Category: Construction

The shelves felt like  a small scale “industrial” project … mass production and assembly of parts.

I had already charred a few boards in preparing for the shelves. Now it was time to cut them up and make them into frames.

Then piled them up for charring the remaining parts at the “charring station” just outside the cellar.

After charring I moved the frames into the cellar and over a few days applied two layers of linseed oil to them … both for additional protection and so that we wouldn’t get dirty from touching the charred wood.

After that I prepared the 104 shelf supports and then install them onto the frames (the layout is designed to let us setup different shelf sizes to accommodate the different sizes of jars we typically use).

Meanwhile the temperature in summer kitchen was rapidly dropping uncomfortably close to zero … so While I was busy with the construction Iulia was already busy moving our food from the summer kitchen into the smaller cellar room.

And then came assembly … one frame and then another …

Until we had a skeleton standing and ready for contents:

And just to get a feel for it … I placed a few of the old shelves (I designed the new shelf-frame to use the same size shelves as the old one)  in place and stacked on some tomatoe sauce bottles … and it felt good 🙂

Then lots more packing stuff from the summer kitchen, moving it to the cellar, cleaning the old shelves and moving them also to the cellar, cutting new boards into more shelves (the new frame takes many more shelves), making the rear board for each shelf with a small backing strip to act as a rear stop … LOTS more wood processing.

We got a large roll of plastic-ish table cloth and started covering all the shelves.

… and the shelves started to come together and fill up

… and we brought some root vegetables and cabbages for storage … and they joined some apples and last local pepppers in the small room.

… and then more shelves and more jars and more shelves …

… and the cellar has become a place … the place we imagined it would be.

We started the shelves when the ground was frozen solid (very convenient). Then it got warmer and we had to carry lots of stuff through the mud (very inconvenient). The temperatures are now comfortably parked around zero. We have snow up to our knees … a sight we haven’t seen for 4 or 5 years:

There is still the grainery and another storage cabinet to make … but I don’t know when I will get around to them. The critical things are done and we are settled in for winter. They may wait until spring.

It was 7 years ago that the old shelves were built and loaded (just before winter) with our first winter supplies:

I was and continued to be moved by the site of the old shelves, now standing naked and almost empty.

I feel like I have witnessed a major cycle … and the empty field of the summer kitchen is now available to become something new.

The days are short and cold … and another year is ending … and also … in a way … this feels like an end of this journey. If you’ve been following this Earthbag Cellar chapter of our journey, thank you for your interest. If you’ve visited with us during these two years to lend a hand, thank you also for your material support.

We hope to be back in spring with new projects. Wishing you a warm and peaceful winter 🙂

If like me you enjoyed Donnie Darko then you know that Cellar Door is arguably the most beautiful expression in the English language. This is a story of not one, but two cellar doors!

It started with a vision of a nice arched door that fills the arched doorway. I built the frame, stuggled to shape a rough template for the arch:

I Made an actual arched header (required laminating two pieces of wood) … I don’t have a picture because the result was depressing. The door couldn’t open … it is basic (duh!) geometry when you see it up close and personal. The arch of the door and the arch of the doorway collide.

I remember having to decide where, in the depth of the door opening, to install the framing for the door … I decided to go with the middle. That was a mistake. The framing should be on the side towards which the door opens.

So I had to scratch that option and went for a fixed arch and a rectangular (and slightly low) door (I’ve since banged my head a few times, hopefully I’ll learn).

Then preparing all the boards that would enclose the door … here they are laid out right before charring.

I assembled one side of the door … then filled it with an insulating layer of leftover styrofoam:

… and then closed it up (the frame was charred, brushed and oiled with linseed oil, the filler panels were charred and brushed strongly in preparation for a colored finishing).

