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Passive House + Zero Net Energy + Permaculture Yard

Category Archives: Pretty Good House

Siding Part 2: Charred Cedar (Shou Sugi Ban)

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Building a Passive House: Science, then Art

We wanted the process of creating our new home to be fun, so from the outset we approached the build as a mix of science experiment and art project.

For the structure, this meant utilizing building science research to properly air seal, insulate, and ventilate to ensure that we ended up with a house that’s hopefully durable, stingy with its use of electricity, and that functions well on a daily basis for many years to come.

In terms of design, it meant spending an inordinate amount of time on the floor plan, carefully defining how we would move through and live in the structure, while also carefully considering the seemingly infinite options when it comes to finishes, both for the interior and the exterior of the home (with an emphasis on low or no VOC products to protect indoor air quality) .

With most of the wall assembly details finally in place on the house, putting up the charred cedar siding represented the first real transition from science to art. And with Passive House details mostly taken care of, we could begin to make decisions in real time regarding how we wanted the house to look, both inside and out, in terms of finishes.

Since our house is relatively small, at least by recent American standards, many of the sins associated with McMansions were easy to avoid (McMansion Hell faces lawsuit).

 

 

On a side note, if trends continue, owners of these McMansions may be in for a rude awakening when it comes time to sell:

 

South Barrington McMansions Languishing

 

McMansions at Fire-Sale Prices

 

Affluent Chicago suburbs aren’t alone in facing this dilemma:

 

McMansions No One Wants

 

Killing the McMansion

 

If such reports prove to be accurate, and tastes really are fundamentally changing, perhaps it can be tied to a growing awareness of climate change and its implications. After all, these larger homes tend to be energy hogs, not to mention maintenance nightmares because of poorly planned and executed construction details — in part, a consequence of preferring quantity over quality. Moreover, there’s a growing chorus of voices espousing the benefits of simplicity (e.g. the tiny house movement, or minimalism). This is often wedded to an appreciation for the handmade or artisan object, as opposed to the mass-produced, and typically homogenous, product.

Nevertheless, it seems doubtful that the suburbs will ever be abandoned wholesale, and for any number of reasons.

For more on suburbia, go here: Building in the Suburbs

 

 

Massing: Basic Forms

For our house, the structure is a basic rectangular box with a gable roof (long sides face north and south with the gable ends to the east and west). It’s not unlike the basic form most children would come up with if prompted to draw a house. We really like the simplicity of this kind of roof style for aesthetic reasons, but also for the ease of installation and the long-term durability of the roof.

 

When we concentrate on the essential elements in design, when we omit all superfluous elements, we find forms become: quiet, comfortable, understandable and, most importantly, long-lasting.
—Dieter Rams

 

Bronwyn Barry has even coined a hashtag for this use of very basic forms,  #BoxyButBeautifulespecially popular with Passive House design since it can help eliminate potential thermal bridges while making air sealing more straightforward.

 

1st layer rockwool at frt door

Wojtek installing Rockwool around the front door, next to the garage.

 

We tried to avoid having the garage as part of the front of the house, in particular having the garage door facing the street (a look I’m not fond of), but physical limitations, in terms of the lot itself, left us with little choice in the matter. So rather than repeat the gable roofline of the house, we went with a shed roof for the garage. The shed roof adds some visual interest, while it also ensures that any rainfall in this area immediately gets sent to the north side of the house where we want it — away from the foundation as well as bypassing the driveway altogether (water flows to the north on our street).

We also felt that these two rooflines fit in well with our Urban Rustic design aesthetic. As a mash-up between early 20th century city and farm, both the simple gable and stark shed rooflines would be equally at home in an agricultural setting or on a densely packed inner city block.

In addition, it was important to us to have some fun with color, so on the exterior using black charred cedar with some natural highlights would give us the bold look we were going for, while accent walls inside with bright, playful colors would help bring the interior to life, accompanied by hand-made or hand-selected decorative objects in various bold colors.

When done well, this child-like use of color can lend a space or structure a real sense of vibrant energy.

 

 

Already a fan of Jack White’s use of color for album artwork and the staging of live shows for The White Stripes, I appreciated the way he chose to decorate the exterior of his Third Man Records in Nashville. A form that was as basic as it gets — single story brick warehouse — becomes vivid and hard to miss, in a good way, with a splash of color on what would otherwise be a monochromatic black box. The “insert” around the front door, offering a little shelter with some nice shadow lines, along with the crisp signage finish off what is a clean, sleek, but still playful, look.

 

 

He’s done something similar with the interiors, in this case, for the Detroit store:

 

 

 

Siding Layout for our Charred Cedar (Shou Sugi Ban)

Since we were building custom, rather than working within the constraints of tract housing in a larger subdivision (as we did with our first house) where many of the design choices are already made for you, we knew we wanted to take some chances in terms of materials and layout.

It also helps that we’re in a neighborhood with mixed architectural styles, including single-family homes and townhomes, with structures and exteriors running the gamut between old and new, as well as traditional and contemporary. We felt like this gave us more latitude to try something different without upsetting the overall look of the neighborhood.

With a smaller structure and only two basic rooflines, we knew any experimentation or design risk was going to have to occur at the level of siding materials and their orientation.

Knowing its weaknesses, I never imagined using wood for any part of the exterior of my house should the day come when I could build my own home. Brick, stone, metal, any number of man-made products (e.g. PVC or Boral), all seemed like the smarter way to go to avoid maintenance headaches and costly repairs. I assumed we’d end up using Hardie plank siding, or one of their paneling configurations, or maybe even some kind of metal product.

But then I came across charred cedar, or shou sugi ban.

It’s hard to remember now exactly where I saw it for the first time since it would’ve been before 2015 probably, but I think it was a Dwell magazine profile of Terunobu Fujimori’s work. I may have even first seen the same architect featured in Philip Jodidio’s book Architecture Now! (HOUSES, volume 1). Regardless, once seen, it was hard to forget.

 

 

When we first began working with our initial builder, Evolutionary Home Builders, I brought them some rudimentary drawings I had done, expressing our desire to try something creative and out of the ordinary, especially in terms of siding layout.

 

sketch black:gray

An early drawing of mine showing mostly gray with black accents for siding.

 

Instead, their architect, Patrick Danaher, came back with an extremely conservative layout, one that’s fairly omnipresent when looking at single story ranch homes in the Chicago area.

 

ehb s and w elevations

Proposed siding layout from Evolutionary Home Builders.

 

Our use of charred cedar would have been the one change from what is typically a combination of brick or stone on the bottom 2/3 of a wall with painted or stained wood up above, usually with a limestone ledge in-between to visually and physically separate the two materials.

 

brown - brick typical layout

Popular way to break up the cladding on a ranch home, in this case mixing brick and wood.

 

 

brick w: light sd

Another example of the same layout, this time with lighter colored siding.

 

The photos above are included not to disparage this look, which I actually like, but to give specific examples from our area of this traditional layout; one that’s seen on probably thousands of homes in just the Chicago area alone. Although attractive, I couldn’t help but feel that this layout was a cliched repeat of what’s already been done countless times before, which, nevertheless, would’ve been entirely appropriate had we been asking for a more traditional look.

Instead, it was pretty shocking to get their initial drawings since I had clearly expressed our willingness to think outside the box in order to experiment with something unique and fun, even avant-garde (or, at the very least, contemporary). The fact that Brandon Weiss (the owner) and Eric Barton (chief field officer) were also in these design meetings and they, too, had nothing to offer on this point did not seem to bode well for our project.

Initially I lacked the confidence to argue against Patrick’s suggested layout (they’re supposed to be the experts, right?). I just assumed my ideas were simply too bizarre to work. Over time, particularly as I saw how they did things with a lack of care and a lack of attention to detail (see below), combined with looking around online and seeing how other projects experimented with unique siding layouts, I eventually realized there was no reason not to try something bolder and more well thought-out.

In the meantime, I put together a fairly large sample board, mixing the charred cedar with the natural cedar mostly in accordance with their initial suggested layout:

 

charred cedar sample board with natural

Sample board with natural and charred cedar.

 

This sample board, although attractive, confirmed a couple of things I was worried about:

First, the layout was way too traditional looking, even with the charred cedar.

Second, this amount of natural cedar around the house would be a pain to maintain over the years, costing me significant time and energy, if not money (the maintenance labor would be DIY), probably requiring a fresh coat of tung oil at least every other year, if not annually. Since we wanted a natural look, any kind of traditional spar varnish, or other shiny clear-coat, didn’t seem appropriate. Although one option, open to us even now, is to just let the tung oil break down and let the natural boards turn gray over time (although it can be a somewhat unpredictable process).

Finally, since we felt the charred wood next to the natural was visually so electric, I thought it best to limit the combination to try and heighten the effect.

 

natural-and-charred-together

“Natural” cedar, treated with tung oil, next to the charred cedar.

 

In the end, Patrick’s suggested layout struck me as rather staid and uninspired (if not, to put it bluntly, half-assed).

On a side note, we didn’t have much luck with the three or four architects we came across during our build. They seemed mostly disinterested when they weren’t outright lazy. See the floating toilet in our initial drawings:

 

floating toilet

First look at our initial drawings from Evolutionary Home Builders — note the floating toilet in the middle of the basement floor.

 

No one — not the architect of record, not Patrick, not even Brandon the owner — could be bothered to give the drawings even a cursory edit/revision before handing them over to us. This certainly planted the seed, along with their generally disordered style of communication, that all was not well regarding the level of care, or even interest, our project was going to receive from them for the duration of the build.

I guess the situation could’ve been even worse:

 

 

Unfortunately, the issues we had in establishing our siding layout were emblematic of our overall experience building a new house, whether it was with architects, general contractors, or some (but certainly not all) of our sub-contractors: we were shocked by the overall lack of integrity, curiosity, and workmanship.

Far too often it felt like rather than having partners in an exciting process we were actually being held back by people who didn’t seem to really enjoy what they did for a living. Making matters still worse, not only did they seem bored, but the work itself was often mediocre when it wasn’t clearly incompetent.

Unfortunately, even acting as our own GC didn’t help matters, since a competent GC with a long track record has had the time to develop relationships with subcontractors he or she can trust to deliver in terms of schedule and craftsmanship.

I keep coming back to these issues in multiple blog posts mainly as a warning to others who are considering pursuing their own self-build (or even hiring a general contractor to do the work for them), encouraging them to have realistic expectations and to better understand just what they’re up against when it comes to the construction industry — particularly if they wish to try anything new or different.

At any rate, with the decision made to use the charred cedar, we went ahead and prepped the wood before construction began. You can read about the details here:

Cedar Siding Delivered…
Oiling Charred Cedar Siding

 

 

Installing the Charred Cedar

With all of the components of our wall assembly in place, Wojtek and Mark finally started installing the charred cedar on the house, beginning with the garage. This was easily one of the most exciting moments of the build.

I think Wojtek and Mark were secretly excited, too, if only because they were finally finished with all of the insulation and layers of strapping.

 

1st pce char going on

Wojtek and Mark installing the first piece of charred cedar on the south side of the garage.

 

 

1st few rows south sd sd gar

Wojtek and Mark making progress on the south side of the garage.

 

It was more than a little exciting to see the first pieces going up, especially considering how far off-track our project had gotten early on.

 

s garage char 1:2 way

First few rows of charred cedar going up on the south side of the garage.

 

With no choice but to have the garage thrust forward and so prominent on our front elevation, we just had to make the best of the situation. One way of addressing it was to shake up the orientation of the charred cedar. Since the house itself was going to be all vertical (we just find it more interesting), it made sense to change the north and south sides of the garage to horizontal.

 

south garage 1st pce east wojtek and mark

Wojtek and Mark starting the east, vertically oriented, side of the garage.

 

In doing so, on the south side by the front porch this horizontal orientation would draw in the viewer’s attention, hopefully pointing it towards the front door of the house. Even as you walk up the front steps this horizontal orientation, I would argue, does its subtle magic fairly well. At the street, or out in the front yard, this effect seems to work even better.

 

garage south sd start east wojtek and mark

Finally getting to see the combination of horizontal and vertical orientations combined.

 

In mixing the siding’s orientation in this way it also helps to show what the material can do visually. Lastly, having these two sides of the garage oriented horizontally should also emphasize that this portion of the structure serves a different function (i.e. garage vs. house).

After having the charred cedar hidden away in storage for so long, it was extremely rewarding to finally see it going up.

 

close up char on garage texture

Close-up of several charred cedar boards.

 

It was nice to see that it was every bit as beautiful and interesting to look at as we had initially thought while making it.

 

oil and texture on garage sd

The range of textures and subtle variation in color makes the charred cedar truly unique.

 

In keeping with our Urban Rustic aesthetic, the charred cedar — which would look just as good on a farmhouse or outbuilding as it would on an early 20th century artisan workshop or small factory warehouse — also represents our desire to bring in elements that reflect the Japanese notion of wabi-sabi.

 

 

For example, stressing the wood with fire instantly gives it an aged appearance, and the amount of variation also makes clear it’s a natural material, as opposed to an industrial product manufactured to meet narrow and precise tolerances, with the goal being absolute uniformity. Whether it’s the knots, the lighter or heavier areas of char, some areas of natural cedar peeking through, or the ‘oil stain’ marks, the charred cedar emphasizes and celebrates imperfections and inconsistencies in the wood, sometimes to great effect even within a single piece — to the point where the most singular board catches your eye and you can’t help but linger over it. Instead of being annoyed by difference, the charred cedar actually encourages you to go looking for the most unique boards.

 

 

Following installation guidelines, Wojtek and Mark used only stainless steel nails to attach all of the cedar siding.

 

garage sd out front door

View of the garage from the front doorway.

 

 

south gar sd mostly done mark in bg

First look at a large section of the charred cedar siding installed.

 

 

south gar sd bringing you in to frt dr

A second view.

 

With the south side of the garage mostly complete, Wojtek and Mark could move on to the north side.

 

n side garage furring and coravent

North side of the garage prepped and ready for siding.

 

 

1st pce north gar sd

First few pieces going up on the north side of the garage.

 

For the soffits, we were initially going to use another Cor-A-Vent product, their PS-400 Strip Vent to complete our ‘cold’ roof assemblies, which on the house already included a ridge vent.

 

Cor-A-Vent PS-400 Box

Box of PS-400 strips for soffit ventilation.

 

But after opening the box and really taking a look at the product, they just seemed really flimsy. I’m sure they work fine, but holding them in your hand doesn’t exactly breed confidence. Also, seeing Wojtek’s stink face as he carefully studied a couple of pieces only confirmed that we needed another option.

After looking around online, I ended up finding a product at a local Home Depot.

 

mesh for soffits

Metal mesh product we used for soffit ventilation.

 

Not only did the metal mesh appear more substantial, I thought it would look better with the charred cedar than the PS-400, making for a nice contrast with the wood. I also really liked how it revealed some of the structure through the mesh for a more raw, unfinished look — again, in keeping with our Urban Rustic design goals.

 

close up soffit screen complete

Close-up of the soffit metal mesh installed.

 

 

outside view n gar soffit

First section of soffit going up with the metal mesh in place for ventilating the roof.

 

 

mark w: gar soffit screen mostly complete

Mark waiting for a cut, with most of the soffit and siding installed on this side of the garage.

 

 

garage soffit w: screen complete

Section of soffit complete with metal mesh installed.

 

 

north garage sd soffit complete

North side complete, with the frieze board finishing off the rainscreen details.

 

We were going to copy a Hammer and Hand diagram for the top of a wall, in particular their rainscreen detail for the frieze board:

 

https:::hammerandhand.com:best-practices:manual:4-rain-screens:4-1-top-wall:

Courtesy of Hammer and Hand and their Best Practices Manual.

 

After talking through the details, Wojtek and Mark found the notch in the frieze board to be an overly fussy detail, preferring to keep this piece fully intact. To do this, they ripped down 2×2 furring strips to a thickness they could use as blocking behind the frieze board, pushing the frieze board out just beyond the plane of the siding, leaving a roughly 1/4″ continuous gap.

Apart from slightly more room directly above the Cor-A-Vent strip, the end result is much the same — a small gap between the frieze board and the top piece of tongue and groove siding allows air behind the siding to flow freely up and out of the wall assembly through the top of the Cor-A-Vent strips.

The Cor-A-Vent strips are kept about a 1/4″ below the initial blocking directly above them.

 

wd view top of garage rscreen

Top of the wall is ready for siding, and for establishing the air gap for the wall’s rainscreen.

 

 

mark blocking 4 frieze and vent

Mark adding blocking in preparation for the frieze board to finish off the top of the wall.

 

A close-up view from the side showing the details for the rainscreen at the top of the wall:

 

wide view garage frieze w: blocking sd

Top of the Cor-A-Vent and the top piece of siding. Frieze board being installed over blocking in the background.

