The team (finally) beat the rain for a few days and finished stacking the two test buildings. The construction process is extremely quick due to the threaded rod construction method. The team organized the wood on site then spent a few days stacking each piece of timber on the threaded rods.
Next step is the metal roof! For now, here are a few aesthetically pleasing mass timber photos for your feed.
The Breathing Wall Mass Timber Research Project team has been quickly jumping between testing scales as the research continues. The test cell, introduced in the last blog post, is now finished- fully covered in a rigid layer of Geofoam insulation and ready for testing! The team is currently working on a large scale thermally active surface design to get these tests running.
In the meantime, the team also built 1 of 2 test buildings. As a reminder, there will be two test buildings. One will be only mass timber construction and the other will couple mass timber construction with the Breathing Wall system. The team took advantage of every ounce of sunshine last week to build the mass timber test building in just under 3 days. Because of all the wood prep done before Christmas break and the threaded rod construction, all the team had to do was stack the 2x4s and 2x6s to form the walls.
The ceiling was the real trick. Because the threaded rods for the walls run through the floor and the ceiling (tying the whole test building together), the team had to ensure the holes on the ceiling would line up perfectly with the vertical threaded rods. So the team built the ceiling off site, tightened it down to an exact measurement, drilled the holes, then took it apart. When the walls were up, the ceiling was installed in exactly the same order as it was assembled before to ensure the holes lines up with the threaded rods. Next up, doors!
Stay tuned for another test building, doors, and a roof coming together very swiftly.
Praying for sunshine,
The Always Damp Breathers
Soundtrack: Have You Ever Seen the Rain? | Creedence Clearwater Revival
Oh hi, didn’t see you there behind my giant block of Geofoam insulation! Let me explain. Recently, Thermal Mass and Buoyancy Ventilation Research Project Team has been designing their first experiment, the desktop scale experiment known as “the chimney,” and building a mock-up of it.
The team used the data obtained from the thermal conductivity testing in Auburn University’s material testing lab along with their test concrete panel making experience to choose which concrete mix to use. They are going with Quikcrete Pro-Finish 5000, a high strength, smooth finish mix. Next, the team poured nine new concrete panels at the adjusted thickness. The thickness of the panels increased slightly due to inputting the exact thermal properties of the concrete mix into the code of the optimal tuning application.
The desktop experiment takes the form of a 3″ x 1″ x 1″ chimney with the thermal mass panels facing the interior. The desktop experiment needs to operate in nearly ideal conditions which means eliminating as many variables as possible. It is important to remember this is a scientific experiment of an unproven theory of how an internal thermal mass can be sized for a space to control temperature and promote proper ventilation. Therefore, to eliminate the variable of heat loss or gain from the exterior to the interior, and to understand how the thermal mass panels themselves are working, the chimney needs to be highly insulated.
When you need R50 insulation, even for such a small structure, it can get expensive and big. Their creative solution to getting the proper insulative value without spending hundreds of dollars per test was combining Geofoam and Rockwool! EPS Geofoam is much like rigid insulation but is typically used for earthwork such as building up underneath highway on-ramps. It is very dense giving it more insulative value per inch. Rockwool is a rock-based mineral fiber insulation. Thankfully, Rural Studio had extra R30 from a previous donation. The Geofoam was also donated, the Breathing Wall Mass Timber team got in touch with a construction operation that had extra and transported it to Newbern. In the drawing above you can see the concrete panels screwed onto a piece of 1/2″ OSB and 2″ Geofoam which is then surrounded by 9″ of Rockwool then encased by another layer of 2″ Geofoam. This combination of materials results in R50 insulative value.
The Geofoam comes in giant 8″ x 4″ x 3″ blocks because they are typically stacked underground. So another creative solution was needed, how to cut it down to the size we need. The TMBV team did not have to think too hard on that one because their big sister research team, the Breathing Wall Mass Timber squad, had already built a hot wire cutting system for their own Geofoam needs. A copper wire was spanned at the desired height above a table and heated using cables and an external power source.
Next, the Geofoam block was slid across the table and cut through by the hot wire. Once the Geofoam is at a more manageable size it can be cut using a hack saw. Shout out to the best big sister research team ever, Fergie, Jake, Preston, and Anna, the TMBV team appreciates you!
Whew, that was a lot of insulation talk! To ease everyone’s mind here is a beautiful Newbern sunset. See you next week!