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The 3,300-square-foot Gates Residence in the Santiam Canyon was built on the site of a family fishing cabin lost in the 2020 Santiam Canyon wildfire. The home is a multigenerational retreat and a working demonstration of mass timber construction technology.
Designed by Skylab Architecture and constructed by Kaufman Homes on a steep site above the Santiam River, the project is built almost entirely from Mass Ply Panels manufactured by Freres Engineered Wood. The veneer-based engineered wood product is made from small-diameter timber harvested from sustainably managed Oregon forests.
More than 12,000 cubic feet of Mass Ply Panels form the floors, walls and roof of the home. Because the panels serve simultaneously as structural elements and finished interior surfaces, all mechanical, electrical and lighting systems required full coordination during design and shop drawing phases before fabrication began.
鈥淪kylab Architecture worked directly with our team during the design and shop-drawing phases to ensure every panel routing, connection detail and service pathway was resolved before fabrication began,鈥� Tyler Freres, vice president of sales at Freres Engineered Wood, said in the Top Projects submission form. 鈥淭hat kind of partnership is what allows Mass Ply to perform at its full potential.鈥�
The panels were fabricated off-site using CNC milling, then craned into place on site. The primary structure 鈥� including walls and roof 鈥� was erected in approximately three days, reducing site disturbance on the steep riverfront property. The off-site fabrication approach also improved jobsite safety. Because panel openings and connection points were completed in a controlled factory environment, on-site cutting, drilling and fitting were significantly reduced. The shortened structural framing period further limited worker exposure time on the challenging terrain. Kaufman and installation contractor Carpentry Plus coordinated lifting operations and sequencing to ensure safe handling of the large panels.
The project incorporated several sustainability measures. Mass timber construction stores carbon within the building structure, reducing the environmental footprint compared to conventional systems. The home also features fire-resistant exterior materials, noncombustible mineral wool insulation and unvented eaves.
The design team worked with Freres Engineered Wood to develop a marine-grade variation of the panels for protected exterior use, allowing interior and exterior surfaces to share a continuous material language. MPP offcuts were repurposed as furring and nailers, minimizing the use of conventional dimensional lumber.
The residence features two parallel gabled volumes with Shou Sugi Ban wood cladding and metal siding on the exterior.