… and we hung it … and voila … cellar door #1:

We’d already done a lot to protect from rodents, Iulia asked for more … and so the arched header was covered with a hidden metal plate

on top of which were installed the arch panels:

Because this is the outside door, I took advantage of the spaces in the arch to stuff in more insulation:

… closed it up and then it was time for experiments with color:

The final touches were rodent protection on the bottom of the door and … handles:

… and rinse, repeat (though not exactly the same) … and the cellar door #2 (separating the two rooms) came into being:

All of this was possible because the floor, though not yet completely set, has hardened enough for us to walk on it … which meant, that with doors in place we could also start moving in.

After finalizing measurements of the planned shelves we built a couple of frames to mockup the size … and were happy with the result (4 meters long, 2.26 meters tall, 60cm deep)

The day before yesterday we moved some things from our summer kitchen into the smaller inner-room of the cellar as transition storage:

… and that was in preparation for today when we moved the freezer into its new home. It was somewhat of a balancing act for the two of us relatively small-folk … but with the help of the wheelbarrow we got it done. Here it is out in the sun where Iulia defrosted and cleaned it.

It was a freezing day … so the frozen contents stayed frozen:

… and here it is in place, plugged in and fully loaded.

And the cellar is becoming an actual place!

Next are the shelves … and the last project on my list (thankfully since the days are getting short and freezing cold) for this year is the grain-storage.

This seemingly small part of the project turned out to be a place where I immersed myself more than I expected.

The initial objective was to protect the ventilation exhaust pipes from sun (they are made of plastic), rain and rodents. But as it came into being I felt it was a surprisingly prominent aesthetic element  that invited me to give it more attention.

I was not able to give this all the attention and quality I wanted because of numerous constraints, especially, in this case, the position of the pipes makes it difficult/precarious to reach.

The first step was to build forms in place (no pictures) and to pour a concrete base.

The next step was to build a brick chimney. I felt comfortable with bricklaying from my experience with rocket stoves. I did experiment with a new (to me) mortar mix (1 lime : 1 concrete : 6 sand).  I quickly gave up on trying to lay the bricks  perfectly  level because of the limited access to the work. I tried to incorporate some anchoring mechanisms into the chimney.

Then it was off to figure out how to design, build and install the head of the chimney. Originally I wanted to create a triangle-shaped roof. But as the chimney came up and took on character in relationship to the cellar, that felt wrong. A more soft and round form appeared in my mind and I set out to draw it … make cutting templates … and finally into the workshop to make it.

First came the base:

… and on top of it … the arch form I envisioned.

After a dry-assembly failed I made a change that would make assembly of the two parts easier … then it was off to char and oil all the wood surfaces:

Next was partially fixing the wire mesh onto the base:

… and initially assembly of the base (to get a sense of progress and make space in the workshop):

Then came the metal-roof preparation. First measuring real sizes and cutting the sheet to size and bending it. I’ve got a slightly tedious but fairly reliable strategy for bending:

In reality it was a sequence of bending and cutting actions that led to a sheet that could be bent and folded onto the curved arch.

… and then mounting it and nailing down the mesh and:

I am not confident that my anchoring strategy has worked ou well … so we will see if this thing holds in high winds or if it will need some reworking next spring!

Tomorrow we hope to get some wood boards that I need for working on the front door … and the earth-floor has set enough that we can carefully walk on it … so it may be possible to also approach the inner door and shelves (without putting them in place yet) … so that when the floor does set we’ll be ready to go!

We finally got around to converting the three stumps of wood in the retaining wall into a bench.  Long pieces of wood were laid length-wise (and some anchored down with bent nails).

… and then covered with cob:

… on top of which another layer of cuttings was laid out (to extend the width of the bench):

… and on top of that another layer of cob (no picture yet … imagine the same picture as above just thicker).

