounds, mantlepieces, and various miscellanea — to begin rehabilitating them.
Hroth and Tony transporting repurposed columns from carriage barn hayloft to icehouse. (Photo: R.P. Murphy)
It’s worth noting that I played with the perspective on the photo above in order to best view the column emerging from the carriage barn. Hoth’s face and figure suffered slightly Silly Putty disfigurement in the process. Please forgive me, Hroth!
Capital from column that will be reused in the icehouse rehab (Photo: R.P. Murphy)
The capitals are not connected to the columns, perhaps because installation is more convenient. Or perhaps as a casualty of our 2006 deconstruction (or sixteen years of getting bumped into while in storage?) But the elements are intact and ready for cleanup and reassembly. I’ll update the repurposed column progress as they move forward on their journey toward installation.
Capital from column that will be reused in the icehouse rehab (Photo: R.P. Murphy)
Although it’s still a little premature to photograph the columns inside the icehouse, and since we have some long overdue cleaning and refinishing to undertake before these towering twins are ready to preside over their new environment, it’s helpful to imagine where we’re headed. To that end I’ll conclude with the most recent interior elevations that include the columns. There are inevitably tweaks that will emerge in the weeks and even months ahead and we massage the icehouse rehab into shape, but these drawings might sate your curiosity for a while.
Icehouse interior elevations including repurposed columns, as of November 11, 2022 (Credit: Tiho Dimitrov)
In closing, thank you Hroth and Tony for recovering the repurposed columns with such care. Thank you, Pam, for months of dimension documentation and photographs to ensure that Tiho was able to integrate these into the plan. Thank you, Tiho, for your perennial willingness to accommodate our sometimes challenging guidance and requests. And thank you, Rosslyn, for providing and supporting and nurturing our vision(s). Your gifts are without end.
The master bedroom balcony decking has been in need of attention for a while. Years of moisture and sunlight have accelerated the red cedar’s decay. So at last the time has come for undecking the balcony, removing the failing decking to make way for new balcony decking.
Undecking the Balcony (Source: R.P. Murphy)
Pam took charge of this project which required some delicacy to ensure thorough removal of the cedar decking without inadvertently puncturing the waterproof membrane underneath. Demo (see video below) was reasonably simple given the wood’s decay.
https://www.instagram.com/reel/Cjq2JPagc1Q/
The old decking sections were designed to be removable for maintenance and replacement, but given each panel’s ungainly size and fragility, it was easier to further dismantle and transport individual boards.
Undecking the Balcony (Source: R.P. Murphy)
The underside of the panel above reveals long term moisture damage. The same is evident in the panel below.
Undecking the Balcony (Source: R.P. Murphy)
In addition to replacing the red cedar with garapa which is considerably more weather resistant, some design changes will be incorporated to better evacuate moisture from rain and snow.
Balcony Decking Debris (Source: R.P. Murphy)
With some help from Tony and Hroth, Pam made quick work of demoing the old panels and undecking the balcony. Here’s a closeup of the spongy red cedar.
Spongy Decking (Source: R.P. Murphy)
With the rotten red cedar panels broken into boards and all of the debris transported to the dump, cleanup is the final step of undecking the balcony. Now we’re ready to finalize the plan, dimensions, and materials list in order to redeck the balcony.
At the time it looked as if his gruesome pumpkin (at left in photo above) would win uncontested. But my haste inspired a fierce 11th hour contest from Pam who carved up a sinister Jack-o’-lantern (at right in photo above and in video below) that is especially eye-catching after dark.
https://www.instagram.com/reel/Cka_dH6Azuw/
So, just when you thought Halloween was safely behind you, when you hoped spooky and haunted would give way to joyful gratitude and Thanksgiving, when you wished the season of tricks and treats would surender to the steady crescendo toward Christmas and New Year’s Eve, I’m backsliding briefly to the height of Halloween haunting with a Jack-o’-lantern post mortem.
Pam’s Jack-o’-lantern (Photo: R.P. Murphy)
With two cleverly crafted Halloween Jack-o’-lanterns contending for 1st place, I knew I needed another judge to assist me. Fortunately Susan was quick to volunteer and quick to judge.
Best Jack-o’-lantern 2022
And the winner is… Both!
No, Susan didn’t deem the contest a tie. She awarded Hroth’s Jack-o’-lantern (closeup below) the daytime win and Pam’s Jack-o’-lantern the nighttime win. So there you have it. Straddling the light/dark divide, Susan has awarded both winners!
Hroth’s Jack-o’-lantern (Photo: Hroth Ottosen)
In closing, it is worth noting that Hroth further embellished his Jack-o’-lantern after sending me the photograph this weekend. Perhaps he was feeling a little heat?
Adaptive reuse has become an increasingly important principle for me in recent years. And one of the most ambitious (yet most critical) objectives for the icehouse rehabilitation project is repurposing surplus building materials and existing architectural salvage from previous projects; upcycling decking debris and other deconstruction byproducts from sixteen years of remodels and rehabs; and miscellaneous materials reclaimed from Rosslyn’s buildings, fields, and forests (such as a carriage barn full of cured ash, elm, and other lumber that was harvested, milled, and dried on-site.)