 

On the house, the guys adjusted the placement of the frieze blocking, lowering it so that it was in line with the first layer of 2×4 blocking, thus closing off any unnecessary open space behind the frieze board.

 

close up rainscreen gap n garage

Close-up of the soffit with frieze board and air gap for the rainscreen directly below it.

 

With the north and south sides of the garage mostly complete, the guys moved on to the front of the garage.

 

garage south sd start east wojtek and mark

Wojtek and Mark moving across the front of the garage with the charred cedar now oriented vertically.

 

The change to our wall assembly — using 2×4’s instead of 1×4’s for our first layer of strapping so that the siding could hang down just past the metal flashing and Rockwool on the foundation — had one nasty unintended consequence for the north side of the house: the 14′ boards we had purchased, charred, and oiled were now about 3″ too short — they were initially supposed to sit just above the flashing and Rockwool, not hang down several inches below this area.

With little time to spare, since Wojtek and Mark were cruising right along, my wife Anita and our friend Maria worked tirelessly to get longer boards completed in time, while I tung oiled each board almost as soon as it was burned.

 

char as garage sd east goes up

Anita starting to burn additional boards as Mark and Wojtek keep working.

 

 

most of east side garage complete

Mark mostly done with the front of the garage.

 

For the front of the garage, Wojtek and Mark repeated the same rainscreen details, only this time with the siding oriented vertically.

 

sd soffit w: frieze for vent gap

Overhang on the front of the garage: frieze board completing the rainscreen, soffit boards, and rake boards being installed.

 

 

garage soffit and rake

Closer view of garage soffit and rake being installed.

 

 

garage side view strapping vent sd

Cut away view of the siding with a rainscreen set-up behind it.

 

Wojtek and Mark did a nice job with the soffits at all of the outside corners.

Note the ‘tiger striping’ on the bottom edge of the rake fascia board, along with the variation in color and texture from one board to another — an example of ‘perfectly imperfect’ according to wabi-sabi principles — including the subtle pencil marks for their cuts (still visible almost two years later).

 

outside corner soffit w: tiger stripe

Close-up of the garage soffit at an outside corner.

 

 

nw corner garage start n sd

The guys making the transition from the garage to the north side of the house.

 

For the north side of the house I wanted to keep the charred cedar a monolithic black. The only real relief from this was the change in orientation of the siding from the north side of the garage to the house, along with a single window for my daughter’s bedroom.

 

north side char

Charred cedar on the north side of the garage and the house.

 

Knowing that the other three sides of the house would be getting some natural cedar accents, I thought keeping at least one side of the house entirely black would make for a nice overall effect.

 

mark at mechanicals

Mark working around the mechanicals on the north side.

 

The Pittsburgh Steelers did something similar, having their team logo on only one side of their helmets, leaving the opposite side a solid black. I always thought this was visually striking.

 

 

 

 

Installing the Natural Cedar Accents

The west side of the house would be the first opportunity to use some of the natural accents. Based on my initial drawings and the sample board, I wanted to limit the natural as much as possible while still allowing it to have a strong visual punch.

 

stacks of nat'l and char in garage

Natural cedar boards tung oiled and ready to be installed.

 

I wanted to take advantage of the drop-off in grade that’s present in the backyard by using the natural boards around the window on the left. In doing so, it would draw attention to the change in grade, emphasizing that the left side of the west facade is significantly taller than the right side.

Using the structure of the window itself as a guide would help me to decide exactly how many natural boards to use.

 

west 1st cple pcs nat'l wojtek and mark

 

In addition, I knew I wanted a more informal look, making it consistent with our Urban Rustic and wabi-sabi design goals, so using an odd number of boards in an asymmetrical way would help achieve this.

 

west after 1st few nat'l pces

Adding natural boards around the window on the west facade.

 

By focusing on the window in this way, 11 natural boards turned out to be the right number. Looking closely at the way the window itself is framed (large center piece of glass surrounded by two smaller pieces), if we had gone with fewer boards the natural would be too far away from the dead center of the window opening, so insufficiently ‘wrapping around’ the window, while any additional natural boards would’ve risked being too close to dead center, making the overall look too symmetrical.

Obviously, a lot of the details regarding these decisions are subjective, but having some kind of framework for a final decision is nice to have, rather than going strictly on instinct alone.

 

mark just past nat'l on west

Mark completing the natural accent around the left window.

 

It was only after Mark went back to the black charred siding that I was sure we had exactly the right amount of natural boards around the window.

 

mark and wojtek west sd after nat'l

Mark approaching the center of the west facade.

 

By going just past the first piece of glass, the natural boards have a nice asymmetrical look to them — hugging or slightly wrapping around the window just enough, making a connection, but not too much.

After so many months of planning, worrying, and waiting — and then finally getting to see this combination of charred cedar with the natural cedar — watching the siding go up was easily one of the most gratifying parts of the entire build.

 

wojtek burning cut edge

Wojtek and Mark were nice enough to take the time to char all the cut edges.

 

When the guys got to the middle of the west facade they were in for a nice surprise — dead center of the peak lined up perfectly with the seam between two boards.

 

lking up sd at west peak

Looking up at the center of the west facade.

 

 

lking up sd at west peak wider view

Wider view of the peak on the west facade.

 

On most houses the back side tends to be rather boring, as if it were mostly forgotten about (at least in visual terms). In part this is no doubt because the details used to create visual interest are normally reserved for the front elevation where they can show off to the street. Where the front might be covered with stone accents, metalwork, elaborate lighting fixtures, or some other decorative accents, the other three sides tend to blend together as the basic siding material just continues its standard layout or pattern around the perimeter of the house. These decorative accents add cost to a build, so it makes some sense to reserve them for the side of the house that most people will see.

 

west facade sd after peak

 

Sometimes, however, this effect can be jarring. In a Chicago suburb there’s a house that uses elaborate stonework on the front facade, which in this particular case is actually two sides that face the street, but when you walk around to the back of the home the siding material transitions to wood. Because the transition is so abrupt, and the quality of the materials is so different, in terms of both cost and visual impact, it almost feels like walking behind the elaborate facade of a building on a movie set to discover it’s only a single wall propped up to mimic a much more substantial building. This lack of cohesiveness lends a kind of sadness to the house, as if it announces that the elaborate plans for the exterior cladding were ruined by unexpected budget constraints.

 

west sd mostly done guys start south

 

Consequently, we felt it was important to give each side of the house its own distinctive face. Because of the size and layout of our lot, and the way the houses next to us are positioned, it’s difficult to view more than one side of our home at any one time, which only encouraged us to make this a priority.

 

west facade after sd b4 gutters

West facade mostly complete.

 

Quick side note: these windows on the west facade are the ones with Suntuitive glass. Because of this, we’ve never required any blinds or any protection from glaring afternoon sun. As a result, we’ve been able to enjoy a constant, unimpeded view of the backyard.

More than a year after the siding had been up my daughter and I were in the backyard doing some gardening when she pointed out that the back of the house looks like David Bowie’s Aladdin Sane makeup. We have a magnet of Bowie on our kitchen fridge. She has a point.

It’s not difficult to see a face in the facade, and the music reference fits in nicely with our rock ‘n roll theme for the interior of the house.

 

 

The effect of the natural cedar is also reminiscent of racing stripes, especially those seen on sports cars or muscle cars, or even motorcycles (e.g. the graphics on racing sportbikes). This was partly done with tongue planted firmly in cheek — if high-performance cars and motorcycles look good with racing stripes why not on a high-performance home? — but mainly because I’ve always enjoyed the visual power of these types of graphics.

 

sd west b4 gutters

Waiting for gutters and downspouts.

 

Also in keeping with the racing stripes idea, we wanted the house to look distinctive on every side, much like the well-designed shape of the most memorable sports cars or motorcycles that look good from almost any angle.

At the beginning of each episode of Comedians in Cars Getting Coffee Jerry Seinfeld does a great job introducing each vehicle, explaining why some of them — even if decades old and built with what we consider now to be obsolete technology — can still elicit such intense feelings of affection or outright joy.

 

 

And there’s no shortage of design options when it comes to racing stripes and their various layouts.

Many are symmetrical, for instance, a double stripe laid down in thick pairs with little space between. This style is popular on the hoods of muscle cars.

 

Shelby stripes

Shelby Mustang. This one is more elaborate with the added red stripes along the outside edges.

 

Sometimes the striping is fairly subtle, arguably more of a pinstripe effect:

 

 

And of course the racing stripes don’t always have to impart a sense of speed or domination, sometimes they’re a nod to smart, even cute, styling.

 

 

Motorcycle graphics are probably the most extreme version of racing stripes, many of them even outlandish, but mostly in a vibrant, fun way.

 

 

Ducatis look great when they’re fitted out in monochromatic red, or even all matte black, but white stripes definitely add another dimension to the overall look of the bike:

 

 

This is one of the more iconic layouts, from Honda’s factory MotoGP racing team, Repsol.

 

repsol full

 

I think the layout and color combination looks even better in close-up as a screensaver:

 

repsol screen saver

Vivid screensaver.

 

My favorite racing stripe layout is a combination of one thick and one thin, probably because of the asymmetry since it’s typically applied off to one side, or offset, rather than applied directly down the center.

 

love bug

“Herbie” for sale in an antique shop in Cincinnati.

 

Another example of this thick-thin combination:

 

racing strip hash marks wheel

Hash marks on the wheel of a Dodge Charger.

 

The other nice thing about the racing stripe idea was that, as a visual motif, we could carry it over into some of the interior finishes. This is something we intended to do with the charred cedar as well — using an element from the exterior to decorate a part of the interior.

The blue-green-white combination, long associated with Kawasaki, would prove to be the most overt example where we would borrow some famous imagery from motorcycle racing and apply it inside the house in a new context, but for much the same reason, namely trying to impart a sense of playful energy and added brightness (more on this in a future post).

 

 

At any rate, I really enjoyed coming up with a kind of narrative for the look of the house, hopefully showcasing, in a unique way, what the charred cedar and the natural boards can do visually as siding on a home.

For the south side, we decided to use the kitchen door as our guide for putting up the natural cedar, while the front door would be used on the east-facing facade.

Another element around the two doors to consider was exterior lighting. A single fixture at each door would project an upward and downward concentrated beam of light, highlighting the natural boards in the dark as they pinpoint their focus on this band of natural wood surrounded by total blackness.

mark ready for natl at kitch

Mark almost ready for the natural cedar boards.

 

We started the natural boards to the right of center of the door’s glass, cheating a bit so that they started pretty much directly above the door handle.

 

1st couple at kitch

 

It also worked out nicely that the natural boards ended up in an A-B-A pattern from back of the house to front; meaning to the left of the window in back, to the right of the kitchen door, and then to the left of the front door.

 

mark past natl at kitch

Mark and Wojtek moving past the natural cedar boards.

 

We ended up at 5 boards for this side of the house, allowing the striping to stay proportional to the size of the opening while sitting just beyond the eventual light fixture. It also helps that the kitchen door, made up largely of glass and a neutral gray color, doesn’t take any attention away from the natural boards.

 

kitch dr

Kitchen door with its charred and natural cedar.

 

At the front door, I initially pictured the natural boards installed on the right side of the entryway. In two dimensional drawings this seemed to make sense, but after seeing everything in place in reality, it became pretty clear that to the left of the front door would be far better. To the right of the front door would’ve meant the natural boards would look ‘squeezed’.

 

1st pce nat'l at frt dr

Putting up the first piece of natural cedar around the front door.

 

 

mark finishing up nat'l at frt dr

Mark nailing in the first couple of natural boards.

 

Starting the natural boards just outside where the light fixture will sit, we ended up at 7 total boards for around the front door. Since the front door is slightly larger than the kitchen door, and it’s the main focus of the house, it made sense to have slightly more natural boards in this area.

Many thanks to Wojtek and Mark for their patience in playing along as I figured out exactly how many natural boards to use, and exactly where they should be positioned.

 

mark just after nat'l at frt dr

 

As each section of natural boards went up, it was evident that beyond a certain point the racing stripe effect would be lost: one too many boards and it wouldn’t look right, in effect, overpowering the opening; too few boards would mean not enough impact — less like a proper decorative accent and more like a disconnected mistake.

 

sd done b4 frt dr

First look at the east facade fully sided. Our little black box almost complete.

 

Bob Riggs, his son Brian, and Jason were nice enough to come back to install my front door for me. We used the Hannoband expanding foam tape to seal around this door, just as we did for all of the other windows and the kitchen door.

Check out the details of their installation here:

Windows, Doors, and Suntuitive

 

Brian Jason Bob install front door

Brian, Jason, and Bob install our front door.

 

 

frt dr frt yard

Front door just after installation.

 

The front porch with its charred cedar, natural cedar, and the bright red door reminds me of Coco Chanel’s famous “little black dress ensemble” — the charred cedar the little black dress, the natural boards the string of pearls, and the front door the splash of red lipstick.

 

 

Our shiny front door is the one sleek, clean, and clearly new element of our exterior. This contrast between industrially produced, sharp looking object and the burnt and heavily knotted wood in some ways personifies the Urban Rustic aesthetic.

 

frt dr clup b4 trim

Close-up of the front porch just after the door was installed.

 

 

Installing Sill Pans

When most of the siding and overhangs were complete, Wojtek and Mark started installing the metal sill pans for all the windows and doors.

Greg, the owner of Siding and Windows Group, suggested we use Lakefront Supply for all the flashings, which turned out well as they were able to create exactly what we needed.

 

sill pan inside edge b4 return trim 2nd view

Metal sill pan slid under bottom aluminum edge of the window.

 

In the photo below you can see the horizontal layer of 1×4 strapping, which becomes a nailing surface for the 1×6 cedar board that will be used as a return back to the window frame.

 

inside corner sill pan b4 return trim

A second view of the same area.

 

 

mbr wdw w: sill pan b4 final pce trim

From inside looking down at the sill pan.

 

 

side view sill pan edge beyond sd

Outside edge of the sill pan.

 

 

south wdw after sd b4 trim

Window waiting for the last few pieces of trim.

 

We were going for a “frameless” look for the windows; meaning, once all the trim was installed, very little of the window frame is left exposed.

 

k wdw trimmed out fmly rm wdw bg

Kitchen window with all the trim pieces installed.

 

 

innie wdw face - frameless look

Once the screens were installed, there was almost no room to spare. We really like this “frameless” look combined with the “innie” window position — it creates some really nice shadows at various times during the day.

 

 

frt dr sill pan

Front door sill pan installed.

 

 

kitch dr sill pan

Kitchen door with the sill pan installed.

 

 

Wojtek installing first sill pan

Wojtek pulling off the protective plastic on the sill pan.

 

 

mark and wojtek install 1st pce garage roof flashing

Mark and Wojtek installing flashing on the top of our garage roof.

 

 

2nd shed rf flash

Wojtek screwing down the flashing.

 

All of the elements finally in place: master bedroom window with natural accent, charred cedar used to return the siding back to the frame of the window, with the metal sill pan underneath.

 

mbr wdw frame sill pan

 

 

Gutters and Downspouts

For the gutters and downspouts we went with Nordic Steel. They’re expensive, but they’ve lived up to the marketing claims: with a larger half-round gutter and wide diameter downspout, we’ve never had to clean out our gutters (so far, anyway). They also look really nice, and they fit in well with the Urban Rustic feel we’re going for.

 

nordic ne

 

 

nordic n

 

 

Decorative Details

It was exciting to finally get the small, decorative pieces for the exterior out of storage. For example, I purchased our metal house numbers and our front doorbell on Etsy, at Modish Metal Art. As it turned out, Etsy proved to be an invaluable resource, both for decorating the exterior and the interior of our house (more on this later).

Our exterior lights were found on Amazon: Hyperikon

 

house numbers out of storage

‘Wobbly’ house numbers.

 

 

doorbell

Gecko doorbell finally installed.

 

 

house # and drbell

Front door details complete: trim, sill pan, doorbell, house numbers, and exterior light.

 

I found these white porcelain numbers on Etsy — made in Japan, so they seemed perfect for our shou sugi ban. Unfortunately, this Etsy store is no longer in business.

With some Spax screws, and the charred cedar as a background, the white numbers really pop.

 

708 white porcelain w: spax

 

 

Stucco for Inside Window Wells

For inside our basement window wells we initially thought we would just carry the wood siding all the way down. Once the retaining walls were in, and we saw how complicated the cuts would need to be around the stone — not to mention all the work required in hammer drilling concrete bolts into the foundation to establish strapping for the charred cedar — we realized wood wasn’t really a viable option.

After contacting Rockwool directly, they told me stucco over the exposed Comfortboard 80 would work fine, although it wasn’t presented as an option in the paperwork they had originally given to me. This was a great relief, and Wojtek had a friend who installed stucco, so it ended up working out really well.