There isn’t much to show in terms of cobbing … lots of sieving soil, mixing cob, loading it into buckets and applying it to the walls (first layer to fill in the spaces between the levels, second to flatten the wall). This is what it looked like inside when we stopped work to focus on the final burial … more than half way through the rear wall in the large room:

We invited the excavator for one last time (we thought) to finish the burial: this time to cover the umbrella and restore the part of the hill that was excavated behind it during the previous (pre-umbrella) burial. This is what the ready-for-burial umbrella looked like before we started:

We were too busy to take any pictures when the cellar itself was being covered, but this is what it looked like when that was done (the top is now a flat area):

This was done with subsoil from behind the cella (from a depth we’d already excavated from/to). We decided we did not want to use existing top-soil since ours if full of weed-seeds. We will try to build new top-soil on top of and around the cellar (maybe more on that in a separate post).

Then we started filling the back. We used this opportunity to clear out of the field two small hills (that we created years ago). Here Iulia is guiding the driver to the piles:

… and he cleared a path and started moving earth (lots of it):

… and that wasn’t nearly enough (I’ve given up trying to estimate soil quantities … I keep under/over estimating quantities when it comes to soil) … and so we started excavating from a hill not far from the cellar site:

… and then the driver informed us we were done for the day (he too underestimated the work) … he returned a couple of days later and finishes the job:

… and the tractor went back and forth …. until the back of the structure was filled:

… since then we’ve been doing LOTS more earth-finishing … today we completed the large room and moved into the smaller one … and applied a first test of final fine finishing.

 

 

So (this post is already a few days too late to be written in the present tense … especially since we’ve more progress since then … but I will do so anyway) we had Razvan visit with us for 5 full days of work and we got lots done.

We had already started applying finishing (first two layers) on the left retaining wall and started looking nice:

Part of it was already “scratched” in preparation for receiving the final coat (a soon-to-come) experiment with lime finishing.

My attention  was constantly reaching one step ahead, making preparations so that Iulia and Razvan could continue working fluently. In this case that included applying a protective (mouse and rat proof) wire-mesh on the opposite (right retaining wall).

… and then one side started to take on its final form: it connected to the small retaining wall on top of the entry-roof … and the image I had been holding for two years started to come to life.

… and we crossed over the arch

… and so I finally had to take action on another small experiment … creating a “foundation” for the cob on the arch using bent branches:

… and I looked down and decided to finally liberate the form that was holding the earthen floor (which is cracking!):

… and to protect this new edge I decided to finally complete the concrete (again: protection against digging animals) entrance … which has a small “step” which is hopefully going to act as part of the door-stop.

… and in the back of my mind I started realizing we may be moving inside soon …. and so I started thinking about bringing electricity … and soon the first pieces of that sub-system were in place and we had (temporary) lights on in the cellar:

… and then it was time to face the outer end of the right-retaining wall. It was not in good shape: earthbags had torn and eroded (I wish I had taken more pictures … because this was quite a rescue). It is also the most difficult back-fill area … because it had limited access and a very steep incline (much learning taking place in this project!). So the first challenge was to gain access to the wall … and that took some careful digging:

… then after much cleaning, wetting, re-activating clay, carefully applying cob, adding a large mesh (a small part of which was needed anyway as the entrance to the ventilation pipe) … the wall was rescued. In this picture you can see the last three sack-edges peeking out … waiting to be covered with the cob rolled up at the bottom-center of the image:

… and then, suddenly, the full form that I imagined came to be … an earthen funnel that leads into the hill:

… here Razvan and Iulia are simulating the bench, soon to be incorporated into the wall:

We also added a bit more height to the top-retaining wall:

… and the arch was calling to us :

… and working on it inevitable led us to the inside:

While Iulia was cobbing inside, Razvan and I got to working on the water-shed umbrella (another experiment I was looking forward to encountering). This involved more physical labor, so I was grateful to have Razvan’s help with it.

We started by digging a slightly sloped trench around the back of the cellar.

The trench was planned to go all the way around, but because of the steep front slopes it couldn’t (not effectively). So we went around one side slightly, and connected a small trench on the other side.

