Climate is a diverse and beautiful factor that significantly influences building design. Elements such as temperature, humidity, wind, and precipitation shape a structure’s aesthetics, functionality, construction process, material choices, and longevity. With rising construction costs, even minor errors can significantly impact a project’s budget and timeline. Ensuring precise execution is particularly critical for exterior building materials that protect a structure from the natural elements. Field mockups for exterior wall assemblies are essential tools to verify material selection and construction techniques before the project begins.

What is Field Mockup?
A mockup is typically a smaller-scale representation of the actual building, designed to mimic the building’s structure and construction. Field mockups are typically placed at or near the construction site. They provide a tangible, three-dimensional representation of a design, allowing architects, designers, contractors, and owners to assess functionality, aesthetics, and quality before full-scale production.

Why Use Field Mockups?
A mockup is useful for evaluating the integration of construction systems and the performance of materials. Each structure and location are unique, and with countless building material options available, BIM or CAD detailing cannot address field-dependent variables as effectively as a full-scale field mockup for exterior wall systems. Moreover, when working with natural materials like wood, climate plays a large role in shaping how the wood weathers. Mockups help verify the material’s suitability for specific climatic conditions and ensure quality construction. By simulating real-world conditions, mockups deliver many benefits to the architects, contractors, owner, and stakeholders:

• Weathering Observation: Monitor how materials weather over time.
• Product Appearance: Evaluate the appearance of materials over a larger field.
• Confident Material Specification: Ensure the chosen product suits the specific exterior conditions of the construction site.
• Wood Movement Tolerance: Assess wood movement in the project-specific climate.
• Ventilation & Drainage Effectiveness: Monitor the effectiveness of rear ventilation and drainage through assembly details (e.g., rainscreens).
• Construction Best Practices: Serve as a teaching tool for trade partners, promoting efficient and accurate practices during constructions.
• Stakeholder Review: Enable stakeholders to observe and assess the weathering process of materials and construction structures, helping to set expectations and facilitate stakeholder approval.

reSAWN’s Mockup Program
At reSAWN TIMBER co., we are dedicated to delivering exceptional results and ensuring complete satisfaction. We offer a mockup program and always encourage our clients to take advantage of a field mockup. Certain reSAWN products require a field mockup prior to full ordering.

When possible, mock-ups should be installed well before materials are delivered to the project site (8-16 months in advance) to allow the materials to acclimate and weather according to the region’s climatic conditions.

If you are interested in learning more and seeing how our exterior cladding perform on your project site, please fill out this form, and a reSAWN representative, along with our technical team, will work with you directly to customize a field mockup best suited for your project.

Coastal environments present a unique challenge for building materials. Constant exposure to salty air, high humidity, and intense sunlight can significantly degrade traditional construction materials. However, pre-finished wood has emerged as an excellent choice for facades in coastal applications, offering both durability and aesthetic appeal. This article speaks to the benefits of using factory-pre-finished wood for coastal homes, highlighting its durability, aesthetics, sustainability, and long-term cost-effectiveness.

Durability and Resistance to Elements
One of the biggest benefits of pre-finished wood is its enhanced durability. Coastal areas are notorious for their harsh weather conditions, which include high winds, heavy rainfall, and exposure to saltwater. These factors can lead to rapid degradation of untreated wood, causing warping, rotting, and discoloration. Factory-finished wood, however, undergoes a meticulous treatment process, including sealing and staining, protecting the wood from the outside elements. These factory-applied finishes are designed to penetrate deeply into wood fibers, providing a barrier against moisture and UV rays. The additional layer of protection ensures that the wood retains its structural integrity and appearance over time, making it a reliable choice for coastal facades.

Low Maintenance
Maintenance is crucial for any building material, especially in challenging environments. Pre-finished wood can significantly reduce the need for frequent upkeep. Selecting and applying high-quality finishes during manufacturing ensures the wood can withstand the rigors of coastal climates. This treatment reduces the need for frequent re-staining or sealing compared to untreated or site-finished wood. This translates to lower maintenance costs and less labor over the lifespan of the building. Additionally, pre-finished wood is less susceptible to issues like peeling, flaking, or blistering, which are common problems in high-moisture environments. 