Hroth is continuing to experiment with the garapa decking we salvaged from our summer 2022 deck rebuild. I’m hoping to repurpose this honey toned Brazilian hardwood as paneling in the icehouse bathroom. Hroth has planed these boards down to 5/8” and the lumber is beginning to look really good. Maybe 1/2” will be perfect?
https://www.instagram.com/reel/Cj7Igsig6Uo/
In addition to milling off the grooved edges (originally used for securing hidden fasteners to deck substructure) and planing the boards down, the next step will be choosing a suitable joint between boards. I’ll share updates as we continue to explore upcycling the old garapa decking.
What the Heck is Upcycling?
Nowadays we throw around words like upcycling, recycling, repurposing, adaptive reuse, etc. without stopping to ensure that we all understand what these words even mean. Upcycle That, a (@upcyclethat), a website launched in 2012 to showcase upcycling ideas and inspiration, offers this clear and concise way to think of upcycling.
Upcycling is taking something that’s considered waste and repurposing it. The upcycled item often becomes more functional or beautiful than what it previously was. That’s why it’s called upcycling, because the value of the item is increased! (Source: Upcycle That)
Junk, debris, byproducts, and leftovers reimagined and transformed into valuable new items. That’s upcycling.
If this sounds a little bit like recycling, let’s turn to the Upcycle That team again for help clarifying the difference between upcycling and recycling.
Recycling and Upcycling have different processes. In the recycling process, items are broken down to be reused. Paper is shredded and turned into pulp, plastic is shredded and melted into pellets, glass is smashed and melted to be recast. This downcycling is an essential step in the recycling process, but it does degrade the value of the materials.
Upcycling is a creative process where waste is looked at as a resource. Materials are reused in a clever new way, giving them a second life and function. Think of a pallet coffee table. Upcycling transforms the pallet into a lovely piece of furniture. (Source: Upcycle That)
I would add to the downside of degrading the source materials another frequent cost of recycling: energy consumption. Not only can the act of recycling gradually diminish the quality of the paper, glass, plastic, etc., but the process(es) by which the down cycling takes place almost always consumes energy. By sidestepping the down cycle-step in recycling, upcycling reduces the need for energy consumption.
Energy Use to Upcycle Garapa
As a quick followup to this last question of energy consumption during the downcycling vs. upcycling processes, I should note that transforming our old garapa decking into a finish material for the icehouse bathhouse is not without its own energy inputs. As you can see in the video above, these boards are being passed through a wood planer and they’ve already had their sides trimmed on a table saw. So, electricity has been an inevitable input in order to transform what on another project might have been considered demolition debris into what on our icehouse project will become beautiful bathroom paneling.
Icehouse Concrete Work Complete (Photo: Hroth Ottosen)
It’s been another monumental week! After the concrete subcontractor melted down a week ago, mere days before starting work on the icehouse, our in-house team decided to undertake the foundation and slab themselves. Today I can report with profound pride and pleasure that it was a total success. The crew is gathering tomorrow to celebrate two exemplary pours and an end result that is — in all candor — most likely superior to what we would’ve wound up with in the first place. Sometimes setbacks are actually the inspiration to regroup, reboot, and outperform original expectations.
Needless to say, it’s been an uber productive but looong week with a staggering level of accomplishment to celebrate, so I’ll keep this update short and sweet. I promise to share a more detailed look at the full court press made by Hroth, Pam, Peter, Supi, and Tony (as well as the concrete collaboration extraordinaire they have to show for their efforts) soon, probably even tomorrow or Sunday.
Team Barbecue: Peter, Hroth (back l-to-r), Supi, and Pam Hroth (front l-to-r)
Another short and sweet post to mark the end-of-week team barbecue. With four fifths of the icehouse concrete dream team present (Tony was unable to join), it was a well earned chance to take a break from work and celebrate.
Susan and I are profoundly grateful for the problem solving and priority juggling and camaraderie and diligence and expertise and enthusiasm and accomplishments of this crew. Thank you.
Eric Crowningshield Framing Icehouse Floor (Photo: R.P. Murphy)
What. A. Week. It’s a bit of a three ring circus at Rosslyn lately. So many projects happening concurrently. And so many invested, industrious, upbeat, solution-centric colleagues helping us repurpose Rosslyn’s circa 1889 icehouse rehabilitation into the ultimate 21st century flex-work-lifestyle hub. And as of today the first floor is framed!
Icehouse First Floor Framed (Photo: R.P. Murphy)
Vision + Ambition + Skills
With such a fortunate gathering of capable tradesmen (and woman) progress this week has reached a new level. A shared vision. An eagerness to advance the mission. An absence of ego. And a shared enthusiasm for the project. If only ever week can run this smoothly!
