SugarShack with Cordwood Walls

[TedA]

After three seasons of cooking in snow, rain, wind, etc., I decided to move our operation indoors. I researched sugar shacks on this and other websites and decided to build a structure that was functional, creative and attractive. I really like the looks of timber frame buildings but do not have the equipment nor the know-how for a true mortice and tenon strutcure so we settled on a modified post-n-beam frame. There are some impressive homes and outbuildings in N Wis and the UP of Mich that have cordwood walls so we decided to follow that path. In this application the cordwood walls will not be structural (load bearing). Last winter I found a supplier of northern white cedar (best for cordwood walls). It was already dried several years and cut to the length that I wanted (12 inches). The journey will be longer than I expected. In February the cordwood was delivered. March and half of April were taken up with collecting and cooking sap down into maple syrup. In late May we broke ground for an 18x24 sugar shack. That may be a bit large for my current operation (2x4 hybird pan & 100 taps) but it gives me room for storage and future expansion. In mid-June we had a cement slab poured. Later that month, we put up the posts and beams (all are western red cedar). In July came the trusses, the roof and two courses of cement block (base of the cordwood wall). In the next few weeks we will be putting on a metal roof, running the stacks (7" for the arch & 10" for the steam) through the roof and adding some cross bracing on the four corner posts. By the way, if anyone has any advice on how to run two stacks sequemtially through a metal roof while getting a watertight seal, I'm all ears. Early in August, I hope to begin work on the cordwood walls. As soon as I get the pictures uploaded, I will attached a few. Will add more as the cordwood walls begin to take shape.

[TedA]

Here are pictures of the site prep and slab.

[buckeye gold]

This will be interesting to watch

[TedA]

Making steady progress. Here are pictures from late June.

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[TedA]

More pictures of the post-n-beam structure as we add cedar to the soffits, roof edges and gable ends.

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[Zucker Lager]

Hey TedA
nice looking shack so far. many years ago my uncle helped make an octagon shaped cordwood house just down the road from us when I have time I'll take a pic of it and post it. Jay

[RC Maple]

That looks like a lot of fun TedA! The sugarhouse design and construction threads are my favorite to look at. The pictures and ideas are always fun to see. I'm sure you'll have a blast boiling inside next season. Good luck with your building project and keep the pictures coming.

[TedA]

Last weekend we put down two rows of split-face block. Pictures attached. If you keep the cordwood up off the ground, it holds up better. I really like the looks of the split-face block and am considering adding another row. 118751187611877

[n8hutch]

Looks nice, your going to have something to be proud of there for sure.

[Zucker Lager]

Hey TedA:
Here is the picture that I promised you this was built around 30 to 40 years ago. An interesting design, octagon shape,11878 on a slab and the walls are in contact with the slab with no knee wall. Wood is still in very good condition after all these years even almost touching the ground. Thought you might like to see this its the only one I've ever seen. Jay

[jond]

Hi TedA,

Have you made any more progress on the sugar shack? I love the idea of a cordwood sugar shack and may one day go that route as well.

[TedA]

Progress continues on our sugar shack. Two weeks ago, we got the steel roof on and cut holes for the stacks. Meanwhile back down at the base, I liked the looks of the split face cement block so well that I decided to add another course. Finally last week we started laying up cordwood. Pictures attached. We have a long ways to go but so far it looks good 118901189111892

[TedA]

Just got a few more pictures downloaded. My first wall is nearly half way up to and starting to go around the window opening. We use a few glass bottles to add color. 1189311894

[unc23win]

Looks great nice job!

[maple flats]

Looks good, just make sure you always keep your firewood supply such that you don't get tempted to take down a wall for fuel in the evaporator!

[Sugarmaker]

Very beautiful Sugarhouse! The cordwood walls are very good looking! Thanks for posting the pictures as you progress!
Regards,
Chris

[RC Maple]

That will be one cool looking place. Looking forward to more pictures.

[TedA]

Spent the last +3 weeks building cordwood walls in our sugar shack. It is slow going but the end product is very attractive. Attached are a few more pictures.
Will send more pix when the windows are in.

[unc23win]

Looks great keep up the good work.

[lpakiz]

I like it a lot! That will be one of the most unique buildings ever constructed, and is especially appropriate for making syrup.
NICE!

[optionguru]

I absolutely love the bottles in the walls.

[TedA]

Every weekend we make a little more progress. The slow set of our mortar mix requires that we stop building walls a week or two before the first hard frost. Here in N Wis that usually comes near the end of September. Hence we will work on the walls one more weekend and then shut down until next spring. However, even as the wall building comes to a close for this season, there is still plenty to do - staining and installing windows and doors, prepping more cordwood for next spring/summer, running the arch stack through the roof and sealing it up, installing the steam hood and stack and running through the roof, re-bricking the arch, running electrical for lights and outlets, and on and on and on, or so it seems. All things being equal, our sugar house should be complete by this time next year. I've got the doors and windows but haven't installed them yet. The front cordwood wall is fully up so I've included a picture inside and out. Probably no more pictures until the front windows and door are in.
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[billyinvt]

This building is going to be work of art for sure. Heirloom quality stuff.