The window bucks around the basement windows took a real beating during the prolonged construction process, so I touched up the sills with Prosoco’s Fast Flash to make sure they were watertight.

 

Tomasz

Tomasz installing the lathe with long concrete screws in preparation for our traditional 3-coat stucco.

 

Tomasz would eventually take the stucco up to the Cor-A-Vent insect screen, and then Wojtek and Mark would lower the charred cedar below this point by several inches, completely hiding the seam between the two materials.

 

stucco 2nd coat k dr

Charred siding, corner of the window well, and the stucco (only 2 coats at this point) meet.

 

For the railings around the window wells we wanted to use a hog wire panel (in keeping with the Urban Rustic theme). Initially, I thought I would use Wild Hog Railing combined with wooden posts, but decided an all-metal railing system would be better, mainly for durability reasons.

 

wdw wll 3

Gutters going up just after the railings around the window wells were installed.

 

 

wdw wll 2

View of the railing from a basement window.

 

 

How Durable is the Charred Cedar?

Initially at least, our luck hasn’t been great with the charred cedar.

For instance, during our first summer with the siding last year we noticed that we had some carpenter bees buzzing around the house. At first, I didn’t think much of it since the charred cedar is supposed to be insect-resistant. But then I noticed a bee digging a hole above one of the windows and realized something needed to be done.

After reading up on their lifecycle, I used a spray inside the holes that were present (about 10 total after I went looking), following up a couple of days later with a few puffs of diatomaceous earth. After waiting two more days, I then stuffed each hole with some steel wool before covering each entry point with some black sealant. Once patched, these areas are virtually invisible.

This spring and summer we kept a careful eye on these specific areas, along with the house more generally, but no bees emerged, so it looks like the problem has been resolved. Nevertheless, it’s something we’ll need to look for every May and early June.

Looking back, the bees nested in the exposed sub-fascia on two sides of the house before the siding and overhangs were installed. At the time, not understanding their lifecycle, I just plugged these holes with some caulk, thinking that would suffice. Unfortunately, it wasn’t, and their offspring emerged the following spring/early summer digging through the charred cedar fascia. If I had properly addressed these spots with a spray and then diatomaceous earth combination initially, there’s a good chance I could’ve avoided this problem altogether.

Since their offspring return to the area where they initially emerged to create their own nest sites (or even to reuse the existing one), it’s extremely important to address the problem as soon as possible, otherwise one or two small nests can quickly expand to dozens of bees swarming around the eaves of a home in early summer. And, even more sinister, it’s these nesting tunnels that attract the attention of woodpeckers who go looking for them, hammering the wood to get to the larvae below the surface, and scarring, if not ruining, the wood in the process.

In fact, this past January there was a morning where I heard a sound like a machine breaking down, almost like a chain breaking off its wheel. When the sound moved across to the other side of the house I suddenly realized it was a woodpecker. Luckily, he was sitting on a downspout right outside our window, so just opening the window was enough to startle him and make him fly off. When I went outside to look for damage I only saw a couple of small spots, as if he were just testing the wood for insects and found nothing. Thankfully, he hasn’t been back since. We’re hoping it stays that way.

Also, after the siding was up for about a year, especially after its first summer, it started to show some wear. Since the north side has held up the best, I can only assume it’s exposure to the sun that caused most of the wear to occur on the other three sides of the house and garage (although I’m sure rain played its part, too).

 

north light orange

Although showing some wear, these boards have retained their orange and yellow undertones on the north side of the garage.

 

In general, areas with a heavier layer of char have held up better, but sometimes even in these areas we’ve seen some missing char develop.

Here are some pictures showing the extent of the fading:

 

west b4 tar

West facade facing the backyard.

 

 

kitchdr19b4

South side.

 

 

s east end b4 tar

Another view of the south side.

 

 

south garage b4 tar

South side of the garage.

 

 

garage b4 tar

East-facing side of the garage.

 

The wear occurred slowly, so it kind of crept up on us. At some point, both my wife and I started to remark on the changes. And some areas are far worse than others:

 

close up missing char

Arguably the worst area of fading on the charred cedar.

 

Although the charred wood wasn’t in any immediate danger, and I enjoyed this ‘aged’ look, my wife said she preferred the original, more opaque, black look of the siding. And to be honest, since many of these exposed areas were turning gray, I worried about how well any product we might try in the future would soak in and adhere, so I decided to address it this year rather than wait any longer.

Thankfully, I was aware of Kent’s blog, Blue Heron Ecohaus, having seen it featured on GBA. He goes into detail regarding his decision to use Auson black pine tar instead of going with a shou sugi ban finish.

Our siding was installed in the Fall of 2017, and last summer I experimented with the recommended 50/50 mix of Auson and linseed oil, using it to touch-up a handful of boards, including all the cut edges that Wojtek and Mark had meticulously burned. Without any tung oil, these exposed edges had faded badly, almost to the same consistent gray on every piece. Again, this may be because they didn’t receive an especially heavy level of char when burned, but I can’t know for sure.

The guy in this video had a lot more fun applying the product than I did:

 

 

Even though the charred wood is said to easily last for decades, we also knew that it should get oiled about every 15 years to improve its durability, so having to do touch-ups wasn’t as heartbreaking as it might otherwise have been. I guess our 15 year mark came early. It also helped that it wasn’t necessary to do any overhangs (fascia or soffit) — those areas seem to be holding up really well, including the areas of ‘tiger striping’.

 

tiger striping on south overhangs

Area of fascia and soffit on the south side of the house with ‘tiger striping’.

 

Here are some pictures of the ‘refreshed’ charred cedar:

 

w sw as pine tar being applied

Starting on the west side with the black pine tar.

 

 

pine tar fmly rm wdw - bleached out to rgt

Making progress on the south side.

 

Our little black box with revitalized skin:

 

w after tar evening

West facade complete.

 

 

south west fmly rm after tar

Southwest corner after pine tar.

 

 

south tower after tar

Another view of this southwest corner.

 

 

porch after tar

Front entry and the south side of the garage after pine tar.

 

 

front after tar

Another view of the east facade after the pine tar.

 

 

708 after tar

Closer view of the charred cedar after the pine tar.

 

 

close up char texture after tar

Close-up: the black pine tar had no negative impact on the heavily charred areas.

 

 

after tar still variation color texture

On areas with the lightest char the black pine tar soaked in but didn’t completely make the surface an opaque black. My guess is, a second coat probably would’ve made it opaque.

 

If I was going to do charred cedar, or shou sugi ban, again — at this point, that’s a big ‘if’ — I would definitely insist on doing a uniformly heavy char finish (or ‘gator’ finish), and I would use the black pine tar to try and seal-in the char as much as possible. As beautiful as the lighter charred areas were when they first went up, they just couldn’t stand up to the weather — at least that was our experience anyway.

Nevertheless, the pieces of shou sugi ban that we’ve incorporated into our interior have held up nicely with just a tung oil finish, showing no signs of deteriorating, presumably because they’ve avoided any direct sun or rain (more on these areas in a future post).

Another option would be to use a metal siding version of charred wood:

 

Bridgersteel

 

I’m guessing it’s expensive, but it could be a viable alternative, especially for those unwilling or unable to do maintenance chores for the charred wood siding over time but who are, nevertheless, in love with the look of real shou sugi ban.

 

Still another product worth considering:

 

Thermory USA

 

This product is newer, so its long-term durability is still debatable until time proves definitively one way or the other, although the idea does seem promising.

On a bad day — like when I had to hunt down carpenter bees, or touch-up the char with the pine tar — I know I should’ve gone with a more care-free siding material like metal. And yet, on most days, when the overhangs and siding are perfectly fine, it’s hard to argue against the singular look that charred cedar can produce.

 

sd at kitch dr at night

Kitchen door and stoop with the light on.

 

So even with all the time, effort, money, and frustration that’s gone into making the charred cedar work, I still love the way it looks every time I pull into the driveway, or notice it while working in the yard. It’s just important to understand that as with anything worth doing, or any labor of love — like building our house it could be said — it comes at a price.

 

frt dr w: light

 

Building in the Suburbs

0

Once you’ve decided to pursue a new construction build, regardless of where you buy land, it’s likely to raise some issues regarding unintended consequences (whether or not the homeowner, builder, or developer wishes to acknowledge this is another matter).

In a rural setting, for example, you’re likely to be removing fertile farmland, or cutting down someone’s idea of a pastoral idyll or enchanted forest.

 

Look out the plane window on a flight from New Orleans to Chicago, or Denver to Cincinnati. Everything you see is already in agricultural production. This huge expanse of naturally fertile ground literally feeds the world. The suburbs growing around any city show that we are losing agricultural land even as the human population continues to grow. 
— David R. Montgomery, Dirt: The Erosion of Civilizations

 

With nature setting limits on land viable for agriculture, future generations may be horrified by our willingness to build over these acres of fertile soil with so little thought for the potential long-term consequences.

Many of Wendell Berry’s essays lament this lack of respect for the land, whether it’s cultivated field or wild forest:

 

 

In a larger city, on the other hand, you might be tearing down something people find historically significant, or maybe just significant to the character of a specific block or neighborhood.

 

 

Building in the suburbs, even when it’s done on a previously empty infill lot in a well-established subdivision like ours, still comes with its own set of unique implications.

 

 

For example, at one extreme there is a great fondness for suburbia, even a kind of utopian idealism.

 

 

It’s not uncommon at this point in their history for this idealism to be wrapped up in fond childhood memories, eliciting a vibrant strain of nostalgia (some might suggest of an unhealthy, cloying variety) for suburban life.

 

 

All too often suburbia is just the unquestioned background for mainstream life, for example, in the string of popular 1980’s films by John Hughes:

 

 

Although it’s hard not to notice in this case, at least, that the main characters escape from the suburbs to the big city when they’re in the mood for some excitement, adventure, and cultural enrichment.

At the other end of the spectrum there is utter contempt for suburbia and its perceived values, readily apparent in any number of movies, novels, or the DIY Punk movement of the late 1970s and early 1980s (and still going strong).

 

 

 

 

 

From this perspective, the suburbs are where the soul goes to die (particularly for the adults who have made their peace with authority, or so the argument would run). In other words, there may be safety in the suburbs, but it comes with a price. In fact, for many of its critics, suburbia represents mostly denial rather than any kind of meaningful affirmation.

 

The Revolutionary Hill Estates had not been designed to accommodate a tragedy. Even at night, as if on purpose, the development held no looming shadows and no gaunt silhouettes. It was invincibly cheerful… A man running down these streets in desperate grief was indecently out of place.
— Richard Yates, Revolutionary Road

 

For many young people the suburbs are what you end up trying to escape. The suburbs are missing something; the only thing on offer is the bland, the same, the quiet, and the sleepy. At best the suburbs in this case can be thought of as an uncomfortable launching pad, or a spur motivating escape plans. Your dreams and aspirations lie elsewhere, and the sooner you can move on the better.

 

 

As far apart as these two extremes might appear, feelings about the suburbs can even fall somewhere in-between (especially for those of us who were raised in suburbia), as a kind of bittersweet mix of love and contempt — e.g. ‘I didn’t choose to grow up in the suburbs, but that’s where many of my most vivid memories reside‘.

 

 

Early on in his 33 1/3 study of Arcade Fire’s album The Suburbs, Eric Eidelstein makes a similar point, “There’s nothing I wanted more than to leave my suburban upbringing. Now that I have, a part of me wishes I could dip my toes back into the bubble… Suburbia is innocence and ignorance… freedom and constraint… lightness and darkness.” The key, and devastating, word in that passage being ‘bubble’.

 

 

This Smashing Pumpkins song and video captures a similar feeling:

 

 

Two wildly different episodes from the original Twilight Zone TV-series reflect these violently divergent attitudes towards suburbia. The first is a love letter to a golden childhood, forever lost to the passing of time and the realities of adulthood. The second represents a kind of hell of conformity, reeking of paranoia and dread. Civility is revealed to be only a thin veneer that easily falls away under the slightest pressure, exposing ugly truths buried just below the surface of everyday life. For anyone who grew up in the suburbs these storylines are relatable, no doubt to varying degrees.

 

The Monsters are Due on Maple Street:

 

 

Walking Distance:

 

In my own case, living in the suburbs entailed countless hours of playing various sports with friends in the neighborhood, and seemingly endless bicycle rides through contiguous subdivisions waiting for the day we could drive cars (or ride motorcycles) and actually go somewhere, alongside memories of the ‘perfect’ neighbors who, later it was revealed, had separately engaged in fraud and embezzlement at work, seemingly out of unadulterated greed since neither of them ‘needed’ the money.

Perhaps no other work better captures this strange mixture of paean and warning about what lays just below the surface in the suburbs than David Lynch’s Blue Velvet:

 

 

For decades Americans have abandoned small farming communities and larger metropolitan areas to flee to the suburbs, mainly in the hopes of rounding off the sharp edges of life as its experienced on a farm or in a large city.

 

The suburban ideal offered the promise of… an environment that would combine the best of both city and rural life.
—Kenneth T. Jackson, Crabgrass Frontier

 

What was clearly being left behind were the extremes. For example, brutal, albeit beautiful at times, farm life.

 

Days of Heaven:

 

 

Dawn to Dusk:

 

 

And the seemingly cartoonish, but no less lethal, aggression often associated with the big city.

 

The Warriors:

 

 

Mean Streets (NSFW):

 

As Jackson notes in Crabgrass Frontier, the suburbs “offered the exciting prospect that disorder, prostitution, and mayhem could be kept at a distance, far away in the festering metropolis.” Simultaneously, although nurturing a carefully manicured lawn (a practice that dates back to at least the 19th century), the average suburban plot freed its owner from the back-breaking labor associated with farming, along with its attendant risks like crop failures, the vagaries of maintaining livestock, or the whims of the marketplace.

In staking out a middle ground, suburbia tries to avoid the excessive “liveliness” of the big city, while also studiously avoiding the brutal cycles of life and death that anchor and allow a working farm to thrive. Nevertheless, suburbia remains tethered to city and farm; almost entirely dependent on the city’s industry and markets (both for employment and consumption), while the farms supply virtually all of its food supply. In a way, then, suburbia represents both a denial of life and death.

 

 

But the extremes are no less real, and they remain virtually impossible to avoid altogether. Denial just makes the situation worse.

In the case of Blue Velvet, for instance, where the villain, Frank Booth, is presented as evil incarnate stalking around the suburbs at night, things may be even worse than they first appear. As David Foster Wallace points out, “…the real horror in the movie surrounds discoveries that Jeffrey makes about himself… not of Dark Frank but of his own dark affinities with Frank is the engine of the movie’s anxiety.” Lynch, according to Wallace, drives this point home in the car scene when Frank turns back to Jeffrey and says “‘You’re like me’. This moment is shot from Jeffrey’s visual perspective, so that when Frank turns around in the seat he speaks both to Jeffrey and to us [emphasis added].”

If the suburbs at their worst represent an attempt to push away harsh realities, then it can’t go on forever, and, in the meantime, the attempt itself can produce some pretty nasty consequences.

This kind of angst in the suburbs almost seems inbred at this point; not only has it survived but it’s thrived for decades, seen in the boredom and unfocused rage of Rebel Without a Cause right up to the grunge and riot grrrl movements of the early 90’s and beyond.

 

The chicken run from Rebel Without a Cause:

 

 

Bikini Kill’s Rebel Girl:

 

Meanwhile, the kind of human wreckage detailed in Madeline Levine’s The Price of Privilege is clearly deeply rooted in suburban realities and conventional notions of what constitutes success and ‘the good life.

 

 

As a result, reasons for disliking the suburbs are legion, especially evident once you start looking for opinions. Moving beyond the general stereotypes of conformity and isolation, there are also stark realities regarding how suburbia came to be and how it’s been maintained, which is especially devastating when you realize nothing was a foregone conclusion, and that choices have been made at every stage of their progression.

 

 

In confronting “The prevailing myth… that the postwar suburbs blossomed because of the preference of consumers who made free choices in an open environment,” Jackson points out that “Because of public policies favoring the suburbs, only one possibility was economically feasible.” Once government programs like “FHA and VA mortgage insurance, the highway system, the financing of sewers…”, not to mention “…the unusual American practice of allowing taxpayers to deduct mortgage interest and property taxes” are taken into account, the suburbs seem not only inevitable but carefully planned for — even if many of their long-term consequences were not.

 

 

 

 

Understanding this historical context makes a work like Family Properties even more of a heartbreaking read. Whether it’s the well-documented history of red lining, blockbusting, ‘contract selling’, restrictive covenants, or even more publicly overt acts of racism, the suburbs certainly have an ugly past.

 

 

 

 

As Beryl Satter makes clear, being forced to ‘buy on contract’ meant African Americans lost “their savings during the very years when whites of similar class background were getting an immense economic boost through FHA-backed mortgages that enabled them to purchase new homes for little money down… While contract sellers became millionaires, their harsh terms and inflated prices destroyed whole communities.”

