Decon ’16: Let’s Get Ready to Rumble (Recycle)

The Building Materials Reuse Association gI_86481_Decon16-logo-bannerEagele(BMRA) has announced that (our very own) Jonathan Orpin of Pioneer Millworks and New Energy Works will be featured as the keynote speaker for the Decon ’16 conference in Raleigh, North Carolina. Our fearless leader will kick-off the conference on February 29th with a forward-thinking address titled “Everything is Possible. Stories of de-constructible buildings, recycled wood, and companies that can thrive doing so.” Are you getting excited yet?

Decon ’16 is the premier international conference on building deconstruction, materials reuse, and C&D recycling and this forward-looking address will seed the future of a world without waste. “Jonathan’s experience and remarkable portfolio of projects will be an inspiration as the conference opens, and sets the bar high for all of us in the circular economy of materials,” shared Anne Nicklin, Executive Director of the BMRA. Thanks, Anne!

After three years, the biennial conference of the Building Materials Reuse Association will make its righteous return, serving as an international gathering of practitioners using both knowledge and experience to create a world without waste. The conference will be hosted by Habitat for Humanity of Wake County and NC State University February 29th through March 4th, 2016.Jonathan bio image

“I am equal parts thrilled and anxious to be speaking at Decon ’16, as this group has led the way for a long time in this exceptional field. Let’s keep turning up the dial, from understanding the story and source of our materials, to using them for really great and beautiful projects, to creating sustainable business models and partnerships to get the good work done,” shared Orpin.

As you may know already, Orpin is the President of Pioneer Millworks, which over our 25 years in business, have recycled more than 25 million board feet of wood; he’s also the President of New Energy Works Timberframers. Combined, our companies employ 130 community members, have shops in NY and OR, and we work hard to use the Triple Bottom Line of People, Profit and Planet as our guiding business principle. Orpin is also past President of the Timber Framers Guild, which supports the craft, science, and business of timber framing. As an organization, the Guild seeks to perpetuate and strengthen the robust craft of timber framing, communicating information about building methods, events, people, and the timber frame building community.

Barn Demo 2More than forty speakers from around the world will present case studies, emergent research, and inspire the diversion of construction and demolition waste towards productive markets during Decon ‘16. Live presentations and exclusive training opportunities will be offered, including a workshop on handling salvaged wood for woodworking and furniture making. Local tours of deconstruction sites, reuse stores, and local high performance buildings will also be available for attendees.

More information about Decon ’16 can be found at http://www.bmra.org.

The Building Materials Reuse Association (BMRA) works to create a vibrant building materials economy as part of a world without waste. For more than twenty years, they have done this through elevating the issue to the public, moving the market for reused materials, and inspiring and supporting the industry.

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Custom Eco-Friendly Engineered Floor Made from Reclaimed Bleacher Boards

Here at Pioneer Millworks we have a menu of more than 50 standard products. But we continue to push the envelope and work with clients who come to us with their own unique vision. In fact, nearly half of all the jobs we do each year are custom. We love these partnerships into uncharted waters and all the challenges that they entail. The extra sweat and tears spent in the production of these orders often leaves us feeling especially proud of the end results.

One recent custom order of which passed through nearly every hand in our shop was 8,000 square feet of Eco-Friendly Engineered Floor made from Reclaimed Douglas Fir Bleachers. Destined for a large corporate headquarters in California, here is what was involved:

  1. Bleachers were sourced from across the nation, from Webster, New York to Portland, Oregon and numerous stops in-between. Because only solid Douglas Fir bleachers could be used for this order, our acquisitions team traveled across the country to find the perfect stock. This was something of a treasure hunt as most bleachers that were installed in the last 50 years are plastic, pine or laminates. Bleacher - 0
    reclaimed bleacher board art pioneer millworks

    Some of the gum and graffiti we found on our collection of boards.

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    2.After the bleachers were cut to 8′ lengths (the length of the plywood), we fully surfaced each board in our moulder and put them in our kiln for several days. This brought all the wood to a consistent moisture content and killed any nasty fungus that might have resided after decades of sweaty gym shorts leaving their mark (we learned this the hard way).Bleacher - 3Bleacher - 4Bleacher - 5

  2. The holes left from the original carriage bolts which once secured the bleachers to a metal frame, are drilled out and filled with custom plugs. Our detail oriented crew did an exceptional job matching the grain of the plugs to the grain of each board. Bleacher - 6Bleacher - 7Bleacher - 8Bleacher - 9Bleacher - 10Bleacher - 11
  3. Once plugged, each board was again surfaced in the moulder and then run through our frame saw. Here, a series of blades sawed each board into three thin wear layers.
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    Going in.

