Sited on a hillside overlooking Long Island Sound, the This Old House 2020 Farmhouse in Fairfield County, Connecticut, blends traditional agrarian aesthetics with cutting-edge residential construction technology. The project demonstrates how modern engineered materials, smart features, and proven building techniques combine to create a home that is both visually timeless and technically advanced. Every decision by builder Greyrock Homes and the TOH team reflects a commitment to durability, energy efficiency, and coastal resilience. This article examines the key construction phases and material choices that define this project, offering practical insights for custom home builders. For a broader view of how technology is reshaping residential construction, see our coverage of exciting innovations happening in the construction industry.
Foundation and Structural Systems
The foundation work began in early January, with crews pouring a concrete foundation that would eventually support the entire farmhouse structure. What makes this foundation notable is the treatment of the above-grade portion, which receives a stone veneer cladding that ties the building visually to its hillside setting. This approach serves both aesthetic and practical purposes: the stone provides a durable, low-maintenance exterior at ground level while creating a seamless transition between the built structure and the natural landscape. For homeowners exploring sustainable construction methods, resources like green building programs and their latest developments offer valuable guidance on environmentally responsible foundation and site work.
Once the concrete was in place, the structural backbone of the first floor went in: super-size laminated veneer lumber (LVL) beams. These engineered beams provide exceptional dimensional stability, resisting the warping, splitting, and shrinkage that can plague traditional solid lumber in coastal environments. The LVL beams used on this project came from Weyerhaeuser’s Microllam line, sourced through Ring’s End, a regional building supply partner. The decision to use engineered lumber for primary structural elements reflects a broader industry shift toward materials that offer predictable performance under load. The beams support the first-floor structure while maintaining tight tolerances that make subsequent framing and finishing work more accurate.
| Foundation Component | Material | Key Benefit |
|---|---|---|
| Foundation walls | Cast concrete with stone veneer cladding | Rustic aesthetic + hillside integration |
| Primary floor beams | Microllam LVL by Weyerhaeuser | Dimensional stability, resists warping |
| Floor joists | TJI engineered joists (16” o.c.) | Lightweight, squeak-free, quick install |
| Subfloor panels | Diamond Premium OSB panels | Self-draining, tongue-and-groove edges |
Engineered wood floor joists for the entryway were laid at 16-inch intervals, balancing structural capacity with material efficiency. The TJI joists from Weyerhaeuser are lightweight for quick installation yet strong enough for long spans without intermediate support. Their dimensional stability prevents the twisting that causes squeaky floors in traditional framing. Over these joists, the crew installed Diamond Premium OSB panels with self-draining technology, valuable during the wet winter build. The tongue-and-groove edges locked together quickly, creating a rigid base for the white oak flooring installed later.
Advanced Framing with Engineered Lumber
The farmhouse was framed entirely on-site, a traditional approach that allowed the crew to adjust to site conditions in real time. However, the materials chosen for the framing package were anything but conventional. Laminated veneer lumber beams were used for window and door headers, providing extra strength where it matters most without the dimensional inconsistencies of solid lumber. The project also made extensive use of laminated strand lumber (LSL) studs, particularly in the barn-inspired wing of the house and on interior walls where pocket doors demanded dead-straight, non-warping framing. For a deeper look at how traditional farmhouse forms are adapted with modern materials, see this case study on colonial farmhouse restoration with modern design principles.
The barn wing required tall, straight framing members for its soaring ceiling heights. TimberStrand LSL studs from Weyerhaeuser were chosen for their exceptional straightness. Manufactured by orienting wood strands under heat and pressure, LSL resists bowing and twisting common in long dimensional lumber. The same material was specified for interior walls with pocket doors, where even minor warping could prevent smooth operation.
One of the more visible framing operations during construction was the raising of the gable walls, a process that required coordination among multiple crew members. The team used engineered lumber for these wall assemblies to ensure that the tall, heavy sections went up straight and stayed that way. The project also employed LVL beams in the garage area, where single-ply beams for the garage door headers eliminated the need to assemble multi-ply beams in the field. This approach saved labor time while ensuring consistent beam strength across all three garage bays. The use of single-ply engineered headers is a detail worth specifying on any custom home with wide garage openings.
Weather Protection, Windows, and Roofing Systems
In a coastal location like Fairfield County, weather protection is not optional. The TOH farmhouse employed a multi-layered approach to keeping wind and moisture out. The sheathing chosen was the ZIP System, a structural panel with an integrated weather-resistant barrier that eliminates the need for separate house wrap. Crew members taped every seam on the insulation-backed sheathing, creating a continuous air and water barrier around the building envelope. This system proved especially effective in the screened-in porch area, which will eventually house an outdoor kitchen and required particular attention to moisture management. For those interested in preservation techniques for older structures, the restoration of a colonial stone farmhouse offers lessons in blending old and new building methods.