 

 

In effect, one group of Americans enjoyed the benefits of homeownership, including selling years later for a substantial profit (in many cases passing this money on to a second generation as part of an inheritance), while another group of Americans lost their entire life savings.

 

 

And that past, unfortunately, never seems to be very far away.

It is this kind of historical context that helps explain, at least in part, the resonance of a movie like Get Out:

 

 

It’s undeniable, then, that the suburbs, as an idea and a physical reality, are overdue for some kind of transformation — in terms of socioeconomic issues, resource demands and energy use, architectural aesthetics, transportation, water management, their relationship to nature (both wild and cultivated), etc. The list of issues that could be addressed is truly daunting.

 

Here is one attempt:

 

The suburbs are also dragging around other cultural baggage besides just single-family homes and endless miles of congested highways. For instance, it’s almost impossible to bring up suburbia without acknowledging the rise and fall of the shopping mall, at least the dominant style of mall popular since the second half of the 20th century:

 

 

 

 

As others have clearly documented (perhaps most vividly by Dead Malls), many of these shopping malls look to be on their way out, as both cultural touchstones and architectural objects:

 

 

 

 

In their place, one proposed solution is Lifestyle Centers. It’s not at all clear that anyone has a definitive, bullet-proof, strategy for overhauling these structures, and ‘lifestyle centers’ appear to be little more than a variation on the original shopping mall form. In fact, it appears cities and developers are just guessing at what might work.

One solution for the suburbs in general might be pockets of self-contained neighborhoods, mimicking the dynamic energy of urban living Jane Jacobs wrote about in Death and Life of Great American Cities, which is reminiscent of many traditional European city, and even smaller village, neighborhoods:

 

 

 

 

Whether or not the housing density necessary to achieve this is possible (e.g. building up to avoid excessive sprawl, with each individual residential unit smaller than what we’ve grown to think of as normal), it would also require a high-level of city planning and cooperation amongst all the stakeholders to incorporate all the services and day-to-day needs of the population, all while managing to also maintain and hold onto significant green spaces. A tall order indeed.

Even so, there have been pioneers and experiments trying to explore various possibilities.

For example, Village Homes in Davis, California, developed in the 1970’s, pursued a more holistic approach to residential construction.

 

 

His comments at the end of the video regarding their battle with the status quo is particularly telling. You can read more about the project here: Village Homes

More recently, the founding partners of GO Logic worked to create Belfast Cohousing Ecovillage.

 

 

The hope is that living arrangements and social networks like these will improve the participants’ quality of life.

 

 

These kinds of cooperative living and working arrangements are growing in popularity, with a major historical antecedent being Mondragon in Spain.

 

 

As Americans grow increasingly disenchanted working for large, unaccountable corporate entities, these kinds of organizations have the potential for significant expansion, even in places like Cincinnati, which is hardly thought of as a progressive redoubt.

South Mountain Company, based on Martha’s Vineyard, would be one successful example from the construction and design fields (Marc Rosenbaum, who’s had a significant presence on GBA, is one of their employees/co-owners). John Abrams, the founder, wrote Companies We Keep, a compelling and detailed read on the evolution of the business.

For anyone who’s interested, the US Federation of Worker Cooperatives is an excellent resource for those wanting to pursue this idea further.

There are still other projects, for instance, community gardens or larger scale suburban permacultureguerrilla gardening, or even Brad Lancaster’s street project, which try to improve the quality of life at the neighborhood level of a subdivision or even a single block (note that it’s no accident that all of these smaller projects improve our connection to nature).

 

 

Even something as small as planting a hell-strip on your own with colorful perennials is a start — something we see more and more of in the residential neighborhoods just outside of downtown Chicago, and even out here in the suburbs. Considering their tiny area of square footage, these mini-gardens have an incredibly powerful visual impact.

 

 

These projects represent mostly small-scale, but no less valid, attempts to make suburban life better and more meaningful for residents and visitors alike. In addition, these projects point to our intrinsic need for maintaining a real connection with nature, now often referred to with the buzzword notion of Biophilic Design, itself an outgrowth of E.O. Wilson’s biophilia hypothesis.

 

 

 

 

Almost anything would be preferable to the typical mix of poorly built cookie-cutter homes surrounded by congested roadways and the endless, and largely undifferentiated, strip mall hell that we currently endure:

 

 

As with strip malls, if houses prove to be equally unloved, even despised, it’s easy as a culture to let them rot or just bulldoze them and start over. If people are going to put in time, money, and effort to save something, it had better be well-loved, i.e. fulfill some pretty fundamental needs.

The existing and aging housing stock ringing every large city in America isn’t going anywhere. Whether rehabbed in a sporadic and piecemeal way, with varying amounts of success (both in terms of build quality and energy consumption), or the issue is addressed head-on by local and federal programs, something will need to be done.

It’s possible to imagine a large-scale retrofit program, with Passive House, or at least Pretty Good House, goals set as the benchmark. After tearing down the most dilapidated units, making way for the new, there would still be ample opportunity to rehab existing structures in a thoughtful way that could be a real boom for employment (maybe even allowing us to finally establish a much needed national apprenticeship system) as it also works to draw down on our housing stock’s demand for energy. It would also be offering people work that has real, tangible benefits to our society and the world as a whole, something that’s missing from most construction work at the moment.

If one’s intent, however, is just to dismantle the logic of the suburbs, there’s certainly no shortage of intellectual rocks lying around if you want to pick some up and start throwing them through the shiny, glass-filled facade of suburbia.

And frankly, it’s kind of fun to do. For example, how about suburbanites as brain-dead zombies out to mindlessly consume:

 

 

Whether it’s their costly infrastructure and massive energy consumption, their car dependency, their love affair with lawns, their lack of density, their total isolation from farming (or nature more generally; even where it does pop up it tends to look and feel like an afterthought), or the isolation from what the city has to offer, the suburbs certainly have their issues, many of them profound if not existential.

 

 

And even though I think all of these issues are certainly well worth thinking about, especially if you have the ability to choose between rural, urban, and suburban locations for work, the fact remains that for many people the suburbs are, in fact, still the best option for housing.

So the question remains: How do we make the suburbs better? 

In our case, my wife works less than ten minutes from home. Unfortunately, a car is still the only real option for transportation (rather unbelievably) — e.g. busy roadways and a lack of continuous pedestrian or cycling pathways make what is an otherwise short commute somewhat perilous to navigate. Nonetheless, moving into Chicago proper, or out to a rural setting, didn’t make much sense to us, mainly because of the added drive time.

 

 

After deciding that we would try and build something new here in Palatine, a suburb of Chicago, we concluded that we should do our best to make something that would be loved and cared for long after we’ve moved on.

For the house itself this meant making choices regarding the structure, while for the yard, at least in our case, it meant pursuing permaculture principles rather than the more typical suburban lawn with some foundation plantings (more on the specific details in future posts).

 

 

Obviously, one house here or there that bucks current trends isn’t going to change much about an entire culture. A house like ours is mostly just to demonstrate what’s possible. Nevertheless, there’s real opportunity for large scale change, whether in our bigger cities, rural areas, or even the suburbs.

 

 

In the cities it could mean carving out space for many more community gardens, insisting on Passive House (or at least Pretty Good House) structures, limiting the use of cars while overhauling public transportation, all while giving priority to pedestrians.

Also, coming up with various strategies to avoid gentrification so that once a neighborhood is fully revitalized the original, long-term residents aren’t forced out by a higher cost of living (mainly through increased rents and property taxes).

As Aaron Shkuda documents in his book The Lofts of SoHo (Gentrification, Art, and Industry in New York, 1950-1980), a large influx of artists and the culturally much-maligned ‘hipsters’ is typically the initial spark a struggling neighborhood needs to begin a turnaround.

 

“The form of development that artists pioneered in SoHo provided a way for cities to confront the urban crisis without the financial and social costs of slum clearance… the mode of development that grew in SoHo was the antithesis of urban renewal. It was unplanned, and it stymied the attempts of experts or politicians to control it… SoHo provided a distinctly urban alternative to the structures built through urban renewal. These projects mainly attempted to provide urban residents with amenities found in the suburbs, such as easy auto access, security, and a verdant, non-urban feel. SoHo was gritty, urban, dense, and all the more popular for it… the history of SoHo demonstrates that it is perhaps the neighborhoods that artists create, rather than the artists themselves, that help draw and retain [educated professionals].” 

—Aaron Shkuda, The Lofts of SoHo

 

In fact, as Shkuda points out, this formula has repeatedly proven so successful that “it is difficult to find a contemporary American city without residential lofts.” In effect, large, empty or abandoned, spaces converted into residential lofts is a stamp of approval, announcing that a specific neighborhood is now desirable or even the height of ‘cool’.

The trick is making sure the transformation — making an area worth going to because of art galleries, artisan shops, unique restaurants, bars and coffee shops, and overall cultural vibe — doesn’t overshoot the mark, moving past rebirth to a stage where only the wealthy can afford to stick around and participate.

Moreover, the fact that SoHo emerged from the ashes of deindustrialization not through centralized planning but rather the hard work and vision of individuals is worth celebrating. More importantly, it’s worth remembering as others take on the largely thankless task of urban renewal in their own neighborhoods (perhaps much the same applies to rural and suburban areas: if you want something different, make it different).

 

 

In rural areas we could encourage a transition from factory farms to a more holistic agroforestry model (hopefully inspiring some young people to come back from the city and suburbs to pursue a viable and rewarding career in farming). This model could include ample opportunities for agro-tourism, both to benefit locals and those who will visit from the suburbs and cities.

In the suburbs, in addition to renovating aging housing stock (again, to Passive House or Pretty Good House levels of performance), the development of walking and cycling trails, not unlike the Atlanta Beltline, for example, which would include walkable areas that thoughtfully combine residential and commercial zones, all while remaining focused on our need for nature via biophilic design strategies, could be the transformation that allows the suburbs to move beyond well-earned, but stale, cliches.

 

 

In addition, the suburbs require not just a new vision regarding mixed use, but also mixed income, providing housing to all, whether poor, old, young, or its more traditional economically secure nuclear families.

Unfortunately, if the glacial rate of change from conventional to ‘green’ building techniques in the construction industry is any indicator, then the suburbs may just carry on doing their thing, loved by some as they alienate and agitate others, all while remaining quietly, but defiantly, resistant to change.

Siding Part 1: Continuous Insulation with a Rainscreen

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Continuous Insulation vs. Double-Stud Wall

Although builders can make either approach to high-performance walls work, we decided continuous insulation (or CI for short) made the most sense to us. And while continuous insulation has its own challenges, especially in terms of air and water sealing details around windows and doors, intuitively we felt insulation on the outside of our sheathing would give us our best chance at long-term durability for the structure.

In spite of the fact that these kind of wall assemblies are climate specific, for anyone interested in the performance of various wall assembly approaches this BSC paper is an excellent place to start:

 

High R-Walls

 

Or you can check out Hammer and Hand’s evolving wall assembly strategies here:

 

Passive House Lessons

 

And here’s a mock-up wall assembly by Hammer and Hand showing many of the details we incorporated into our own house:

 

 

While many believe a double stud wall simplifies much of the framing, we decided that a continuous insulation approach, which in theory should better manage seasonal moisture changes inside the walls while it also eliminates thermal bridges, was worth the extra effort.

 

 

2 Layers of Rockwool over Zip Sheathing

Based on the drawings from our original builder, Evolutionary Home Builders, who was going to use 3.75″ inches of rigid foam, and the recommendations of both PHIUS and Green Building Advisor for our climate zone 5 location (leaning heavily towards PH performance), we decided to go with 4″ of Rockwool Comfortboard 80 on top of our Zip Sheathing.

For more information regarding how we came up with the specifics of our wall assembly, go here:

Wall Assembly

 

 

Finding Subcontractors for a Passive House

In the Chicagoland area it’s still a struggle to find builders or subcontractors who are knowledgable about, or even interested in, “green building”. In fact, despite our well-documented experience with Evolutionary Home Builders, clients continue to hire Brandon Weiss (Dvele and Sonnen) and Eric Barton (apparently now on his own as Biltmore Homes, or Biltmore ICF) presumably because the options here in Chicago remain so limited. We assume this is the case because we still get the occasional email from current or former clients who have also had a negative experience working with Brandon or Eric. In addition, even though PHIUS has dozens of certified builders and consultants listed for Illinois and the larger Midwest region, it’s unclear just how many of them have worked directly on an actual Passive House project.

Until there’s more demand from consumers, or the building codes change significantly, it’s difficult to imagine the situation improving much in the near future. This is unfortunate since particularly here in the Chicago area, or the Midwest more broadly, homes could really benefit from the Passive House model, or something close to it, e.g. The Pretty Good House concept, because of our weather extremes (dry, cold winters and hot, humid summers). The combination of meticulous air sealing, high R-values, and continuous ventilation associated with any high-performance build is hard to beat in terms of day-to-day occupant comfort, not to mention the significant reduction in both overall energy demand and the cost of utilities.

In our own case, when I think of all the individual trades we had to hire, securing a siding contractor was far and away the most difficult. Our HVAC contractor for the ductless mini-splits was already somewhat familiar with “green” building and PH, so working with me on air sealing details and dealing with a thick wall assembly didn’t worry him. Also, if I had it to do over, I don’t think I’d bring up all the PH details with a plumbing or electrical contractor when getting bids since the air sealing details are pretty straightforward and can easily be planned for and executed on-site after they begin their work (assuming someone else, most likely a rough carpenter, GC, or homeowner is tasked with all the air sealing chores). And if the concrete sub is unfamiliar with insulation under a basement slab, or over the exterior walls of the foundation, then it’s easy enough for framers, or even homeowners if necessary, to do this work, along with installing a vapor barrier like Stego Wrap before the basement slab gets poured.

For siding, however, because of the level of detail involved before the siding itself could be installed, it was a real challenge to even get quotes. As things turned out, we had nearly twenty contractors (a mix of dedicated siding contractors and carpenters) visit the job site before we received an actual estimate. Many of those who visited the job site expressed genuine interest, most going so far as to acknowledge that this kind of wall assembly made sense and would probably be mandated by the residential code at some point in the future, but almost without exception they would disappear after leaving the job site — no bid forthcoming, and no response to my follow-up phone calls or emails.

Clearly they were terrified, not without justification, to tackle something so new, viewing our project through a lens of risk rather than as an opportunity to learn something new. From their point of view, why not stick with the type of jobs they’ve successfully completed hundreds of times in the past? It also didn’t help that I was a first time homeowner/GC, rather than a GC with a long track record of previously built homes in the area.

In addition, not only is continuous insulation over sheathing a novel concept in the Chicago area, especially in residential builds, even utilizing a ventilated rainscreen gap behind siding is almost unheard of — typically Hardieplank lap siding is installed directly over Tyvek or similar housewrap (this can be observed directly on hundreds of job sites across the city and suburbs). And this isn’t entirely the fault of contractors. For instance, how many homeowners when presented with the idea of continuous insulation, or a rain screen gap, balk at the extra costs associated with these techniques without carefully considering the potential energy savings or increased durability for the structure?

While there are any number of certified LEED projects in our area, and even some Passive House projects (both residential and commercial) in Chicago and the surrounding suburbs, for the most part consumers are still largely unaware of Passive House or other “green” building standards like Living Building Challenge. Clearly “green” building, let alone Passive House, has its work cut out for it here in the Midwest if it ever hopes to have a meaningful impact on the construction industry.

 

 

Installing Rockwool over the Zip sheathing

Mike Conners, from Kenwood Passivhaus, was nice enough to recommend Siding and Window Group, which definitely got us out of a jam. Thankfully, Greg, the owner, was up for the challenge and was nice enough to let us work with two of his best guys, Wojtek and Mark.

Initially Wojtek and Mark dropped off some of their equipment at the site the day before they were to start work on the house. This gave me a chance to go through many of the details with them directly for the first time. Although a little apprehensive, they were also curious, asking a lot of questions as they tried to picture how all the elements of the assembly would come together. In addition to the construction drawings, the series of videos from Hammer and Hand regarding their Madrona Passive House project were incredibly helpful (this project in particular was a big Building Science inspiration for us).

 

 

 

 

Also, this video from Pro Trade Craft helped to answer some of the “How do you…?” questions that came up during the design and build phases:

 

 

As sophisticated and intricate as some architectural drawings may be, in my experience nothing beats a good job site demonstration video that shows how some newfangled product or process should be properly installed or executed.

On the first day, while Wojtek and Mark installed the Z-flashing between the Zip sheathing and the foundation, along with head flashings above the windows and doors, I started putting up the first pieces of Rockwool over the Zip sheathing.

 

installing head flashing above wdw

We found it easier to embed the metal flashings in a bead of Prosoco’s Fast Flash. Once in position, an additional bead of Fast Flash went over the face of the flashing, ensuring a water tight connection between the metal and the Zip sheathing.