    Coming out.

    Coming out.

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  4. On our glue line, each wear layer was carefully adhered to a FSC Baltic Birch plywood substrate. Bleacher - 15Bleacher - 16Bleacher - 17
  5. Finally, these glued-up boards were run through the moulder a third and final time where the tongue and groove was milled. After defecting out any remaining irregularities, each board was end-matched and stacked to ship. Bleacher - 18Bleacher - 19Bleacher - 20Bleacher - 21Bleacher - 22Bleacher - 23Bleacher - 24

I think that it is safe to say that everyone involved in the project is especially proud of this beautiful one of a kind floor. Keep the custom projects coming!

 

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US Builders Review – Greenbuild Edition

In November, we traveled to Washington, D.C. for the 2015 Greenbuild Expo –  the premier sustainable building event of the year. After joining more than 600 suppliers and top manufacturers of the latest green building equipment, products, services, and technology available in today’s market, we really felt like we were renewing our commitment to our eco-friendly practices with other like-minded eco-conscious folks. And by golly, we were excited to share new products, including naturally textured reclaimed Hemlock and custom finishes too.

US Builder Reviewthe magazine for leading construction executives – published a special Greenbuild edition of the magazine, covering the several trade show Editor’s Choice honorees. (We were one of the lucky ones!) The Editor’s Choice 2015 honorees represent the most forward-thinking businesses and the brightest of thousands of industry leaders, experts and professionals dedicated to sustainable building in their everyday work.

Read our feature here (on page 96) or below.

US Builders Review- Greenbuild Edition - Pioneer Millworks, Page 1US Builders Review- Greenbuild Edition - Pioneer Millworks, Page 2US Builders Review- Greenbuild Edition - Pioneer Millworks, Page 3

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Foundry Maple Reclaimed From American Crayon Company

The American Crayon Company’s factory in Sandusky, Ohio was slated for deconstruction, so we headed out to rescue the antique wooden bones of the building before it went to waste. We rescued 2 truckloads – that’s 24,000 board feet – of Foundry Maple. The old wood has endured thousands of footfalls, heavy machinery, and a smattering of colorful wax crayon materials.

Here’s a peek inside the former factory:

The American Crayon Factory in Sandusky, Ohio being deconstructed

The American Crayon Factory in Sandusky, Ohio being deconstructed

The factory’s history
When the first superintendent of Sandusky’s public schools wasn’t satisfied with the chunky chalks used on the boards in classrooms, he turned to his brother-in-law to create a new and improved chalk. William D. Curtis’ accepted the challenge and began experimenting in his kitchen in 1850 with what became, years later, the American Crayon Company. ACC became the largest employer in the area and produced many popular art products including crayons, chalk, watercolors, pencils, paste and cleaners.

Over the years, American Crayon acquired many other companies, most notably Prang Educational Company with their trademark Old Faithful geyser logo in 1913, and Dixon Ticonderoga who expanded their industrial supplies line in 1984. The former merger slowly outsourced the labor and plant operations to Canada and Mexico, sadly forcing the Sandusky plant to close in 2002.

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The flooring’s next life

Bundle of Maple Foundry reclaimed from the American Crayon Factory

Bundle of Maple Foundry reclaimed from the American Crayon Factory

After leaving their old factory life behind in Ohio, the raw industrial salvaged Foundry Maple arrived at our eco-friendly shop in Upstate New York where we’re de-nailing and re-milling the planks into paneling, flooring, fixtures, and more to be used in commercial and residential spaces. Limited quantities are available and each ‘batch’ of this grade comes with one-of-a-kind often hard-earned texture, wear marks, and color.

Reclaimed Maple Goundry from the American Crayon Factory

Reclaimed Maple Foundry from the American Crayon Factory

Full of texture, and on occasion original paint, Foundry Maple can be put back into service with little or no finishing. Ranging from browns and golds to greys and occasional lavender tones, Foundry Maple offers unmatched color, original distressing, and character. While this reclaimed Foundry Maple may not be as boldly colorful as the products that passed through the factory, the boards continue to maintain a vibrant history and unmatched durability.

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