Although the collaboration of many ensured that the icehouse first floor was framed this week, especial thanks are due Pam, Hroth, Eric, Peter, Andrew, Ben, and Supi for your various contributions. You are truly inspirational. Thank you.
Video Mashup of Floor Framing
If you prefer a quick zip through, then this video mashup is for you.
Hroth Framing Windows in Icehouse (Photo: R.P. Murphy)
Although sourcing and designing the new windows and doors started this summer, the order wasn’t finalized until late autumn. Rosslyn’s icehouse is a small building, but there were many details to dial-in before production could begin. Precise pitch of the roof (echoed in several windows) and structural integration with windows and doors (especially in the west elevation where the fenestration-to-wall ratio is atypical) were among the challenges that delayed the process. But once the deposit was paid our focus shifted to framing windows.
Icehouse Window Framing Plans with Notes (Photo: Hroth Ottosen)
Starting with the north elevation, the constellation of six windows — three small upper windows echoing the horse stall windows in the carriage barn and three, six-over-six double hung windows, templated from the majority of the windows in the carriage barn — has been framed in. Especial gratitude to Hroth and Eric for jumpstarting this process so that cladding, siding, insulating, electrical installation, etc. can soon follow. Window framing would normally be an exciting step toward natural lighting, but given the lengthy production time on our windows and doors, the rough bucks (window and door framing) will serve as opaque placeholders for a few months longer.
Video Mashup of Framing Windows
Time for a quick zip through framing windows — precisely the first six windows — in the icehouse.
A new perspective is emerging as Hroth frames my future office window (from the icehouse loft). Looking east (actually southeast in this photo), this will be my morning view. Panning to the left 10 to 15° the view will be filtered through the enormous American Linden (basswood) tree and across the upper lawn, through the ancient ginkgo tree and across the front lawn to Lake Champlain.
If this morning view seems a significant spoil, looking west (featuring prominently in yesterday’s blog post) will offer a similarly breathtaking afternoon view. Across gardens, orchard, meadows, and woods the end-of-day drama will be captivating as sun settles into Boquet Mountain and the Adirondacks beyond.
It’s worth noting that there’s a dash of creative mischief in this snapshot. I’ve described it as the “morning view” from my loft office, but the butterscotch light bathing Rosslyn and the lawn in this image is unmistakably “afternoon light” emanating from the western sky as the sunset nears. An amalgam of morning perspective and late afternoon lighting, almost (but not quite) too good to be true.
Much thought has gone into framing the views in this small building. Although historic rehabilitation and adaptive reuse are the defining DNA in the icehouse project, the challenges and restrictions that inevitably arise with an historic property in an historic district allow ample opportunity for aesthetic fine tuning that will ultimately contribute to the lifestyle rewards when the conversion and renovation are complete.
These little glimmers of the future fuel my enthusiasm, and as I remind our dogs, anticipation is half the fun!
What a week! It’s been another productive stretch in the early phase of Rosslyn’s icehouse rehabilitation project. While site work ramped up outside, sculpting existing conditions into the vision percolating in my head, the icehouse’s interior underwent final preparations for structural steel, forming, and concrete. And, as of today, we are ready for rebar.
Icehouse Ready for Rebar (Photo: R.P. Murphy)
In the photo above Hroth and Peter are double checking footer depths and dimensions, checking levels with the laser, and putting the finishing touches on the dirt work in order to begin fabricating our rebar “cages”, etc.
Icehouse Ready for Rebar (Photo: R.P. Murphy)
Resembling an archeological site with pits dug deep into the old icehouse floor, the trenches and holes are actually “forms” for integrated concrete footers, curbs, and stepped slab.
Icehouse Ready for Rebar (Photo: R.P. Murphy)
Next, steel rebar and remesh will be cut, shaped, and structured per instructions of the engineer to meet or exceed structural demands of the rebuild.
Icehouse Ready for Rebar (Photo: R.P. Murphy)
Once concrete is poured and cured, the substructure (consisting of new concrete footers, curb, and slab integrated into old stone foundation) will provide stability upon which to frame the new interior. The resulting monolithic foundation will enable us to confidently proceed with building the next first floor.
Icehouse Ready for Rebar (Photo: R.P. Murphy)
Now that we’re ready for rebar I’ll add a new post when cages start to fill in the footer holes…
FYI, it’s not ALL fun and games at Rosslyn. Sometimes there’s tough work to do! Like root wrangling, for example… But there’s no reason work shouldn’t also be fun, right?
Do you remember that whopper of a storm this summer, the microburst that blasted Rosslyn, snapping limbs and uprooting trees? At last we’ve de-stumped and extracted the root balls.
An excavator muscled the massive root systems out of the earth. And, in the case of the video above, extraction involved breaking the stump and root ball into smaller, more manageable debris.
But the towering sugar maple that was destroyed by the microburst didn’t yield to mechanical muscle quite as readily. And so Bob (driving the tractor) and Hroth (root wrangling) applied the rodeo treatment!