 

For the first layer of Rockwool we installed the pieces horizontally between studs as much as we could, knowing that the second layer of Rockwool would be oriented vertically. This alternating pattern helps to ensure seams are overlapped between layers so there aren’t any areas where the seams line up, an outcome that could undermine the thermal performance of the 2 layers of Rockwool.

 

z flashing nw corner

Z-flashing carried down over the exposed face of the Rockwool on the outside of the foundation walls — once installed, the gravel is pushed back so it covers the area where the flashing terminates on the face of the Rockwool. The other 3 sides of the house had much less exposure in this foundation-gravel border connection.

 

We didn’t worry too much about the orange plastic cap nails missing studs since they were sized to mostly end up in the Zip sheathing. In the end only a couple of them made it completely through the Zip without hitting a stud.

 

1st pcs rockwool going up n side

Putting up the first pieces of Rockwool on the north side.

 

Every so often Wojtek would come around the corner and watch what I was doing before asking questions about specific elements in the wall assembly.

 

orange cap nails for 1st layer rockwool

Plastic cap nails we used to attach the first layer of Rockwool. I purchased these from a local roofing supply house.

 

By the time I had about a quarter of the north side covered, Wojtek and Mark were ready to take over from me.

 

1st layer rockwool n side

First layer of Rockwool mostly complete on the north side. Before installing the bottom row of Rockwool we used shims to create a slight gap between the Rockwool and the metal Z-flashing on the foundation insulation to allow any water that ever reached the green Zip sheathing a clear pathway out.

 

In a pattern that would repeat itself with each layer of the remaining wall assembly, Wojtek and Mark would carefully think through the details as they progressed slowly at first, asking questions as issues arose, before getting the feel for what they were doing and eventually picking up speed as they progressed around each side of the house.

 

20171002_081038

Outside corner showing the Z-flashing covering the face of the Rockwool on the foundation with the first layer of Rockwool covering the Zip sheathing above.

 

Working through the many details with Wojtek and Mark — the majority of which occur at junctions like windows and doors, the top and bottom of the walls, along with mainly outside corners — was both collaborative and deeply gratifying. They demonstrated not only curiosity and an ability to problem solve on the fly, they also clearly wanted to do things right, both for me as a customer and for the house as a completed structure (it felt like both aesthetically and in building science terms).

 

1st layer rockwool at wdw buck

First layer of Rockwool meeting up with a plywood window buck. We tried to keep connections like these as tight as possible, especially since the window buck itself already represents a slight thermal bridge.

 

They never hurried over specific problem areas, arrogantly suggesting they knew better, instead they patiently considered unanticipated consequences, potential long-term issues, and actively questioned my assumptions in a positive way that tried to make the overall quality of the installation better. This mixture of curiosity, intelligence, and craftsmanship was a real pleasure to observe and work with.

 

starting 2nd layer rockwool n side

Mark and Wojtek beginning the second layer of Rockwool on the north side.

 

If a GC built this level of rapport with each subcontractor, I can certainly understand their refusal to work with anyone outside of their core team — it just makes life so much easier, and it makes being on the job site a lot more fun.

 

2nd layer rockwool at utilities

Second layer of Rockwool installed around mechanicals. Note the sill cock, or hose bibb: although it runs into the house, we left it loose so that it could be adjusted until the siding was complete — only then was it permanently soldered into place.

 

 

weaving outside corner w: 2nd layer

Weaving the seams at the outside corners to avoid undermining the thermal performance of the Rockwool.

 

 

2nd layer rockwool fastener at wdw

Close-up of the fasteners we used to attach the second layer of Rockwool.

 

For the second layer of Rockwool, Wojtek and Mark tried to hit only studs with the black Trufast screws. In fact, screwing into the studs with these fasteners, in effect, became a guide for accurately hitting studs with the first layer of strapping.

 

plates for 2nd layer rockwool

 

These Trufast screws and plates worked well and were easy for Wojtek and Mark to install.

 

trufast screw bucket

 

 

inside bucket trufast screws

The Trufast screws and plates were purchased from a local roofing supply house.

 

 

w side 2 layers rockwool

West side of the house with 2 layers of Rockwool complete.

 

 

1st layer rockwool into s side garage

First layer of Rockwool filling the gap between the house and garage framing.

 

If our lot had been larger, we would’ve gone with a completely detached garage, but unfortunately it just wasn’t an option.

 

2nd layer rockwool closing gap at garage

Second layer of Rockwool closing the gap between house and garage completely, ensuring our thermal layer is unbroken around the perimeter of the house.

 

 

nw corner 2 layers rockwool

Northwest corner of the house with the 2 layers of Rockwool installed.

 

It was exciting to see the house finally wrapped in its 4″ of Rockwool insulation.

 

 

Installing Battens and Creating our Rainscreen

Initially we were going to use 2 layers of 1×4 furring strips (also referred to as strapping or battens); the first layer installed vertically, attaching directly over the 2×6 framing members through the 2 layers of Rockwool and the Zip sheathing, with the second layer installed horizontally, anticipating the charred cedar that would be oriented vertically on the house.

Pro Trade Craft has many really informative videos, including this one on using a rainscreen behind siding:

 

 

Nevertheless, as the second layer of Rockwool went up, Wojtek and Mark pointed out that putting the siding in the same plane as the Rockwool/metal flashing on the basement foundation would be needlessly tricky. In other words, maintaining about a 1/8″ horizontal gap between the bottom edge of the vertical siding and the metal flashing on the foundation around the house would be nearly impossible, and any variation might prove unsightly.

As a solution, we decided to use 2×4’s for the first layer of strapping. By adding to the overall thickness of the remaining wall assembly it meant the eventual siding — now pushed slightly out and farther away from the Z-flashing covering the face of the Rockwool on the foundation — could be lowered so that visually it slightly covered what would’ve been a gap between the top of the metal flashing on the foundation insulation and the bottom edge of the siding. Wojtek and Mark also found that the 2×4’s were easier to install than the 1×4 furring strips directly over the Rockwool so that it didn’t overly compress the insulation (an easy thing to do).

Unfortunately, increasing the overall wall thickness with 2×4’s meant having to use longer Fastenmaster Headlok screws (it would also cost us later when it came to the siding on the north side of the house — more on this later). Apart from this change, the additional overall wall thickness mostly just increased the air gap in our rainscreen, which arguably just increased potential air flow while also expanding the drainage plane behind the eventual siding.

 

 

In one of the Hammer and Hand videos Sam Hagerman mentions that at least 1.5″ of screw should be embedded into the framing (excluding the thickness of the sheathing) for this type of wall assembly, but when I asked a Fastenmaster engineer about this directly he recommended a full 2″ of their screws should be embedded into the framing members in order to avoid any significant deflection over time.

As a result, we ended up using 8.5″ Headlok screws. The screws work incredibly well, requiring no pre-drilling, and they’re fun to use with an impact driver (keep your battery charger nearby). Along with the plastic cap nails and Trufast screws, I think we ended up with less than a dozen fasteners that missed the mark for the entire house — a testament to Wojtek and Mark’s skill. I was able to seal around these errant fasteners from the inside with a dab of HF Sealant.

 

headlok missed framing

Sealing around a Headlok screw that missed a 2×6 framing member.

 

During the design stage, using these longer screws prompted concerns regarding deflection, but based on this GBA article, data provided by Fastenmaster, along with some fun on-site testing, the lattice network of strapping (whether all 1×4’s or our mix of 2×4’s and 1×4’s) proved to be incredibly strong, especially when the siding material is going to be relatively light tongue and groove cedar.

For the garage, since insulation wasn’t going to cover three of the walls (only the common wall with the house was treated as part of the house wall assembly), we used significantly shorter Headlok screws for the first layer of furring strips.

 

monkey on furring strips

The Beast testing out the structural integrity of our strapping on the garage. Note the Cor-A-Vent strip below the bottom horizontal furring stip, helping to establish a ventilated rainscreen.

 

 

garage only 2x4s

Common wall inside the garage. Only a single layer of strapping was necessary in preparation for drywall.

 

Mark took the time to recess these screws to make sure they didn’t interfere with the eventual drywall.

 

recess 4 screws

Recessed Headlok screw on a 2×4 in the garage. Ready for drywall.

 

A small detail, but one of many examples showing Wojtek and Mark’s attention to detail, not to mention their ability to properly assess a situation and act appropriately without having to be told what to do.

Once the 2×4’s were all installed vertically through the structural 2×6’s as our first layer of strapping, Wojtek and Mark could install the components of the rainscreen, including the Cor-A-Vent strips at the top and bottom of the walls, as well as above and below windows and doors. In combination with the 2×4’s and the 1×4’s, this system creates a drainage plane for any water that makes its way behind the siding, while also providing a space for significant air flow, speeding up the drying time for the siding when it does get wet.

 

rainscreen2.jpg

Why use a rainscreen? Illustration courtesy of Hammer and Hand.

 

In addition to the Cor-A-Vent strips, we also added window screening at the bottom of the walls just as added insurance against insects. We noticed that on the garage, even without any insulation, the Cor-A-Vent didn’t sit perfectly flat in some areas on the Zip sheathing. Since the Rockwool on the foundation, now covered by the metal flashing, was unlikely to be perfectly level, or otherwise true, along any stretch of wall, it made sense to us to double up our protection in this way against insects getting into the bottom of our walls at this juncture.

 

starting 1x4s n side

1×4’s being installed horizontally on the north side in preparation for the charred cedar that will be installed vertically. Also note the Cor-A-Vent strips just above the foundation and below the window.

 

 

cor-a-vent-product-label

The main product we used to establish our ventilated rainscreen.

 

 

insect screen for rscreen

Window screen we cut to size for added insurance at the bottom of the walls around the Cor-A-Vent strips.

 

Wojtek and Mark also did a nice job of taking their time to shim the 1×4 layer of furring strips, thus ensuring a flat installation of the charred cedar.

 

shims behind 1x4s

Shims behind some of the 1×4 furring strips to ensure a flat plane for the vertical cedar siding.

 

This really paid off, not only making their lives easier when installing the tongue and groove cedar, but also providing aesthetic benefits in the overall look of the siding. This was especially true on the north side of the house, which has the largest area of charred siding with almost no interruptions, apart from a single window. It’s also the tallest part of the house, so without proper shimming the outcome could’ve been really ugly. Instead, once the cedar siding was installed it was impossible to tell there was 4″ of Rockwool and 2 layers of strapping between it and the Zip sheathing.

Really impressive work by Wojtek and Mark.

 

lking down furring behind rscreen at fdn

Looking down behind the ventilated rainscreen — 2×4, 1×4, with Cor-A-Vent and window screen at the bottom, just above the top of the foundation. This gap behind the siding provides ample air flow for the cedar siding, ensuring that the wood never remains wet for long.

 

 

rscreen furring at foundation

Strapping and rainscreen elements around a penetration near the top of the foundation.

 

Things got somewhat complicated around windows and doors, but once we worked through all the details for one window it made the remaining windows and doors relatively straightforward to complete.

Below you can see all the elements coming together: the window itself, the window buck covered with tapes for air and water sealing, the over-insulation for the window frame, the Cor-A-Vent strip to establish air flow below the window and behind the eventual cedar siding, along with the strapping that both establishes the air gap for the rainscreen while also providing a nailing surface for the siding.

Once most of the siding was complete around each window, but before the 1×6 charred cedar pieces used to return the siding to the window frames were installed, each window received a dedicated metal sill pan. The pan slid underneath the bottom edge of the aluminum clad window frame and then extended out just past the edge of the finished siding (I’ll include photos showing this detail in the next blog post about installing the charred cedar siding).

Here’s a JLC article discussing a couple of options for trim details in a thicker wall assembly with similar “innie” or “in-between” windows:

 

Window Trim

 

And here’s a detailed slide presentation by Bronwyn Barry regarding details like these for a Passive House wall assembly:

 

Sills and Thresholds – Installation Details

 

wdw rscreen and frame detail

The many details coming together around a window. In addition, each window eventually received a dedicated metal sill pan as a durable way to ward off water intrusion.

 

 

from int wdw rscreen and sill

Looking through an open window to the sill and the rainscreen gap at the outside edge. Note the Extoseal Encors protecting the sill of our window buck.

 

 

lking down wdw rainscreen

Outside edge of the window sill, looking down into the mesh of the Cor-A-Vent strip with daylight still visible from below.

 

 

rscreen at hd flash on wdw

Head flashing at the top of a window with doubled up Cor-A-Vent strips above it.

 

 

out corner hd flshng ready for sd

Same area, but with a 1×4 nailed across the Cor-A-Vent, creating a nailing surface for the cedar siding.

 

Many of the same details were repeated at the top and bottom of our two doorways. Below is a close up of the kitchen door threshold with Extoseal Encors and Cor-A-Vent again, along with additional metal flashing. Once a dedicated metal sill pan was installed (after most of the siding was installed), it felt like we did everything we could to keep water out.

 

kitch dr prepped 4 sd

Many of the same air and water sealing elements and rainscreen details present around the windows ended up at the top and bottom of doors as well.

 

In the photo below, you can see the many elements we utilized to try and prevent moisture damage around the front porch. For the door buck itself, I applied Prosoco’s Joint and Seam, both at joints in the plywood and the plywood/Zip sheathing connection, but also between the concrete and the door buck, as well as between the Rockwool and the concrete. We also kept the 2×4’s off the concrete, while also using the Cor-A-Vent strips to establish a ventilated rainscreen so that any moisture that does get behind the siding has ample opportunity to dry out in this area before it can cause any rot.

 

frt porch prep - rscreen water

Front porch: elements in place to try and prevent moisture damage.

 

 

west w: 2 layers battens

West facade prepped for siding.

 

 

flashing details on porch

Wojtek and Mark did a nice job with all the metal flashing details around the house — these kind of areas are the unsung heroes of a structure that manages water safely, and unfortunately go largely unnoticed by most homeowners.

 

In the next blog post I’ll go through the details for the top of the ventilated rainscreen when discussing how the charred cedar siding was installed.

 

Mark and Wojteck at front door

Mark and Wojtek installing Cor-A-Vent above the front door.

 

Even without the siding installed yet, it was especially rewarding to see all the underlying prep work involved in finishing our thermal layer and rainscreen come together so nicely.

 

Mark and Wojtek on the roof

Mark and Wojtek on the garage roof finishing up the battens for the front of the house.

 

Many thanks to Wojtek and Mark for executing all these details with such skill!

Blower Door (Air Sealing #9 )

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When it was time to schedule our blower door test we considered using Eco Achievers, but we only knew about them because they’ve worked extensively on projects for our original builder, Evolutionary Home Builders. We decided the potential awkwardness, or even a possible conflict of interest, wasn’t worth pursuing their services. An example of guilt-by-association I suppose, one that is probably unfounded but, nevertheless, the strong affiliation with our original builder made it difficult for us to reach out to them for help. They also hired one of Brandon’s former employees (this employee was nothing but nice and professional towards us as we were deciding to part ways with Brandon), which would’ve only added another layer of awkwardness to the situation.

Unsure how to proceed, I looked online and found Anthony from Building Energy Experts. He was able to come out and do a blower door test for us, helping me hunt down a couple of small leaks, so that we ended up at 0.34 ACH@50 for this initial test.

Here’s a Hammer and Hand video discussing the use of a blower door:

 

 

On a side note: all of the Hammer and Hand videos, along with their Best Practices Manual, were incredibly helpful as we tried to figure out all the Passive House details related to our build. It’s no exaggeration to say that without Hammer and Hand, the Green Building Advisor website, BSC, and 475 HPBS, our build would’ve been impossible to accomplish on our own. I owe an incredible debt of gratitude to all of these great resources who invest valuable time sharing such a wealth of information.

Below is a Hammer and Hand video noting the importance of properly detailing corners to avoid air leaks:

 

 

Because of this video, I sealed all of my corners for the windows and doors like this:

 

HF Sealant in corners b4 blower door

Adding Pro Clima HF Sealant after completing taping of the corner, just for added insurance against potential air leakage.

 

I also added some HF Sealant to the lower portion of the windows, since some air leakage showed up in this area with Anthony where components of the window itself come together in a seam.

 

sealant on wdw components junction

Seam near bottom of window where components meet — sealed with HF Sealant.

 

Where components come together is often an area that needs special or further attention.

 

close up corner and wdw components seam w: sealant

Close-up of this same area — seam in components sealed, along with the bottom corner of the window and the gap between window buck and window.

 

Even with layers of redundancy in place, in the picture below there was a small air leak still present at the bottom plate – sub flooring connection. A coating of HF Sealant easily blocked it.

Once the stud bays were insulated (after most of the siding was up), the interior walls would eventually be covered with Intello (I’ll cover the details in a future post on interior insulation), adding yet another layer of redundancy for mitigating potential air intrusion.

