Monday, March 29, 2010

Never underestimate the strength and beauty of recycled paper and it's many uses!!

First shot you will see is of a panel after an initial clear coat and has had it's ends 45'd and cut down in order to properly join other panels with only glue (no screws or nails). The next shot is of one panel that has been run through the biscuit joiner. This just proves that anything that is built using plywood or mdf as the core can effectively be transitioned into a more eco minded solution.

Secondly,We freaked a few people out today when I proposed we do an in house test of the strength of the PurePanel.We really freaked them out when they witnessed the results. I am a true believer in the product but I was even blown away with what we saw today. Basically what you are going to see is one shot of me standing on a 4' long x 3" wide x 1 1/2" thick piece of purepanel (recycled paper that has 1/4" plywood skinned to either side, there is absolutely no deflection and I weigh 190 lbs. The next image is of me and one of square pegs guys standing on the same piece (roughly 400lbs, 1/8" deflection. The last image is of me standing on a 1" thick piece of purepanel and all it is skinned with is plastibacker (paper backing that goes on prior to laminate 1/16" thick). This is the exact use of materials that we are building the furniture out of except instead of plastibacker we are using a zebrawood veneer. So for any of you that questioned whether PurePanel is going to be strong enough, take a look for yourself. we are estimating that the nightstand we are making will weigh less than 810lbs and easily be able to support any amount of weight that would ever be required. Pretty amazing!!

Below you will see the conceptual design of the furniture we are making. Very minimal design yet very stylish and functional.

All things Solid work their magic!

I need to be very aware how lucky I am to be surrounded by such good people that are so good at what they do and in this case really good at something that they have never done before, and matter of fact, something that no one else in the US has done and they are flying through it. As you can see from the images attached, they are really making some great progress with the lime rendering (base coat or brown coat) on the Hemcrete walls.

Plywood Ceiling looks amazing!

I have to first of all thank Andrew Schultz, his father and Lance for making the vision I had for the ceiling come to fruition. Andrew started planning and taking his measurement friday afternoon late and started his install this morning first thing. I wasn't able to get the site until 3pm today to see what had been accomplished today and I was floored when I walked in was perfect. We are using 1/2" cabinet grade plywood and spacing them 1/4" from each other. In the 1/4" space between each panel Andrew has put in solid wood blocking and painted them black to hide the insulation and roof framing.
Today didn't go by without some type of drama. When our insulation contractor (Home Energy Partners) came by today to inspect work performed last week he started asking questions regarding what we were doing with the plywood. After he found out that we were using 1/2" plywood he began to get concerned that we would not pass inspection due to a flame spread building code. After putting the brakes on Andrew and his crew I proceed to make some calls and then visit the building department with a possible solution (flame retardant paint additive that can be added to a clear coat finish). The inspectors are reviewing the data I gave them and will let me know in the morning whether they will accept it. If they don't accept it, then we have 2 options, 1) remove the plywood and paint the icynene insulation with a flame retardant, 2) add an additional layer of plywood to exceed the 5/*" requirement. Either way it is an expensive proposition an I take full responsibility for this mistake. Fortunately I can use this as a learning experience and continue my education on the job.
On a positive note, look how great it looks.

Friday, March 26, 2010

Purepanel™ Furniture a truly green furniture solution

I can't even tell you how excited I am about what myself and David Humphrey from Square Peg Construction are working on. For most of you that keep up with my postings you are familiar with Purepanel. Purepanelhas been my absolute obsession (besides my 3 girls of course) the previous 10 months. For those of you that are not familiar with the product, here ya' go. Pure Panel is 100% post consumer recycled paper structural panels used to make structural walls, non structural walls, doors, cabinets, countertops, and now as you will see below beautiful furniture. David and I have been collaborating for 2-3 months on designs, construction, veneers and other materials in order to come up with extremely lightweight beautiful and incredibly strong furniture and I think we have nailed it. David and one of his craftsman Mark Akers have started veneering some of the paper core with stunning zebrawood veneer. We are going to be making 2 different nightstands, a headboard and a dining table.I have attached the side panels of the zebrawood nightstand and some shots of the sycamore top and rails of the dining table. Seeing this all come together is so exciting for us because we are the first in the US and even more exciting to have a truly "green" furniture solution for an industry that has a reputation as one of the worst contributors to our environment. Check it out, can't wait for everyone to see the finished product.


Just 2 days ago we started finishing the Hemcrete with the hydraulic lime rendering. and it is "going on like butter". Very clever statement from Doc Summers from All things solid ,talented local craftsman handling the rendering work for us. After prepping the windows,doors soffit transition and bottom of the wall with mud stop and drip edge(very similar to traditional stucco) they proceeded with applying the 5/8" base coat (brown coat) of the german hydraulic lime rendering. Once this layer goes on and is floated out to get a flat level base then it needs to dry 1 day per millimeter until it sufficiently dried then they go back with a 1 mil finish coat. This finish coat will have an integral color mixed in so that the exterior walls will not need to be painted.
Doc and Tommy have done a wonderful job on this first wall of the Martin/Korp cantilevered deck.

Tuesday, March 23, 2010

Master Bath looks great!

The rough plumbing for the master bath is complete and it so exciting to see it come together. This is point of the project that is so exciting to me. You have these visions in your head for months and months of how the space is supposed to look and feel and once you get the tub and the valves in place you can really get a clear picture of what it will look like at the end of the project. So what you are looking at is a picture of the shower and one of the tub. The bathroom design centers around a 5 x 6 open shower that shares the space with the tub, no walls, all open. So essentially while in the shower or soaking in the tub you can look out to the north and east mountains and at 3550 ft elevation, the views are spectacular. The other image is of the wall where the vanity and sinks will be. The vanity will consist of a 8 foot floating slab of reclaimed black walnut with 2 uber modern vessel sinks and Hudson Reed wall mounted vessel fillers.

The final 2 images are of the standing pebbles that will be on the wall where the shower valves and head are and this wall will be 5ft wide by 11 feet tall. The pebbles will be black, not natural like the attached image. This will certainly make a statement.The other image is of the tile we will be using for the floor and for the walls surrounding the tub and shower. On the wall where the sinks and slab will be we are currently searching for the perfect fabric that will work well with the tile, slab and pebbles. We will hang the fabric on the walls as if it were wallpaper. I love to hang fabric on walls, not only are there 1000's of choices to get the perfect fit but it also adds a bit of needed texture to any given space that really looks amazing if it is well executed.