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Structural Integrity – Rosslyn Redux

Tag: Structural Integrity

  • All Zipped Up: ZIP System Installation Complete

    All Zipped Up: ZIP System Installation Complete

    Hroth finishes ZIP System installation on east elevation (Photo: R.P. Murphy)
    Hroth finishes ZIP System installation on east elevation (Photo: R.P. Murphy)

    As it turns out, the snow-blizzard-cum-bomb-cyclone that hepped up meteorologists and newscasters, snarled traffic across the country, and added a decidedly wintery twist to the Christmas holiday for many across the country impacted us two totally opposite ways, one good, the other bad. Ever the optimist, I’ll launch with the glorious news: the icehouse rehabilitation is now officially weathered in. The ZIP System installation is complete, ensuring a weatherproof envelop around the months of winter work ahead. Hurrah!

    The icehouse‘s original 2-ply T&G sheathing is now 100% encases in structural insulated panels, and all of the seams are taped. The ZIP System insulated panels appear to have served us well, and just in the nick of time. Although the worst of the weather, fortunately spared us.

    The winter storm became a bomb cyclone on Friday as it tore through some of the country’s major cities… Atlanta, Boston, Chicago and New York are seeing wind gusts higher than 45 to 55 miles an hour, among other hazardous conditions. Buffalo was the hardest hit Friday, with wind gusts of up to 70 mph, said Greg Carbin, a meteorologist with the National Weather Service. Buffalo was ground zero, and “that’s where true blizzard conditions have been seen,” he said. (Source: Bomb Cyclone Strikes Major Cities as Temperatures Plunge

    Although winds and snows fortunately were not a problem at Rosslyn, we did receive a lot of rain, rain, rain. But just barely completed ZIP System installation ensured that the icehouse was spared the damaging effects of driving rain, flooding, etc. Phew.

    The photo essay below offers glimpse behind the scenes — Hroth, Matt, Pam, and Tony hustling to complete the ZIP System installation before the storm and before everyone headed off for Christmas vacation. And this brings me to the not-so-good news…

    Hroth was planning to spend Christmas with his 91 year old father in California. Flights? Check. Packed? Check. All systems go? Check. But after driving 2 hours to the Albany International Airport on Thursday morning, he learned that his flights (and basically all incoming Southwest flights to Pasadena) had been preemptively canceled. After exploring options, Hroth accepted that he would be unable to celebrate Christmas with his family. He climbed back into his car and drove two hours back to Rosslyn.

    Susan and I deeply lament Hroth’s unfortunate luck, especially because we’re well aware that departing earlier and postponing completion of the ZIP System installation would likely have permitted him to fly to California earlier. And so, we realize that prioritizing the weatherproof sheathing over vacation travel positively effected the icehouse rehab and adversely effected Hroth and his family. I am sincerely sorry.

    Hroth begins ZIP System installation on east elevation (Photo: R.P. Murphy)
    Hroth begins ZIP System installation on east elevation (Photo: R.P. Murphy)

    ZIP System Installation Photos

    In the photo above Hroth is just starting out with ZIP System installation on the east facade. Note the newly installed flashing and custom copper drip edge that helps weatherproof the building’s cladding with accurate design integration templated from Rosslyn’s other historic buildings.

    Fast forward to progress on the southside.

    ZIP System installation on south elevation (Photo: R.P. Murphy)
    ZIP System installation on south elevation (Photo: R.P. Murphy)

    The north and south facades were completely installed approximately two weeks (see “Zipping up the Icehouse” for a gallery and overview), so tackling the south and east elevations at once brings the project to completion. In the photo below Tony’s own weatherproofing gives a hint to how cold it was as the team raced the weather toward the finish line.

    Tony and Hroth installing ZIP System insulated panels on east and south elevations of icehouse (Photo: R.P. Murphy)
    Tony and Hroth installing ZIP System insulated panels on east and south elevations of icehouse (Photo: R.P. Murphy)

    Panel-by-panel, Hroth and Tony zipped up the south and east elevations, knitting together the corners to ensure that the trim be be perfectly aligned and plumb.

    ZIP System installation on south and east elevations (Photo: R.P. Murphy)
    ZIP System installation on south and east elevations (Photo: R.P. Murphy)

    Below, Hroth (foreground) and Tony (torso-less legs on ladder behind Hroth) finish nailing and taping the south facade Zip panels.

    Hroth and Tony installing ZIP System insulated panels on east and west elevations of icehouse (Photo: R.P. Murphy)
    Hroth and Tony installing ZIP System insulated panels on east and west elevations of icehouse (Photo: R.P. Murphy)

    With the south side complete it was time to load up the nailgun and finish up the east side. In addition to the slightly blurry action shot of Hroth rebooting for the final push, the photo below offers an intriguing look both inside and outside the icehouse, inviting contemplation of how this same perspective might look early this summer.

    Hroth 2/3 complete with ZIP System installation on east elevation (Photo: R.P. Murphy)
    Hroth 2/3 complete with ZIP System installation on east elevation (Photo: R.P. Murphy)

    Once the panels are fully secured, it’s critical to seal all of the seams with ZIP tape to fully weatherproof the sheathing.