We then laid out plastic that covered the structure and stretched over the trench and filled the trench with large gravel which should act as a drain:

… with an outlet to daylight (and will stay that way after the final burial):

We then folded the plastic partially back over the gravel (to hold it together):

and then came a layer of geo-textile that will prevent soil from clogging the gravel (and in the hope that it will offer some protection to the plastic layer from the roots of plants that will come in the last layer of soil that will complete the burial):

But the true highlight of this visit was that Tana (our 6 months old puppy) finally got a few great days with a playmate because Razvan brought with him Hera (his very large! one-year old puppy) and the two had a great time together (despite some conflicts between Hera and Indy who plays the role of the Bhudeva badass):

It was a very productive week … moving inside was a big step forward … we can imagine the cellar complete and filled with an abundance of food for the coming winter.

Iulia asked for a few pictures of the cob process … so: first we make a dry mix (we call a lasagna) of sand and our (clay rich) soil in a wheelbarrow … dump it on to a tarp and add water while dancing it into a consistent mix:

We then add straw and dance that in … then roll the mix into a sausage by pulling the tarp (we repeat all this twice … so that the straw is mixed in well and not clumped):

… and that results in cob (which can take on various textures depending on the specific recipe and what we want to do with it):

… and for us it has been many batches going on to the roof … we previously completed the roof on top of the small room (relatively thick cob layer to fill and seal round acacia logs) … and then moved on to the large room (relatively thin and uniform cob layer to cover and seal flat boards):

… and if I recall correctly after 10 batches of cob the large room was also covered:

… we then had an unexpected visit from Alin who stayed with us for a couple of days … his help meant that we finished the entrance segment of the roof earlier then expected (forgot to take pictures of that … but basically more cob).

… and we decided to take advantage of Alin’s presence to tackle the floor. The floor was originally planned for later in the project (after the walls  were done!) … but since we had Alin’s help, and since the floor takes a few weeks to set, and since we are going away for a couple of weeks … we decided to do the floor …. another first experiment for us … another cob recipe … and another application technique … and I am blown away by the versatility of this natural material:

We were then in for another surprise. Alin’s friend Sandu (a high energy athletic person!) decided to also stop by for a short visit on his way home. He arrived late (~21:30) just as we were winding down. He jumped out of the car, changed into work clothes and started cob-dancing … “one more batch” he said … again … (Iulia hung some lights) and again … and again …. and again …

….and we worked almost until midnight … got a large part of the floor done!

… then the next day Sandu called Alin again in the morning … he wanted to see the place in day light and help some more … and he came out with his wife and Alin’s wife:

… and we finished the floor!

The next day (monday) we were planned to have the excavator over to do the burial, but he was only able to get here on Teusday (yesterday). While Iulia was doing our weekly market shopping I completed the plastic covering (if you are wondering about water draining and a flat roof … there is more to come!).

… but then the weather got cloudy with potential for rain … and so I placed tarps back on the plastic to protect it

… fortunately the weather cleared and we were on for burying the cellar.

and the first corner started going under.

… and then the back was almost filled

… and I stopped taking picture because we needed to get involved in moving and directing soil (careful to avoid overloading the roof).

The front sides were a bit difficult because they ended up being very steep (it was a tight construction area). When we excavated into the hill I felt that we dug in too deep … it turns out deeper would have been even better.

the last part was the inner front corner … and that proved the trickiest place to fill (limited access for the excavator).

… and after ~3 hours the cellar was buried … and, as planned, only the opening into the hill remained.

we are going away for two weeks … while we are away everything will have a chance to settle: the newly placed earth, the structure itself and the earth floor. When we come back we will create the water-shed umbrella and do the final burial … then electricity, plenty of finishing work, doors, shelves … healing the surrounding earth … still quite a journey ahead!

We are both tired from the last intense weeks … so glad to be pausing the work and taking some time to relax and breathe.

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