 

area of kitchen sill plate leakage

Area of kitchen sill plate leakage.

 

Anthony didn’t have any previous experience with a Passive House build, so it occurred to me that it might be beneficial to reach out to Floris from 475 High Performance Building Supply (he had already done our WUFI analysis for us), and Mike Conners from Kenwood Property Development to see if there was someone locally who did. Mike is a Passive House builder in Chicago who had already helped me out with some Rockwool insulation when we came up short earlier in our project (the two GC’s we fired repeatedly struggled with basic math), and he was very nice to take the time to answer some other technical questions for me as well.

 

 

Both, as it turned out, ended up recommending that I contact Steve Marchese from the Association for Energy Affordability.

 

 

Steve would eventually make three trips to the house, doing an initial blower door test after the structure was weather-tight and all the necessary penetrations had been made through our air barrier, a second test after exterior continuous insulation was installed, and a final test after drywall was up to ensure there hadn’t been any increase in air leakage during the final stages of construction.

 

Steve starting blower door test

Steve setting up the blower door for his first test.

 

Following Passive House principles for our build, we also followed the same protocols for the blower door tests: Blower Door Protocol

With the structure under pressure from the blower door fan, Steve and I walked around the house while he used a small smoke machine in order to try and find any leaks that I could then seal up.

 

Steve testing window gasket

Steve starting at the windows. Here testing a window gasket for air leakage.

 

The gaskets around our windows and doors proved to be some of the weakest areas in the house although, comparatively speaking, it was inconsequential since the overall air tightness of the structure was fairly robust (favorite word of architects).

 

Steve showing impact of unlocked window

Steve showing me the impact a window in the unlocked position can have on air tightness. The gasket, ordinarily squeezed in the locked position, works to bring the sash and the frame tightly together.

 

 

Steve smoke at family rm wdw

Looking for areas around the windows that might need adjusting or additional air sealing.

 

For instance, even though no substantial air leakage showed up around this kitchen door, during our first winter this same door eventually had ice form outside at the upper corner by the hinges, on the exposed surface of the gasket where the door meets the frame.

 

Steve at kitchen door

 

After figuring out how to adjust the door hinges, there was no longer any ice showing up this winter, not even during our Polar Vortex event in late January.

 

 

Much the same thing occurred around our front door as well, with the same solution — adjusting the hinges to get a tighter fit at the gasket between the door and the frame.

 

Steve testing attic hatch

Steve testing the attic hatch for air leaks.

 

Steve was nice enough to go around and methodically check all the penetrations in the structure.

 

Steve testing plumbing vent in kitchen

Steve testing for air leaks around the kitchen plumbing vent and some conduit.

 

 

Steve testing for air leaks @ radon stack

Steve testing for air leaks around the radon stack.

 

 

Steve @ radon stack close up

Close up of radon stack during smoke test.

 

There was one area in the guest bathroom where the Intello ended up getting slightly wrinkled in a corner during installation. With Tescon Vana and some HF Sealant I was able to address it so nothing, thankfully, showed up during the smoke test.

 

Steve testing wrinkled area of Intello

Steve testing area of Intello that I inadvertently wrinkled during its installation.

 

After looking around on the main floor, Steve moved down into the basement.

 

Steve testing for air leaks @ main panel

Checking for leaks at the main electrical panel.

 

 

Steve testing for air leaks @ main panel exit point

Checking for leaks at the conduit as it exits the structure.

 

 

Steve testing for air leak @ sump pit cap

Looking for air leakage around the sump pit lid.

 

The lids for the sump pit and the ejector pit were eventually sealed with duct seal putty and some Prosoco Air Dam.

 

Steve testing for air leaks @ ejector pit

Testing the ejector pit for air movement.

 

 

Steve testing for air leaks @ Zehnder exit point

Checking for air leakage around one of the Zehnder ComfoPipes as it exits the structure.

 

 

Steve testing for air leaks @ pvc:refrigerant lines

Looking for air leaks around the heat pump refrigerant lines as they exit the structure.

 

 

Steve smoke at sump discharge

Checking around the penetration for our sump pump discharge to the outside.

 

Before the second blower door test, I was able to add some duct seal putty to the lids of the sump and ejector pits.

 

ejector pump lid w: duct seal

Ejector pit lid with some duct seal putty.

 

Below is a copy of Steve’s blower door test results, showing the information you can expect to receive with such a report:

 

Final Blower Door Test Results

 

For the last two tests Steve used a smaller duct blaster fan in order to try and get a more precise reading for air leakage.

 

Steve at front door

With Steve just after the initial blower door test was complete.

 

Steve would be back two more times — once before drywall, and once after drywall — just to ensure we had no loss of air tightness develop in the interim stages of the build (especially after continuous exterior insulation with furring strips were installed).

Here are the final figures noting where we ended up:

 

0.20 ACH@50 and 106 cfm@50

 

We are well below Passive House requirements (both PHI and PHIUS), so there was a great sense of relief knowing that all the time and effort put into air sealing had paid off, giving us the tight shell we were looking for. Even so, it was still pretty exciting news, especially for a first build.

And here’s an interesting article by 475 HPBS regarding the debate over how air tightness is calculated for PHI vs. PHIUS projects, and the potential ramifications:

 

Not Airtight

 

Dressing up the Basement: Steel Beam and Concrete Walls

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With the Zehnder and the Mitsubishi systems installed, I had some time to kill waiting for the siding guys to start, and for my first blower door test to take place, so I moved on to painting my structural steel beam and the exposed concrete walls in the basement. Apart from a couple of walls for my wife’s office that would eventually be drywalled and painted, and a decorative finish for the concrete floor, these were going to be some of the limited finished surfaces in the basement.

We’re glad we decided to leave the basement ceiling unfinished. In doing so, not only did it mean a more straightforward installation process for mechanicals, it also means if any issues develop in the future we’ll have easy access to identify and solve any problems.

I debated whether or not to spray the basement ceiling — the floor joists and the underside of the sub flooring — but decided that the color change (some shade of gray? black?) wasn’t worth the effort.

Although obviously not to everyone’s taste, we like the unfinished look of the ceiling, especially when combined with the texture of the painted concrete walls and our painted steel beam (not to mention the eventual decorative finish for our concrete floor slab — I’ll go through the details in a future blog post since it was applied much later in the build).

For the beam, I first used a wire brush and some sandpaper to remove any loose and flaking rust. Using a Sherwin Williams primer, their All-Surface Primer tinted gray, I applied a heavy, uniform coat to help prevent the return of any rust in the future (keeping humidity in the basement under control should help a lot in this regard).

 

beam w: primer and rusty red

After wire brushing off loose rust, priming the beam in preparation for paint.

 

After priming, I then applied two coats of a Safecoat product, their semi-gloss in Patriot Blue.

 

Safecoat semi-gloss Patriot Blue for steel beam

Patriot Blue for the steel beam.

 

If I could do it over, I think I’d use Safecoat primers and paints for almost all of the interior surfaces. For the sake of convenience, since they have stores near me, I mainly used Benjamin Moore’s Aura Matte and Satin for walls and trim, and ended up mostly disappointed with their performance — hiding is pretty mediocre, flashing when you try to do spot touch-ups, and over-priced for the level of quality. Benjamin Moore does a great job with their marketing materials and with the look of their labels, I just wish the same level of thought and attention to detail went into the quality of their finishes.

Safecoat is available at various stores in the US, but unless you want a stock white, tinting may happen at Safecoat headquarters before shipping to individual stores, so there can be a wait involved (check with your local supplier for details).

I had good luck ordering from Green Building Supply in Iowa. After ordering online, the products are shipped directly to the job site or your home. This gives you access to high quality No or Low VOC products that, at least in my case, are otherwise currently unavailable in local hardware or paint stores.

Unfortunately, they can’t ship during cold spells, since the paint could freeze and be ruined. When it was cold and I needed product, I found Premier Paint and Wallpaper just outside of downtown Madison, Wisconsin (about a 2 hour drive for us). They’re a family-owned shop, and it shows. They have a nice selection of Safe Coat products. In fact, their wide range of products from various brands is impressive, and the people who work there are really helpful and just easy to work with. Unfortunately, I haven’t found a similar paint store in my area. Around me, Benjamin Moore (aka JC Licht), Sherwin Williams, and Pittsburgh Paint stores dominate the market. The smaller mom-and-pop stores, for the most part, don’t really exist anymore, which is a shame.

 

beam w: primer and paint

Paint going over the primer.

 

The Safecoat products that I’ve used typically have some odor, but what little smell they do have tends to dissipate rather quickly (this is particularly noticeable if you change back to a more conventional coating with more VOCs that may take weeks before its distinct odor finally disappears).

 

painted beam w: zehnder and hpump

Finished beam.

 

It’s a shame that so many structural beams end up covered over, normally considered too humble, i.e. ugly, to be left alone. In keeping with our Urban Rustic design aesthetic, we think that if they’re given even just a little bit of attention and care they can prove to be a real visual asset to a space, especially in a basement if a more relaxed, informal look and feel is acceptable or even ideal.

 

cu paintd beam in basement

Close-up of the painted I-beam.

 

Leaving the spine of the house exposed like this with a bold color emphasizes the job it’s actually doing, and it honors the material by making it front and center visually in the space, rather than trying to hide it away behind drywall or wood. This seems only appropriate since beams like this help keep a house standing upright.

 

basement walls primed

Another view of the beam, and the recently primed concrete walls.

 

Once the beam was completed, I moved on to priming the exposed concrete walls.

 

beast helping me prime basement

Getting some help priming the concrete walls. She lasted about 15 minutes, at which point it clearly turned into work.

 

Paint color can be a finicky thing. After priming the concrete walls, I used a Benjamin Moore color, Jute, as the finish coat. In the basement it looks great, exactly what we were looking for: a nice, warm neutral khaki color. Upstairs, however, when I later did a test swatch on the new drywall this same color looked horrible, taking on pinkish flesh tones, so we ended up having to use a different color for most of the first floor. Testing out colors, even in relatively small areas, can save a lot of time, money, and headaches later on.

 

painted basement walls

Concrete walls after paint.

 

It was really important to me that the basement foundation walls be left exposed, with no insulation or drywall.

 

20190831_120510

 

I wanted all of the texture, imperfections, and overall character of the exposed concrete to be vividly on display.

 

20190831_120625

There are a couple of areas of ‘honeycombing’ around one basement window. Under the right lighting, it creates a nice visual effect.

 

 

20190831_120205

Areas with exposed conduit were also painted.

 

 

20190831_120703

 

 

20190831_115629

 

With a good chunk of the basement complete, it was time to move outside and get some work done before the siding began, and before we had our first blower door test.

HVAC Part 2: Ductless Mini Split

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System Requirements

The plan for our house was to combine an HRV or an ERV (for a continuous supply of fresh air), with a ductless mini split air source heat pump system for our ventilation, heating, and air conditioning needs. Almost all of the projects I had read about utilized this same combination, especially here in the US.

 

 

The only real debate, apart from specific brand options, was whether or not to utilize only one distribution head on our main floor, as opposed to installing multiple heads for a more ‘dialed-in’ level of comfort (e.g. in the basement or the bedrooms).

Our original builder had in our construction drawings one head in the kitchen/family room and one in the basement, which was pretty standard for a Passive House level project. It was, therefore, pretty shocking to find out that our second builder (there were two partners) and their HVAC subcontractor were suggesting a system that was grossly oversized for our needs. You can read about the details here: GBA: Oversized System 

This was just one of many ‘red flags’ that convinced us to move on and GC the project ourselves. It’s also a reminder that old habits die hard, meaning even seasoned contractors, in any trade, need to be willing to learn new ideas and techniques if they want to truly be considered professionals and craftsmen — unfortunately, they’re the exception to the rule, at least in our experience.

One of the disappointments associated with our build is, in fact, the disinterest (in some cases even outright hectoring contempt) shown by various tradespeople in our area for ‘green’ building generally. Doubtless, at least a partial explanation for why much of the Midwest seems so far behind in adopting ‘green’ building techniques, especially when it comes to air sealing, insulation, and IAQ beyond code minimum standards. Hopefully this changes significantly in the coming years.

Consequently, I took Steve Knapp’s advice (from the comments section of my question) and contacted Home Energy Partners (their new name: HVAC Design Pros). Isaac responded quickly and eventually did our Manual J, confirming we needed a much smaller system, one that is more consistent with a Passive House project, or even just a high-performance build more generally.

Here are a couple of Matt Risinger videos detailing a mini split set-up that’s fairly typical for a Passive House or a Pretty Good House (GBA article on the 2.0 version).

 

 

 

 

Once we were on our own, in addition to going with a Zehnder ERV and a Mitsubishi ductless mini split air-source heat pump system, we also pursued the possibility of using a Sanden heat pump water heater.

After seeing it used on a Hammer and Hand project, we thought it was a really interesting piece of cutting edge technology:

 

 

Unfortunately, after getting a quote from Greg of Sutor Heating and Cooling, and a poor response from Sanden regarding questions we had about the system (they were unresponsive to emails), we decided to stick with our Zehnder, the Mitsubishi heat pump, and then go with a Rheem heat pump water heater (going with the Rheem saved us just over $6,000 in initial cost). Hopefully, as it becomes more popular in the US, the Sanden can come down significantly in price, or maybe less expensive copycat products will someday show up on the market.

Greg was initially willing to work with us, even though we were technically out of his service area, when the Sanden was involved, but once it was only a ductless mini split he suggested we find a Mitsubishi Diamond installer closer to us, which we understood. He was nothing but professional, taking the time to answer any number of technical questions and offering what proved to be sage advice regarding various details for our system.

In fact, taking Greg’s advice, we contacted a Diamond installer close to us, but unfortunately the first installer we contacted disappeared when we were trying to get him to communicate with our electrician on installation details (an infuriating and painfully common experience when trying to build a new house — especially one with unconventional Passive House details).

 

 

Finding our Installer

At this point, we were lucky to find Mike from Compass Heating and Air. He came out to the job site and we walked through the details together. He proved to be knowledgeable, helpful, detail-oriented, and extremely professional. Installing our Mitsubishi ductless mini split system with Mike proved to be one of the easiest portions of our build. We never felt like we had to look over his shoulder, making sure he got details right, or that we had to constantly confirm that he did what he said he was going to do — in fact, it was the opposite: ‘Mike’s on site, so that’s one less thing I have to worry about’.

 

Compass truck on site

Mike and his crew at the job site to install our Mitsubishi ductless mini split system for heating and air conditioning.

 

Mike also confirmed what Greg and Isaac also pointed out: comfort issues may develop if we tried to get by with just one distribution head on the main floor.

In fact, looking back through old emails, Greg was nice enough to walk me through some of the options employed by those trying to get by with a single head for an entire floor (sometimes even two floors), including leaving bedroom doors open throughout the day (ideally, even at night), and even the use of Tjernlund room-to-room ventilators.

 

 

Again, to his credit, Greg tried to stress how important it was that homeowners have realistic expectations regarding the overall effectiveness of these techniques and options.

He also was at pains to make clear how the work of any competent HVAC installer can be easily undermined by a structure that underperforms. In other words, they can design an appropriately sized HVAC system for a Passive House, but if shortcuts occur during the build and the final blower door number comes in higher than expected, or the budget for insulation gets cut, reducing R-values in the structure, then the system they designed has little chance of working as intended. Based on what he wrote, I’m guessing he has dealt with exactly this outcome in the real world — not fun for him, or the homeowners to be sure.

Consequently, by the time Mike from Compass Heating and Air got involved, we had pretty much already settled on using multiple heads. Although it was nice to hear the same consistent message from Greg, Isaac, and Mike in this regard.

In the end, we decided to delete the head in the basement, instead going with three separate heads on the main floor — the largest in the kitchen/family room, and then the other two would go in our bedrooms.

Here are the specs for our system:

Hyper-Heat Compressor (30,000 Btu)

MSZ-FH15NA  (kitchen/family room)

MSZ-FH06NA  (master bedroom)

MSZ-FH06NA  (2nd BR)

 

head in mbr w: section of drywall

Master bedroom Mitsubishi head and Zehnder supply, both covered to protect against construction debris.

 

Having the Zehnder supply diffusers on the same wall and near the head of the Mitsubishi has been working well for us. As far as we can tell, there are no discernible issues with this arrangement. By way of comparison, the Mitsubishi head and Zehnder supply diffuser are on separate walls in my daughter’s bedroom — in effect, they’re pushing air towards the center of the room from walls that are perpendicular to one another — but we can’t tell any difference in terms of performance, either when heating or cooling.

 

mbr and family rm erv:heads construction

Facing camera: Family room Zehnder supply diffuser with Mitsubishi head. To the left, and facing MBR — Zehnder supply and lines for another Mitsubishi head.