    Tony tapes ZIP System panels on east elevation (Photo: R.P. Murphy)
    Tony tapes ZIP System panels on east elevation (Photo: R.P. Murphy)

    Tony is ensuring that the sealing tape properly laps upper-over-lower seams to ensure proper water shedding both during the build and into the future once the building is redlaw in clapboard.

    Tony tapes ZIP System panels on east elevation (Photo: R.P. Murphy)
    Tony tapes ZIP System panels on east elevation (Photo: R.P. Murphy)

    Getting close, Tony!

    Hroth fitting final ZIP System panels on east elevation (Photo: R.P. Murphy)
    Hroth fitting final ZIP System panels on east elevation (Photo: R.P. Murphy)

    Hroth is scribing and installing the final triangular panels at the gable end on the east elevation. So close…

    Hroth finishes ZIP System installation on east elevation (Photo: R.P. Murphy)
    Hroth finishes ZIP System installation on east elevation (Photo: R.P. Murphy)

    You can almost hear the Paslode nailer sinking those final nails through the paneling and into the icehouse’s street timbers.

    Hroth puts the finishing touches on the ZIP System installation. All four elevations of icehouse are now weathered in! (Photo: R.P. Murphy)
    Hroth puts the finishing touches on the ZIP System installation. All four elevations of icehouse are now weathered in! (Photo: R.P. Murphy)

    I’ll wrap up this bittersweet installment with heartfelt thanks to the team for seeing this critical project through to completion to ensure that increasingly inclement weather (we are after winter solstice, after all) spares the icehouse AND similarly heartfelt regrets that Hroth has been stranded at Rosslyn, unable to join his family for the holiday.

    That last photo above offers a fun glimpse from my future loft study, capturing Hroth as he concludes the ZIP System installation.

    Zip-up Mashup

    And, for good measure, a quick video commemorating this chapter.

    https://www.instagram.com/reel/CmjmDZbhETV/?utm_source=ig_web_copy_link

  • Zipping Up the Icehouse

    Zipping Up the Icehouse

    Zipping Up the Icehouse (Photo: R.P. Murphy)
    Zipping Up the Icehouse (Photo: R.P. Murphy)

    Nothing like a region-wide winter weather system barreling down on you to accelerate winter-proofing the construction site, right?!?! But racing the arrival of a pre-Christmas blizzard isn’t the only motivation for the sudden transformation from 100+ year old T&G sheathing to green ZIP System insulated panels though. We’ve been working toward this goal for weeks. Zipping up the icehouse is actually accomplishing several objectives at once.

    Okay, let’s start with the most obvious, short term, practical objective of installing the insulated panels on the exterior of the building. But first, I should qualify what I meant by transforming “100+ year old T&G sheathing to green ZIP System insulated panels.” In this case, transformation does not imply replacing the existing sheathing with the SIPs. Instead, these insulated panels are being installed over top of the existing sheathing. And, as explained previously, the existing sheathing for the icehouse exterior walls is actually two layers of 3/4” T&G sheathing separated by perpendicular furring strips that accommodate ooolllddd school insulation that appears to have been made from shredded newsprint.

    Given midwinter construction, adding the ZIP panels efficiently creates a building envelope around the entire structure, allowing interior climate control. Windows and doors will not be delivered and installed until springtime, so this cocoon will stabilize the temperature and humidity for construction while significantly improving the work environment.

    Zipping Up the Icehouse (Photo: R.P. Murphy)
    Zipping Up the Icehouse (Photo: R.P. Murphy)

    That’s the short term, practical objective.

    There are some structural benefits as well, augmenting the existing structure (which predates our modern building codes) by creating a structural exoskeleton, that, among other things, dramatically improves sheer strength.

    We’re using ZIP System 1-1/2“ thick R-6 insulated panels from Huber Engineered Wood. In addition to insulation and structural objectives, these panels also provide a moisture and air barrier between interior and exterior environments.

    ZIP System Insulated R-sheathing is the simple all-in-one structural panel with built-in exterior insulation. Featuring integrated moisture, air and thermal protection, ZIP System R-sheathing completely reimagines traditional wall assemblies by streamlining exterior water, air and thermal management.

    Huber Engineered Wood
    Zipping Up the Icehouse (Photo: R.P. Murphy)
    Zipping Up the Icehouse (Photo: R.P. Murphy)

    And there are some aesthetic benefits specific yo the icehouse. Preserving the original mortared stone foundation created meant working around inconsistencies such as spots where the framing was proud of the foundation and others where the foundation actually extended out beyond the framing. Aside from the visual incongruities, this has created moisture penetration and rot issues over the building’s many years of service. When we stabilized the structure in 2006-7 it was necessary to replace large sections of the rotten sill. Additional rehabilitation was necessary this fall as well. By adding an extra 1-1/2” skin around the exterior of the icehouse (and integrating a copper drip edge / flashing that isolates wood from masonry) the entire build now overhangs the foundation enough to manage moisture, snow, etc. for another 100+ years.

    But wait… There’s more!

    The panels are permitting us to tune up some of the geometry — wall planes and trim lines that have deviated and deflected, sagged and bowed over the years — so that the rehabbed icehouse stands proud next summer.

    https://www.instagram.com/reel/CmO3j84ALdQ/