Aesthetic Versatility
Aesthetics play a crucial role in the appeal of any building. The consistent quality of factory-applied finishes ensures that the color and texture remain uniform across the entire facade, providing a polished and cohesive appearance. The natural beauty of wood adds warmth and character to buildings, making it an attractive choice for coastal applications where blending with the natural environment is often desired.

Environmental Sustainability
Sustainability is becoming an increasingly important factor in construction decisions. Many manufacturers adhere to stringent environmental standards, ensuring the wood is harvested sustainably, using environmentally friendly finishes, and processed to minimize environmental impact. Wood is a renewable resource that sequesters carbon dioxide, contributing to a reduction in greenhouse gases. The longevity and durability of pre-finished wood subsequently lead to fewer replacements and less frequent maintenance, further reducing its environmental footprint. 

Enhanced Property Values
High-quality materials like pre-finished wood cladding can significantly enhance a property’s value. The aesthetic appeal, durability, and low maintenance requirements of pre-finished wood facades make properties more attractive to potential buyers or tenants. Coastal properties, in particular, benefit from the added protection against harsh environmental conditions, ensuring that the building remains in excellent condition over time. Investing in pre-finished wood cladding for facades can provide a return on investment in property value and long-term cost savings.

As the building industry emphasizes sustainability, aesthetics, and longevity, pre-finished wood cladding offers a compelling option for those looking to enhance their coastal properties with a functional and visually appealing material. Pre-finished wood cladding delivers a harmonious blend of durability and design, ensuring the exterior facades remain stunning and resilient for years.

Here’s a collection of coastal projects that embody resilience and timeless beauty through the innovative use of reSAWN TIMBER co.’s prefinished wood cladding on their facades. The various species, sizes, shapes, and profiles enable unique architectural features and detailed craftsmanship. These projects highlight how prefinished wood enhances the aesthetic appeal of coastal homes and ensures long-lasting durability against harsh marine environments. Architects and builders create structures that look aesthetically pleasing while standing the test of time. 

The Jo Residence
The Jo Residence by Jacobsen Arquitetura is situated on the beaches of Guarujá, Brazil. To combat the region’s intense tropical climate, the architects strategically chose SAMITTO charred Accoya® exterior cladding. Accoya® modified wood undergoes an acetylation process, enhancing its stability and resistance to rot, making it well suited for the humid climate. The Shou Sugi Ban charred layer further strengthens its resilience, significantly improving resistance to moisture, fungi, and UV radiation. 

Dune House
Ryall Sheridan Architects chose to incorporate over 5,800 sq ft. of reSAWN’s charred Cypress on the exterior of the Dune House in Amagansett, NY. The oils in cypress’ heartwood make it one of the most durable woods when exposed to moisture conditions causing decay – a key advantage in moisture-rich coastal settings. 

Atlantic Beach Project
Designed by Martin Architects, this modern vacation home required a material that could withstand the outdoor elements of Montauk, NY. With over 5,000 sq. ft. of NIGIRI charred Accoya®, the property not only exudes elegance but also demonstrates remarkable stability. Accoya®’s exceptional resistance to rot makes it ideal for coastal environments like Montauk. Even in fluctuating climates with hot, humid summers and cold winters, Accoya® remains dimensionally stable. The Shou Sugi Ban charred layer further enhances this inherent stability, which acts as an additional shield against moisture, decay, and rot.

Architecture and design trends have evolved and expanded over centuries, yet some techniques stand the test of time. One such enduring method is Shou Sugi Ban, a traditional Japanese wood charring technique that has long captivated designers and architects worldwide. 

The History and Philosophy of Shou Sugi Ban
Originating in Japan in the 18th century, Shou Sugi Ban, also known as Yakisugi, is a wood preservation technique that chars the surface of dimensional lumber, such as cladding, to enhance its durability and aesthetic appeal. Historically, this technique was used to protect wooden buildings from weathering, pests, and fire. The process involves burning the wood, cooling it, cleaning off the soot, and finishing it with natural oils. The result is a strikingly beautiful, carbon-rich surface that is durable and resistant to decay.

The philosophy behind Shou Sugi Ban aligns with the Japanese aesthetic principle of wabi-sabi, which finds beauty in imperfection and transience. Wabi-sabi is an ancient Japanese worldview centered on accepting the imperfect and transient nature of all things. It values simplicity, asymmetry, and the natural processes of growth and decay. In the context of Shou Sugi Ban, this philosophy manifests through the charred wood’s unique textures and variations, highlighting the material’s raw and unrefined beauty.