 

Mike was also really good about communicating the system’s requirements to our electrician and our plumber. It was nice to watch all of them walk through the details together, thereby ensuring there were no problems once it came time to start up the individual heads.

 

condensate and refrigerant

Components for setting up a ductless mini split: refrigerant lines, electric supply, and a drain for condensate.

 

 

Living with a Ductless Mini Split

Having lived with the HVAC system, both the heat pump and ERV, for about a year now, our only real complaint is summer humidity, which I discussed in a previous post here: HVAC (1 of 2): Zehnder ERV

This summer we’re going to try using a dedicated, whole-house dehumidifier, which we think should resolve the issue.

Otherwise, our system has been trouble-free.

In winter, the heads do make some noise, tending to ‘crack’ or ‘pop’, especially when first turning on, or when they come out of defrost mode. Although I’ve read complaints about this online, it’s never really bothered us. I remember how loud our conventional gas-fired furnace was in our last house, especially when it first turned on, so I think it’s important to remember the level of certain sounds in their appropriate context.

Also, this ‘crack’ or ‘pop’ sound is, I suspect, louder than it otherwise would be say in a conventionally built home, since Passive Houses are known to be significantly quieter because of all the air sealing and, in particular, all of the insulation surrounding the structure.

There’s also a noticeable humming sound when the compressor is going through a defrost cycle (especially noticeable at night when the house is otherwise quiet). The heads also temporarily send out cooler air during this defrost cycle, but the cycle is short enough that it hasn’t posed any real comfort issue for us.

 

heat pump being installed on pad

Setting up the compressor outside.

 

Regarding interior noise generally, the same holds true even for our refrigerator in the kitchen. We virtually never noticed the fridge in our last house when it was cycling, but in our Passive House it’s arguably the loudest, most consistent noise in the house, especially at night, or if quietly sitting and reading. Again, it took some getting used to, but not really that big of a deal.

In other words, having blocked out, or at least muffled, most of the noise from outdoors (due to extensive air sealing and extensive insulation), any noise indoors becomes much more noticeable and pronounced. The Rockwool we installed between bedrooms-bathrooms, and the kitchen-utility room for sound attenuation definitely helps in this regard (more on this in a later post).

 

ext line set fully sealed

Line set for the heat pump system exiting the structure after being air sealed.

 

Just how quiet is a Passive House? Well, one example would be the train tracks that are just a couple of blocks away: When the windows are closed the noise from a passing train is mostly cancelled out — as opposed to when the windows are open, and the train, in contrast, sounds like it’s thundering through our next door neighbor’s yard.

 

pvc tied down w: duct seal

Interior view of the line set exiting the house.

 

As far as extreme cold outdoor temperatures are concerned, the system experienced a real test with our recent Polar Vortex weather. Mike was nice enough to check in with us the day before it started just to remind me that the system could shut down if temperatures fell below -18° F, which is what our local weather forecast was predicting.

In fact, this proved entirely accurate. As temperatures eventually fell to -24° F overnight, the system was, in fact, off for a few hours (the Mitsubishi shuts off to protect itself).

With the Zehnder ERV already set to LOW, and using just a couple of small space heaters (one in each bedroom — roughly equivalent to running 2 hair dryers simultaneously), it was easy to get the interior temperatures back up to 68-70° F in less than an hour (from a measured low of 61° F when we first woke up), at which point we turned off the space heaters.

And it was just under 2 hours before the temperatures rose enough outdoors for the heat pump to turn back on. On the second day, the system again turned off, but the interruption was even shorter this time, so we didn’t even bother to turn on the space heaters.

On both days the sun was shining, which definitely helped as light poured in through our south-facing windows, mainly in the kitchen and family room. Even with no additional heat, either from the heat pump or the two small space heaters, the kitchen remained a comfortable 70° F throughout that first day, regardless of the temperature outside.

In the summer, when we have the AC running, we just set the desired temperature on the remotes and largely forget about the system. The three heads together, even in each individual space, have no problem keeping the house and individual rooms cool enough. In this case, it no doubt helps that we have a substantial overhang on the southern portion of our roof, mostly denying the sun an entry point into the home during the hottest days of the year (and the Suntuitive glass on our west-facing windows takes care of afternoon summer sun).

 

conduit for heat pump thru zip

Conduit for the heat pump exiting the house and air sealed with Roflex/Tescon Vana tape and gasket.

 

You can see more detailed info regarding air sealing penetrations through the Zip sheathing here: WRB: Zip Sheathing

 

refrigerant condensate next to beam

Clean, neat lines for the heat pump.

 

 

Single or Multiple Heads?

As far as using a single head to try and heat and cool the entire first floor, in our case about 1500 sq. ft., I can only say that I’m glad we chose to use multiple heads. This really hit home as I was completing interior finishes. For instance, there were times when only the head in the family room/kitchen area was running. When you walked into the bedrooms you could definitely feel the temperature difference since those heads had been turned off (roughly a 5-10° difference). As Greg, Isaac, and Mike — to their credit — were all quick to point out, for some homeowners this temperature swing would be acceptable, even something that could be calmly ignored, while for other homeowners it might well be a heartbreaking and deeply frustrating realization.

Depending on how sensitive someone is to these temperature differences, it could  prove a devastating disappointment if the homeowner is expecting uniform consistency throughout their home. Also, since much of the selling point of Passive House techniques is, in the end, occupant comfort, and not just reduced energy consumption, moving from a comfortable kitchen, for example, to a bedroom that some would find outright chilly, might induce some homeowners to ponder: ‘What was the point of all that air sealing and insulation if I’m still cold in the wintertime and hot in the summer?’ If they hadn’t been warned beforehand, like we were, it would be difficult to argue with their reasoning.

Obviously it’s only our opinion, but if it’s at all possible to fit it into the budget, by all means utilize more than one distribution head. Even if you yourself never feel compelled to turn on any of the other heads in a multi-zone system, a spouse, one of your kids, or a guest probably will want to have the option at some point.

 

cu beam w: zehnder and hp

Zehnder ComfoTubes and various lines for the heat pump as they enter the basement from the MBR and the family room.

 

In addition, I would also guess that when going to sell the house multiple heads would be significantly easier to sell to a potential buyer (who wouldn’t appreciate customized HVAC in specific rooms?) rather than trying to prove that a single head is sufficient for an entire home, no matter how small or well-designed. Thoughts worth considering before committing to a specific HVAC system.

 

north facade w: siding

Compressor with finished charred siding and decorative gravel-cobblestone border.

 

Also worth noting, utilizing the Q&A section of the Green Building Advisor website is an excellent resource for exploring options before committing to a final HVAC set-up. It’s an excellent way to hear from designers and builders who have experience with multiple ‘green’ projects, not to mention actual homeowners who live in high-performance homes and experience these HVAC systems in the real world, as opposed to just data points put into a proposed energy model (incorrect inputs, along with actual occupant behavior are just two ways a potential system could end up being profoundly inappropriate). This kind of feedback — before construction begins — is undeniably priceless. In fact, I regret not asking more questions on GBA as they came up during the design and construction phases of our build since it is such a valuable resource of useful information.

 

compressor in snow

View of the same area after our recent Polar Vortex (snowfall, then below-zero temps).

 

The one real risk we took with our HVAC set-up was foregoing any direct conditioning in the basement, either heat or AC. In the summer, no matter how high the temperatures outdoors, the basement stays within 5 degrees of the upstairs temperatures and humidity, so no comfort issues in this regard have presented themselves. In the winter, however, the temperature remains in the 59-61° range, with almost identical humidity readings as the main floor.

 

ice under unit

Some ice build-up, but almost all of it on the concrete pad below, not on the compressor itself.

 

Most of the time this isn’t a problem for us, since we’re either working out (the slight chill gets you moving and keeps you moving), or else we’re doing arts and crafts projects, or reading on a couch under a blanket. The only time the chill gets annoying is when sitting at the computer for an extended period of time, so we may try using a plug-in space heater in the office next winter (although the challenge will be to find one that’s reasonably energy-efficient while also remaining effective).

 

little ice build-up

Close-up, showing very little ice present on the compressor itself.

 

 

Mitsubishi Wall-mounted Heads: Beauty or Beast

I’ve read that some interior designers, and even some homeowners, have expressed aesthetic concerns about the distribution heads. If you go on design-oriented websites like Houzz you can come across some really strong negative opinions on the topic.

 

family rm:kitchen hp head and zehnder

 

For us, they’ve never been a problem. Much like the Suntuitive glass on our west-facing windows, or even a dark or bright color on an interior accent wall, after a few days, like anything else, you just get used to it. I never found them to be ugly in the first place though.

 

MBR w: hp head and zehnder

 

I also grew up with hydronic metal baseboards for heat, while in apartments and our first home we had the typical floor supply and wall return grilles for a gas furnace — point being, the details of any HVAC system are never completely absent from any living space. There’s always something that shows up visually and, typically, that needs to be cleaned at some point.

In addition, the Zehnder ERV and the Mitsubishi heat pumps meant we didn’t have to utilize any framed soffits or duct chases (at least in the case of our specific floor plan) in order to hide bulky runs of traditional metal ductwork, typical in most homes when using a normal furnace. Unless designed with great care, these tend to be obtrusive, taking up premium ceiling, wall, or floor space. And if randomly placed simply for the convenience of the HVAC contractor, they can be downright ugly.

In other words, it doesn’t really matter if you’re building conventionally or if you’re building a Passive House, all the details of an HVAC system — whether it’s individual components, or even how these components will be placed inside a structure — should be carefully thought through (again, ideally before construction begins) to address any performance or aesthetic concerns.

 

 

Controlling and Adjusting the System

As far as the remote controls for the individual heads, we haven’t had any issues.

 

heat pump remote closed

 

For the most part, we set them to either heat or AC (roughly 70° and 75° respectively), and then forget about them.

 

heat pump remote open

 

To the extent I’ve looked through the manual, these seem straightforward, but again we haven’t really needed to do much in this regard. And when the weather is pleasant outdoors, we take every opportunity to turn off the system completely and then open windows.

Mike also explained the system could be combined with a Kumo cloud set-up, but we’ve been happy with just the hand-held remotes so far.

 

 

Routine Maintenance

And much like with the Zehnder ERV, I try to check the filters for the individual heads at least once a month (more like once a week when I was still doing interior finishes). Just as it takes much longer for the Zehnder filters to get dirty now that construction is over, the same has proven true for the blue filters in the Mitsubishi heads. It seems like about once a month is sufficient to keep up with the dust in the house.

 

 

Overall, we’ve been very happy with our HVAC set-up, including the Zehnder ERV and our Mitsubishi ductless mini split. As long as the units don’t have any durability issues, we should be happy with these systems for many years to come.

HVAC Part 1: Zehnder ERV

6

Building with Passive House principles in mind, we knew that, in addition to maintaining a tight building envelope, and incorporating substantial amounts of insulation around the structure, we also needed to install continuous mechanical ventilation in order to have adequate levels of fresh air, not to mention the ability to expel stale air.

We also needed our system, either an HRV or an ERV, to be highly efficient, meaning it could hold onto some of the heat in the conditioned air even as it introduced fresh and, oftentimes, cold air by means of heat exchange as the two streams of air (fresh and stale) passed by one another inside the main unit (without actually mixing together).

 

 

After researching the many options, we ended up going with Zehnder’s ERV, in our case, the ComfoAir 350 (the various Zehnder units are based on overall cfm demand of the structure).

We only considered two other brands for our mechanical ventilation (HRV vs. ERV):

UltimateAire

and

Renewaire

In all the research I did prior to construction, these three brands showed up the most in the projects I read about.

Here’s a good debate on the Green Building Advisor website discussing brand options: ERV Choices

Another interesting option would be the CERV system. Because they’re a smaller, newer company, we didn’t feel comfortable pursuing it, but it does look like a viable option worth considering if building a Passive House or Pretty Good House.

I was also familiar with Panasonic units, but I had always read that they weren’t efficient enough in terms of the heat exchange function (or heat recovery) to seriously consider using it in a Passive House or a Pretty Good House in a predominantly cold climate region like ours, here in the Chicago area.

 

 

Our Zehnder ComfoAir 350 is said to be 84% efficient in terms of heat recovery (the same principle applies in summer, only working in reverse, when you’re trying to hold onto cooled, conditioned air). Based on what I read during the design phase, the consensus seemed to be that, although more expensive, the Zehnder has a strong track record of performance and durability.

The Zehnder also came with its own ductwork, which we knew would simplify installation, allowing us to do it ourselves, rather than hire someone else to come in and run more conventional ductwork through the house (conventional ductwork would’ve taken up a lot more space as well). Even though the unit itself was more expensive, we thought we could offset some of the total cost for a ventilation system by installing the Zehnder ourselves, thereby saving some money on labor costs.

As far as the ERV/HRV debate for Northern US states, we decided to opt for the ERV because it was supposed to help us hold onto some humidity in winter months, especially important when most structures in the Chicago area are exceedingly dry for most of the winter (and our winters are long). Although I read repeatedly during the design stage that ERV’s can also help control summer outdoor humidity entering the house, this has not been our experience at all. In fact, the ERV seems pretty useless in this regard (more on this below).

The system quote we received was easy to understand, and Zehnder was nice enough to essentially design the system, both in terms of layout (i.e., where we should put all the supply and exhaust points), along with the quantity, or cfm’s, of air for each point. In the end, after commissioning the unit, the system should be balanced, meaning the unit should be bringing in as much fresh outdoor air as it is expelling stale indoor air.

As far as Zehnder units being DIY friendly in terms of installation, in our opinion, this is highly debatable since the installation manual is far from comprehensive. Our installation manual ended at physically installing the main unit on the wall. Not very helpful.

Without a detailed installation manual showing step-by-step how all the individual pieces fit together, you end up with a pile of what initially seems like random parts.

 

zehnder pile of parts

Everything we need to install our Zehnder ERV. Most of the smaller components are still in the many cardboard boxes off to the right.

 

This was incredibly frustrating, especially since Zehnder units are purchased at a premium when compared to other competitive brands, and with the expectation of durability and design precision. It never occurred to me to ask before purchasing the unit for an installation manual, since it seemed a fair assumption that no one would sell a premium product without detailed instructions on how to put it together.

We were only able to proceed because of numerous online videos, googling Zehnder unit photos, and by staring at and experimenting with the various parts to try and figure out how it all was supposed to come together. It was an unnecessary and torturous puzzle that shouldn’t have needed solving, and it wasted hours of my life that I’ll never get back. If you do an internet search and type in: “google review Zehnder America” the experience Sean Hoppes had with his installation wasn’t all that different from ours.

Looking on the current Zehnder website (February, 2019), I can’t find a more detailed set of instructions, either written or in a video format, which is disappointing. This seems like a pretty glaring oversight on Zehnder’s part, and one that should be remedied immediately.

Having lived with the unit for almost a year now, overall we’re happy with its performance, and we feel like we could install one fairly easily now that we’ve gone through the entire process, so it’s a shame we can’t say only nice things about the product simply because the installation manual was so limited or, more to the point, non-existent.

With each video and each photo, it was possible to glean one more crucial nugget of information, which took hours, whereas a detailed written manual or a step-by-step video would’ve made the process straightforward, and by comparison, frustration-free.

The videos below were especially helpful, but, nevertheless, they still leave out quite a bit of pertinent information necessary for any first-time installer (especially regarding all the parts that need to be installed on top of the main unit):

 

 

 

 

Unless there are no DIYers in Europe installing these units, and this is the expectation Zehnder has for its units both for overseas and here in the US, not having a comprehensive installation manual makes no sense. I’m not sure how even a licensed and competent HVAC installer would fare much better without direct experience installing the units. My guess is they would be searching online for missing info much like we did.

Once we got the main unit installed on the wall, and we figured out how all the parts fit together on top of the unit, by the time we got to installing the small, white 3″ ComfoTubes and the large, gray ComfoPipe, the process became much easier.

 

main unit attached to basement wall

Mounting the main unit to the basement foundation wall with Tapcon concrete screws.

 

In regards to the gray ComfoPipe for the main fresh air supply and the main exhaust, both of which pass through the wall assembly, we found it more effective to put individual sections together on the floor, and, once fully connected, we marked the points at which the pipes met with a permanent marker.

 

marking comfopipe w: sharpie

Marking sections of connected ComfoPipe with a Sharpie while they’re on the floor ensures a tight fit once a connection has been made off the floor.

 

If you try to piece the tubes together one piece at a time in mid-air it’s much harder to gauge when the pieces are actually tightly put together. With each connection point of pipe clearly marked with a Sharpie, it gives you an obvious goal to shoot for once you have the pipe almost in its final position. More to the point, it’s obvious when sections of pipe get out of alignment, or the connection isn’t nearly tight enough — it’s much more difficult to accurately gauge if only going by “feel” once the sections of ComfoPipe are off the floor.

