Vancouver Island Insulated Log Yurts
In May 2023, we won a contract to build 15 insulated log cedar yurts to replace 15 soft wall yurts at a large resort here on Vancouver Island.
This BLOG will introduce you to the world of insulated logs from start to finish (for this project anyway).
We start with western red cedar, put it in our dry kiln or put large fans on it to get the moisture down below 15%.
Then we select the best of the best, leaving any slightly warped, cupped or split boards behind.
The best of the dried cedar is then glued to a type II high density foam using a gorilla glue from Europe. The log blanks are pressed together overnight in our clamp carrier. We can clamp 72 logs at one time.
This project will use 3,100 logs.
As of July 31, 2023 we have over 2,000 logs glued up.
Some of the other moving parts of this project will be added throughout the blog. These will include the 2 part center skylight inserts with triple bubbles, the window and door sections and the entire installation on site in the new year.
Right now all the standing seam metal roofs have been completed and are stored ready to deliver to the site.
Now you may be wondering how these piles of metal roofing actually look as a round yurt roof. Well, here is a sneak peak from a few past jobs completed.
And the inside of the metal roof looks like...
More about the spray foam insulation later.
Perhaps this is a good time to back up a bit and show exactly what our insulated logs will be replacing. Before we created our insulated log, there was no alternative to a lattice and canvas walled yurt. There are thousands of these yurts in every Province.
A beautiful product manufactured by several yurt companies throughout North America. Unfortunately, the life expectancy of the soft wall vinyl roof yurt is 8 to 10 years before it starts to leak. These particular yurts have been up for 12 years.
Jump to September, 2023
All the logs have been run through our molder for the 5 smaller cedar yurts.
Time to start making window and door sections. Best to pre make all the sills, headers, bottom and top logs and have a stock pile so we can make as many window and door sections as possible every day.
These are the 30" high logs that go under every window in this project.
These are the 12" logs that go on top of every window of this project. These are just the parts and pieces for the 5 twenty one foot yurts.
These are the top and bottom sills for every window of this project. Besides the 5 twenty one foot yurts we have 9 yurts that are thirty three feet in diameter.
JUMP TO OCTOBER
Next we place the insulated logs onto one of our jigs and install the emseal log cabin tape in one of the T & G's and a bead of dymonic caulking in the outer T & G.
There are a lot of moving parts that I will not show here like Blueskin, proper flashing, trim etc, however, here is what the inside and outside of a few insulated log window sections look like for this project.
A view looking up from the bottom of the window section (no thermal break).
A look at the inside of 3 window sections of cedar yurts. These can be placed all in a row or spaced around the yurt.
An outside view of 3 separate window sections of our cedar yurts.
We will add more after we finish 30 window sections of the 21' diameter cedar yurts and start on the 54 window sections of the 32' diameter cedar yurts.
All 3,100 logs have been made. All the logs have been run through the molder for the 21' yurts and all 30 window sections have been made.
We are now moving all the logs into a tighter storage area so we can start applying a stain the client has asked for. This will only be applied to the exterior of the cedar. We are starting with 50 gallons.
the rest of the 3,100 logs
Here is a look at the completed window sections before staining and caulking.
JUMP TO NOVEMBER
Start the 9' 6" high window sections
Two of the tall window sections ready for stain.
Speaking of stain, all 30 of the smaller window sections (for the 21' yurts) are finished, caulked, stained and are secured into the first shipping container.
Shown here packed in ready to ship.
Next, and at the same time, we are staining all the logs, allowing them to dry for 24 hours and loading them into the appropriate shipping container.
The doors are pre painted (black) fiberglass with 3 point lock sets.
The first single door is standing. Notice the large wheelchair service sill replacing the regular thick sill. Because these yurts are right on the ocean, the doors are all fiberglass so they do not swell with the wet winter conditions.
Inside look before blue skin and cedar trim. SOLID curved headers custom fit red cedar trim pieces inside and out including both sides of the curved header.
Next, while the guys carry on, I will blow up the 40' tent.
Happy NEW YEAR
Yes, we passed Christmas 2023 and well into 2024 already - where does the time go?
Mentioned the center insert at the very top of the yurt before. We went the extra mile and added triple bubbles to give the client additional insulation value and no chance of condensation. The protective cover is still on and full of sawdust from the shop.
We are replacing 2 different diameter yurts so you see 2 different diameter aluminum inserts below.
Did I mention that we made every insert able to be opened? They can open 10" to exhaust hot air in summer.
On to the window and doors.
There are 90 window sections. You see 20 here.
There is 1 set of garden doors and one person / man door for each yurt.
These are the 5 garden doors for the 21 foot diameter yurts.
These are the garden door sections for the larger 32' diameter yurts.
Learn more about our insulated logs.
We'll be updating this page as the project progresses. Check back often!