The Science Behind Shou Sugi Ban
Shou Sugi Ban is often viewed as a cultural relic, yet it is much more than just the simple technique of charring the exterior of wood. The charring process leads to the carbonization of surfaces, transforming the outer layer of wood into a protective layer.

Carbonization Limits Food Sources for Pests and Microorganisms

• Fungal Resistance: The charring process creates a carbon layer that makes the wood less hospitable to fungi and other decay organisms. The high heat alters the organic compounds in the wood, making it more difficult for these organisms to break down the wood fibers.
• Insect Deterrence: Termites and other wood-boring insects are less likely to infest charred wood. The carbonized surface is not only harder for these pests to penetrate and less appealing as a food source, thus preventing infestations that can significantly reduce the lifespan of untreated wood.

Carbon Layer Establishes a Barrier Against Nature’s Elements

• Moisture Barrier: Charring the wood closes its pores, significantly reducing its ability to absorb water. This water-resistant barrier prevents common issues such as warping, swelling, and splitting caused by moisture infiltration and subsequent drying cycles.

• UV Protection: The blackened, carbon-rich surface of charred wood absorbs significant UV radiation. This absorption prevents UV rays from penetrating deeper into the wood, which would otherwise cause photodegradation., causing the wood to become brittle and lose its structural integrity. 

• Fire Resistance: Shou Sugi Ban wood’s charred layer is inherently fire-resistant. This carbon layer acts as an insulator, slowing down the burning process and protecting the inner layers of the wood. This fire resistance enhances safety and means that the wood can last longer in environments where fire hazards are a concern.

Environmental Benefits of Shou Sugi Ban

Natural Preservation Method
The charring process naturally preserves the wood without chemical treatments. By avoiding chemical preservatives, Shou Sugi Ban helps reduce the release of potentially harmful substances into the environment and minimizes human health risks.

Longevity and Sustainability
Charred wood can last significantly longer than untreated wood, reducing the need for frequent replacements. This extended lifespan means fewer trees must be harvested, contributing to sustainable forest management and conservation efforts.

Reduced Maintenance
compared to traditional wood treatments, Shou Sugi Ban wood requires minimal maintenance. The charring process significantly enhances the wood’s resistance to weathering, meaning it doesn’t need to be re-finished as often. This reduction in maintenance helps lower the overall environmental footprint, as fewer resources are used for upkeep.

Carbon Sequestration
While the initial charring process involves burning, which releases some carbon dioxide, the overall lifecycle of Shou Sugi Ban wood can have a positive environmental impact. Trees absorb carbon dioxide from the atmosphere as they grow, and this carbon remains stored in the wood even after it is cut and used. By extending the life of wood products through charring, Shou Sugi Ban helps keep carbon sequestered for a longer period, which is beneficial in mitigating climate change.

Use of Natural Finishes
In addition to the charring process, the finishes applied to Shou Sugi Ban wood are often natural oils and waxes, which are less harmful to the environment than synthetic chemicals. These natural finishes can enhance the wood’s appearance and durability without adding toxic elements to its surroundings.

Crafting State-of-the-Art Shou Sugi Ban Designs for Lasting Performance
Shou Sugi Ban is more than just a wood treatment; it is a testament to natural materials’ enduring beauty and resilience. At reSAWN TIMBER co., we are proud to bring this ancient Japanese technique to modern design by offering high-performance products that are as functional as they are beautiful. 

Our charring process is meticulously controlled to achieve various aesthetic effects, from a deep, uniform char to a lighter, brushed finish that reveals the wood’s natural grain. By experimenting with different wood species, charring techniques, and finishing processes, we are constantly expanding our product offerings and setting new trends in the industry. All of reSAWN’s charred products are made in the USA. We offer Sylva™, Accoya®, Kebony®, Western Red Cedar, and Cypress for exterior Shou Sugi Ban. For interior applications, we provide Sylva™, Accoya®, Kebony®, Western Red Cedar, Cypress, Reclaimed Hemlock, Western Hemlock, and European White Oak.

Experience the timeless elegance of Shou Sugi Ban with reSAWN TIMBER co., where tradition meets innovation, and craftsmanship meets modern design. Let us help you create spaces that are not only visually stunning but also built to last.