[n8hutch]

Do you treat the ends of the cordwood with some kind of stain or sealer? Or is it a non issue? How thick are your walls? Just curious. Looks cool. I bet it's a fun yet hard process.

[jrgagne99]

I must say that is pretty impressive. Will you be able to finish the walls before the frost comes? I personally would be worried about taking a hiatus from construction- could end up looking like the Washington Monument (http://www.nps.gov/wamo/faqs.htm)in DC . Not a huge deal, but you can always see the transition in the stones on that structure.

[TedA]

In response to a couple of questions raised, no we were not able to finish all the cordwood walls before the threat of frost. Last weekend was our final wall building for this year. We will finish it late next spring and into the summer. We did get the most visible sections done - front and forward half of both sides. Yes, this starting, stopping and restarting will potentially result in some color differences in the mortar but that will only be on the back half of the two side walls. The back wall has not been started so the mortar there (next year) should all be pretty much the same color or hue.

We did not treat the log ends other than to trim them to get a smooth surface. When cordwood arrived, it was already cut to the proper length and dried 4-5 years. Since this wood was cut to 12 inch lengths while still fairly green, the ends shrunk as they dried and created a rather rough surface. Attached is photo showing an end the way I got it alongside an end that I trimmed to get a smoother look. Now that the wood is dry, I do not expect significant shrinkage of the log ends. Since this is an outbuilding (not for habitation), I went with 12 in walls (11.5 after trimming both ends). If I were using cordwood walls on a house, I would go with at least a 16 inch wall or more likely a 20 or 24 inch wall to get better insulation value. 11959

[Sugarmaker]

Very beautiful sugar house! Thanks for posting the updates.
Regards,
Chris

[sluggish]

I can honestly say that is the most inspiring bldg. I have ever seen. I absolutely love it. I am just starting to plan my sugar shack build and now you have me reconsidering the whole thing. My questions for you are about the mortar. What are you using for mortar, how much is it requiring(say based on wall square footage), and how much can you do before you have to stop and let it cure? Also, how did you do the very top, use a bag and squeeze it in to fill the void? Did you use any kind of barrier/gasket between the mortar and the upright posts to protect the posts from rot?

This is all new to me so sorry for all the questions. Thanks.

Again, beautiful work.

[TedA]

Fall weather is here and with the advent of below freezing temps, no further work on the cordwood walls until next May or so. While I didn't get the walls completed, we made good progress. All the windows (except back wall) are in and I hope to install the front door before the snow flies. Until we have the time to properly landscape around the sides of the sugar shack, I put together some boardwalks - using the rough wood that the cordwood was crated in. On the north side, a boardwalk allows easy access to storage barrels. On the backside, a boardwalk helps us bring up firewood over a steep drop off. Following are a few more pictures.12017120181201912020

[highlandcattle]

This is stunning. Just beautiful. Lots of work.

[maple flats]

Very nice job.

[eagle lake sugar]

Nice job Ted! That will be nice and cozy.

[TedA]

This is the latest (and last) chapter in the Chronology of our cordwood sugar shack construction. I believe my last post was late fall 2015 as we were shutting it up for the winter. During the winter of 2015-16, we installed the front door and interior wiring for outlets and lights. When time permitted, I prepped cordwood (fresh cuts on the ends) and bottles for the last wall. With spring came another sap to syrup season. In northern Wisconsin, our 2016 season lasted five weeks. After multiple years in the snow, sleet, wind and rain, working inside out of the weather was a delight. Our season ended in mid-April and our 100 taps yielded nearly 40 gallons on very fine maple syrup. We went back to work on building the walls right after Memorial Weekend. By late June we were filling in the last corner of the last wall. In July we installed the last of the windows, hung the back door and landscaped. Attached are some final pictures. In brief, it was a lot of work but I enjoyed it and the end product was certainly worth it. I am now suffering from "cordwood withdrawal" and have offered to help anyone in the area (Wisconsin) who wants to construct a building with cordwood walls. 1489014891148921489314894

[unc23win]

Absolutely awesome job it is truly a work of art!

[TedA]

Here are a few more pictures of the finished building. 148951489614897

[Bucket Head]

That is a beautiful building! Sugarhouses are a unique structure all by themselves. You now have one that's more unique than all the rest.
Good luck with season #2!
Steve

[MISugarDaddy]

Very nice work...and lots of it from the looks of your sugarhouse. That really turned out to be a beautiful structure. Congratulations.
Gary

[BAP]

What a work of art. Looks fantastic and something to be proud of and enjoy for many years to come.

[sap retreiver]

That's pretty sweet.

[RC Maple]

[QUOTE=TedA;314795]I believe my last post was late fall 2015 as we were shutting it up for the winter.

It doesn't seem like it had been that long since the last update. Your sugarhouse is a very unique one and I enjoyed following along with its construction. Thanks for the last batch of pictures and congrats on a great looking building. You have come in out of the elements in style.

[n8hutch]

That is an awesome building, very nice work, it shows that you put alot of time into it. Looks perfect.

[Sugarmaker]

That is a awesome building! Congratulations! You have a show piece!
Regards,
Chris

[COMSTOCK MAPLES]

AWSOME JOB!!! Looks great You will enjoy it for a very long time.