 

drilling hole for Zehnder exhaust

Making initial cut in the Zip sheathing.

 

Using a piece of ComfoPipe, we outlined on the interior side of our Zip sheathing exactly where we wanted the pipe to end up (trying to get as close to center as possible — makes air sealing around any penetration much easier). After a hole was cut with a 3″ hole saw, we cut out the rest of the hole using a jigsaw.

 

hole in Zip for heat pump pvc

Hole cut and ready for the ComfoPipe.

 

 

hole set-up for comfopipe

Hole made in our Zip sheathing, ready for the ComfoPipe from outside to make a connection with the section inside.

 

 

ext - comfo pipe going thru zip into basement

Ready to push the ComfoPipe into the house from outside to make the connection inside.

 

 

Zehnder chipmunk's back

Chipmunks are back.

 

Once we started using the Sharpie, it was relatively easy to get all the ComfoPipe installed and air sealed around the Zip sheathing.

 

comfo pipe thru zip

Making the connection between inside and outside.

 

 

setting up comfo pipe

Adding a Roflex gasket to make air sealing much easier.

 

 

comfo pipe sealed int.

ComfoPipe air sealed on the interior side with Roflex gasket and Tescon Vana.

 

 

close up comfopipe sealed

Close-up of the ComfoPipe air sealed at the Zip sheathing.

 

 

installing comfo pipe next to main unit

Finishing up the last sections of ComfoPipe as they leave the main unit.

 

Following the directions, we kept the ComfoPipe exit points for supply and exhaust more than 10′ apart outside, where they enter and exit the structure, in order to avoid any possibility of the two air streams mixing, which would undermine the effectiveness of the system.

 

comfopipe ext sealed and covered

Repeating the same air sealing process on the exterior for the ComfoPipe, adding black garbage bags over the opening with rubber bands to keep out dust, dirt, birds, and any critters that might otherwise try to enter the structure during construction.

 

On the outside, we made sure to extend the ComfoPipe out farther than we needed, giving us some leeway once insulation and siding were installed over the Zip sheathing. This allowed us to cut the ComfoPipe back to the proper depth before installing the permanent covers supplied by Zehnder.

 

comfo pipe ext close up sealed

Close-up of ComfoPipe as it exits the structure (before insulation, furring strips, siding, and its final cover).

 

As far as the white tubing is concerned, we really enjoyed how easy it was to put the 3″ ComfoTubes together.

During the design phase, and even after we brought the Zehnder unit to the job site, we always intended to place the diffusers for supply and exhaust points on ceilings. But after really looking at all the cuts in our ceiling service chase that would be required to make this happen, we decided to opt for placing all of them on walls instead.

It proved to be one of the better decisions we made during construction. Not only did we avoid having to make many cuts in our ceiling structure, which would’ve meant a struggle to appropriately map them out around conduit, ceiling lights, and plumbing vents, it had the added benefit of making it much easier to do ongoing maintenance at the diffusers, mainly checking on and cleaning filters, once we moved in.

 

cone diffuser filter

Cone shaped filter for exhaust diffusers (bathrooms, kitchen, laundry room, and basement in our case).

 

In fact, during commissioning, our Zehnder rep told me they have issues with homeowners not keeping their exhaust diffuser filters properly cleaned, effectively undermining the efficiency and overall performance of the units. This is understandable if the diffusers are on ceilings, whether at 8′ or 9′. It would be easy to forget about them, or even if you did remember, one can understand the reluctance to drag out a 6′ step ladder every time they needed to be cleaned. We were also told that placement of the diffusers is extremely flexible — almost anywhere can work (check with Zehnder directly just to make sure your proposed placement will work).

 

inside diffuser filter

Diffuser filter in bathroom after about a month. Once all the construction dust settled down from completing interior finishes, these filters don’t get dirty nearly as quickly as they once did — in other words, this isn’t bad at all.

 

By keeping them around 7′ off the finished floor, it’s easy for me to check and clean the exhaust diffuser filters on a regular basis (1-2) times a month. I always have 2 sets of filters, so it’s easy to remove the dirty ones, put in clean ones, and then rinse and dry out the dirty ones.

 

 

Once we decided to go through walls (both 2×6 and 2×4 framed walls), it was just a matter of deciding where in each wall we wanted the diffusers to be placed, and then cutting the corresponding hole through the wall’s bottom plate and the subfloor — being careful to check, and re-check, in the basement for any floor joists, plumbing, or electric conduit that might be in the way.

For bathrooms we placed the diffusers between showers and toilets, slightly cheating towards the showers to ensure maximum moisture removal.

 

changa drilling for tubes

Apparently cutting the holes through the floor looked like fun, since my wife was happy to take over this chore for me. The DeWalt we were using worked great until it crapped out on us a couple of holes short of finishing. We definitely noticed a difference going back to a normal drill and hole saw set-up.

 

At the unit itself, Zehnder supplied us with blue (fresh air) and red (stale air) tags, to mark each ComfoTube as it leaves or returns to the main unit. This should make any potential maintenance or repair issues in the future easier to resolve, as well as helping to avoid confusion as you set in place each pipe at a diffuser.

 

first few return tubes are in

Attaching the white ComfoTubes to the main unit, carefully labeling each pipe for future reference.

 

 

main unit w: exhaust tubing installed

ComfoTubes being installed at the main unit.

 

 

top of silencers #2

Close-up of the top of the main unit, as ComfoTubes are being installed.

 

 

Sydney helping us

Sydney, one of our former Excel students, was nice enough to stop by and help us pull the ComfoTubes from the basement up to the first floor.

 

 

OB helping us pull and set-up the tubes

OB was also nice enough to come back to help us push and pull the ComfoTubes into place for the diffusers.

 

 

spaghetti

Pulling more tubing than we need up to the first floor. Later it’s cut back to properly fit to the various diffuser boxes.

 

 

setting up a port

Putting together a diffuser box.

 

Since we’re leaving the basement ceiling unfinished, it’s an ideal place to see how all the components come together: ComfoTubes meet at the diffuser box, along with the final cover for the diffuser, in this case for supply air. As you can see in the photo, there’s plenty of room in the metal tube of the diffuser box for deciding exactly where to cut it off in order to establish the finished height for the diffuser cover. In the basement we left them at their full height since there didn’t seem to be much incentive to cut them back.

 

basement supply diffuser

Basement diffuser box with attached ComfoTubes and final diffuser head (supply in this case).

 

 

laundry rm zehnder

Exhaust point in utility room with only one ComfoTube.

 

All of the diffuser boxes required at least 2 ComfoTubes, except for the laundry/utility room, which only required one. Using one of the supplied black plastic caps made it easy to block off one of the outlets in the diffuser box. These black caps are also handy when pulling the ComfoTubes around into position since they help to keep out any construction debris.

 

laundry rm exhaust

One outlet in the diffuser box is blocked off for the laundry room since we only required 12cfm for this area (12cfm per opening/ComfoTube).

 

Our kitchen required the most cfm’s, at 36, so it required a special diffuser box and 3 ComfoTubes.

 

kitchen octopus

3-hole diffuser box (36 cfm) for kitchen exhaust.

 

Again, since we didn’t place it in the ceiling, we put it across the kitchen, basically on a diagonal from the stove. So far we haven’t had any issues with cooking grease or odors, and our range hood (recirculating) seems to be doing its job just as well.

 

sunlight coming down comfo tubes

Sunlight coming down the ComfoTubes into the basement from the main floor.

 

Using scrap lumber, we were able to give each diffuser its proper stability in the wall cavities. Although the mounting hardware for each diffuser box seems rather fragile, we managed to avoid any issues.

Applying a bit of hand soap around each opening in a diffuser box made getting a solid fit between the ComfoTube, the black O-ring, and the diffuser box fairly straightforward.

 

connecting tube in kitchen

Attaching ComfoTubes with black O-rings and sliding clips on the diffuser box.

 

 

tubes for octopus in kitchen

ComfoTubes for kitchen exhaust going through the subflooring and into the basement.

 

 

black 0 ring

Putting the black O-ring on the ComfoTube.

 

It was also fairly easy to get each ComfoTube exactly where we wanted it. Since they’re so small (at least compared to traditional sheet metal ductwork), the tubes are easy to manipulate and move around, whether over a basement beam, around plumbing, electric, or any other structural component that’s not easily relocated. As long as you don’t need to make a short 90° turn, the tubes are easy to work with, so I imagine they would be ideal for renovation work in older homes.

 

long shot before tightening comfo tubes

It was fairly easy to put the ComfoTubes exactly where we needed them to go.

 

With most of the ComfoTubes in place, we just needed to add a couple of walls in the basement before finishing up the last few ComfoTubes.

 

raising basement wall w: Jesus and Eduardo

Jesus and Eduardo were nice enough to come back to help me put up a couple of basement walls.

 

Once all the ComfoTubes were installed at all the diffusers and at the main unit in the basement, we were able to pull all the lines tighter for a less messy final installation.

 

spaghetti comfotubes

Before pulling the tubing tight.

 

Using 2×4’s, we created a little window for the ComfoTubes to pass through under the floor joists. This structure helped to get the ComfoTubes moving away from the main unit in an orderly way that made it much easier to organize all the tubing once it was all installed.

 

zehnder installed w: tubes

All the ComfoTubes pulled tight, up by the floor joists, kept in place with some plumbing hangers.

 

Using plumbing hangers also kept the ComfoTubes under control and organized.

 

hanger straps for comfo tubes

Straps used to corral the sometimes unwieldy ComfoTubes, which can resemble spaghetti if left unorganized. They also worked well at stabilizing the gray ComfoPipe.

 

The commissioning of the unit, after drywall was complete, was fairly easy and straightforward, apart from a couple of wiring and electrical issues that had to be dealt with by phone with a Zehnder rep beforehand. And ordering filters from the Zehnder website has also been a straightforward and painless process so far (they’re not cheap, but they do seem to be highly effective).

The only issue we’ve really noticed with the unit is during summer when outdoor humidity levels are high. Since the ERV is constantly running, there’s no way to avoid bringing in some humid air in the summer.

And, unfortunately, it’s enough so that our Mitsubishi heat pump set-up (a future Part 2 of 2 for HVAC details) can’t properly get rid of the excess humidity either, even as it keeps the interior more than adequately cooled. We tried setting the heads to dehumidify, but they just dropped the temperature (almost to 60° F) without budging the humidity in the house very much — the rooms were freezing and clammy. As noted earlier, an ERV just can’t handle elevated levels of humidity in the summer on its own.

By having meters in various areas of the house it’s easy to see when humidity levels become a problem (we’ve been happy with our AcuRite gauges). Last summer our solution was to buy a couple of small dehumidifies, one for the first floor and one for the basement. They worked, but they also ate up a lot of energy. Setting the Zehnder fan speed to LOW seemed to help somewhat, but not enough to avoid using the dehumidifiers. This summer we’re going to try a stand-alone Ultra-Aire whole-house dehumidifier, which should use less electricity, and it should perform at least as well, if not better, at removing excess humidity.

 

 

 

 

Having read that anything above 60% indoor humidity can be problematic, especially in tighter, high-performance homes, it was disheartening to see the numbers move towards 70% in early summer. This is what prompted the purchase of the dehumidifiers.

From everything I had read during the design phase regarding Passive House, I knew indoor humidity in the summer could be a slight issue, but having experienced it firsthand, it now seems obvious that incorporating a dedicated dehumidifier in any structure that will see elevated levels of summer humidity, even if it’s only expected to last for just a few weeks, is simply a necessity. Based on what I’ve read recently, it sounds like Passive House designers, who were already doing this for Southern US states, are moving towards doing it in states much farther north. Presumably this would also hold true for anyone designing a Pretty Good House as well.

Granted, 60-70% indoor humidity (or even higher) for a couple of weeks probably won’t ruin any structure, but for us, at least, keeping it in the 50-60% range during the hottest days of summer not only gives us some added peace of mind, regardless of the hit we’ll take in terms of overall energy use, but it’s also an issue of comfort (I grew up in a house without air conditioning and still have vivid memories —all of them bad — of enduring hot and humid summer days and, even worse, long summer nights).

Much like the initial complaints of overheating, due to excessive or improper placement of glazing, especially on southern facades, this issue with excessive humidity seems to be part of the evolution in understanding how Passive Houses, or high-performance homes generally, actually work in real-world conditions. Although the concept has been around since the 1990’s, anyone building to or even just towards the Passive House standard should know they are guinea pigs to some extent, no matter how well established the idea may be in building science terms.

In the winter, we’ve had no issues. When temperatures fall below 20° F, we set the Zehnder to LOW, in the hopes that it will reduce demand on the heat pumps slightly, and it seems to hold onto humidity somewhat when the cold air being introduced would otherwise be excessively dry. Indoor humidity levels have been pretty consistent: above freezing they typically stay around 40%, and when temperatures plummet towards zero or below they’ve still stayed in the 30-35% range. We’ve rarely seen indoor humidity drop below 30%, even on the coldest days, which definitely makes a difference on overall comfort levels. I’ve also noticed that wood flooring and wood trim doesn’t shrink nearly as much as it did in our last, conventionally built home.

Also, even when we experienced record low temperatures last month (January, 2019), hitting -24° F without windchill, the Zehnder kept on running without any issues. As far as we know, it never shut off to try and protect itself from the cold (our mini-split system did, but more on that later). The product literature is somewhat vague, only noting that low temperatures could cause a unit to shut off, but it’s unclear at exactly what temperatures or what combination of other environmental conditions might cause this to happen.

Most people either tape or use sealant on the gray ComfoPipe seams to block air leakage. During our blower door test no air leakage showed up, even with a smoke pen test. Nevertheless, during our recent cold snap some frost was evident on the ComfoPipe seams, so I’ll eventually caulk these seams with Pro Clima’s HF Sealant, since there must be some air leakage, be it ever so minor.

In terms of the boost function, when turned on it pulls from all the exhaust diffusers, not just a particular bathroom or the kitchen. Again, for the kitchen, even if we’ve been roasting garlic or cooking something else that’s equally pungent, by the next morning any cooking smell is usually completely gone. There’s never been any lingering smells emanating from the kitchen.

For the kitchen, when you want to utilize the boost function you just set the ComfoSense wall unit to HIGH (the Zehnder equivalent to a standard wall thermostat). Unlike the bathroom boost switches, which run on a timer (set at the main unit in the basement), when you’re done cooking you have to remember to go back and lower the fan speed, otherwise it just stays on HIGH.

The ComfoSense unit also can display error functions or tell you when filters at the unit need to be cleaned. It also has an AWAY function, meaning you can have minimal fan speed to exchange air while you’re on vacation instead of just unplugging the unit altogether.

 

 

 

boost rocker switch

Boost rocker switch in the bathroom.

 

The boost switch in a bathroom is set to run for 30 minutes on the highest fan speed. So far, this seems to be plenty of time for it to work properly. Unlike a normal bath fan, which tends to be quite loud, even when the Zehnder is in boost mode it’s still incredibly quiet, so guests need to know they only need to press the switch once — it is indeed working.

For the bathrooms, the boost function has been working really well at removing moisture after showers. Nevertheless, in the winter, when temperatures are below 20° F and we decline to use the boost function after showers (again, hoping to hold onto some of the added humidity), the bathroom humidity levels still quickly drop from the 60’s and 70’s back to the mid-30’s in less than an hour (and this is even when the Zehnder fan speed is set to LOW).

We’ve also been happy with the diffusers, in terms of installing/removing them when necessary, but also in terms of their overall look. Whether on more neutral colored walls, or something bolder, they just look nice in our opinion.

 

supply diffuser

Zehnder supply diffuser on a neutral background on the wall.

 

They’re subtle enough to blend in to the background, but attractive enough so when they are noticed they don’t stand out in a negative way.

 

Zehnder exhaust diffuser

Utility room with a Zehnder exhaust diffuser on a neutral background — around the corner from the clothes dryer.

 

 

diffuser w: bold colors in bg

Zehnder supply diffuser on a much bolder background.

 

As far as changing filters at the unit, or even cleaning the core itself, so far it’s been a trouble-free experience.

 

 

Here’s a photo of a supply-side filter after one month of exposure in winter:

 

zehnder supply filter

A Zehnder supply-side filter (MERV 13) after 1 month in winter.

 

During the summer, of course, they look much worse after a month with so much more “stuff” floating around (e.g. pollen, debris from landscaping, insects, etc.). Also unsurprisingly, the exhaust-side filter always takes much longer to get dirty as stale air makes its way out of the structure (it probably helps that we don’t have any cats or dogs).

 

 

And since we didn’t need the framed-out HVAC chase in the corner of our Master Bath for all the ComfoTubes that we initially planned to send up into our ceilings, we ended up using this area for some much needed niche shelving for various toiletries and even some towels.

Overall, then, we’ve been extremely happy with our Zehnder ERV unit.