The window package from Marvin includes Signature Ultimate Casement Windows and a 9-foot Ultimate Sliding Patio Door. The casement windows feature a specialized wash mode that allows both sides of the glass to be accessed from indoors, a practical feature for upper floors. The large patio door, flanked by triple casements, frames the Long Island Sound view. Behind this glazing, the cathedral ceiling will receive spray foam insulation and the wall cavities mineral wool, ensuring the expansive glass area does not compromise thermal comfort.
Roofing was handled with a dual approach. The barn section received a standing seam metal roof that evokes traditional agricultural buildings, while the main house was topped with GAF Timberline American Harvest architectural asphalt shingles in Appalachian Sky. These shingles carry wind-resistance warranties appropriate for the coastal setting. Under the metal roof, a GAF VersaShield underlayment was installed, which protects against moisture intrusion and upgrades the metal roof assembly to a UL Class A fire rating. Smart VELUX skylights with rain sensors were integrated into the roof design. These solar-powered Fresh Air skylights automatically close at the first sign of precipitation, providing natural ventilation without the risk of water damage during sudden coastal storms.
Interior Layout and Mechanical Systems
The barn-inspired section of the house measures 40 feet by 20 feet and contains the family room, dining area, and kitchen in an open configuration. A 72-inch-wide gas fireplace anchors one gable wall, with framing already in place above it to support an 80-inch television. The kitchen occupies the opposite end, with living and dining space flowing between. This open layout, typical of modern farmhouse design, allows the cathedral ceiling and large window wall to flood the entire space with natural light.
- Family room, dining, and kitchen share a single 40×20 foot barn volume
- 72-inch gas fireplace with TV recess above
- 9-foot sliding patio door flanked by triple casement windows
- Cathedral ceiling with spray foam and mineral wool insulation
- Pocket doors on interior walls where space efficiency matters
Natural lighting was a priority throughout the design. Beyond the large window wall and skylights, the house incorporates 10 VELUX sun tunnels. Each sun tunnel uses a highly reflective aluminum tube to bounce sunlight from a roof-mounted lens down into interior spaces. These are ideal for tight areas like pantries, hallways, and bathrooms where traditional skylights would be impractical. Each sun tunnel includes a solar-powered night-light that provides soft illumination even on moonless nights.
Mechanical systems were selected for efficiency and code compliance. The home’s propane-fired water heaters, from Navien, are vented through an IPEX System 1738 flue gas venting system. This engineered PVC compound is rated for temperatures up to 149 degrees Fahrenheit and meets current mechanical codes for high-efficiency condensing appliances. The venting system represents the kind of hidden infrastructure that makes a home safe and efficient, even though homeowners rarely see it after construction is complete.
Siding, Exterior Finishes, and Site Details
By early spring, the roof shingles and metal roofing were installed, windows and patio doors were in place, and the crew turned their attention to exterior cladding. The exterior finish strategy differentiates between the two wings of the house. The barn section receives western red cedar siding that has been scored and lightly stained so that it weathers naturally to a soft gray over time. The main house uses LP SmartSide engineered wood strand siding in a board-and-batten pattern, stained a deep gray for contrast. LP SmartSide offers superior protection against hail, wind, moisture, fungal decay, and termites compared to natural wood, making it a practical choice for a coastal home that must withstand harsh weather conditions.
A drainable house wrap was installed beneath the siding, allowing any moisture that gets behind the cladding to drain away rather than becoming trapped against the sheathing. This detail is especially important in coastal climates where wind-driven rain is common. The trim material around windows and at the gable ends also uses LP SmartSide, ensuring consistent performance across all exterior wood elements.
Exterior site work includes a three-car garage with a steel beam supporting the second-floor wall above. The garage door headers use Weyerhaeuser Parallam PSL (parallel strand lumber), a single-ply engineered beam that eliminates the need for field-assembled multi-ply headers. A plunge pool is planned alongside the porch, adding outdoor living space that takes advantage of the site’s views of Long Island Sound.
Key Takeaways for Custom Home Builders
The TOH 2020 Farmhouse demonstrates several principles worth applying to any custom home project:
- Specify engineered lumber for primary structural elements. The dimensional stability of LVL, LSL, and PSL products benefits the entire construction process.
- Invest in a continuous air and water barrier at the sheathing layer. The ZIP System with taped seams protects against moisture intrusion and improves energy performance.
- Choose windows with practical features. Marvin’s wash mode and rain-sensing VELUX skylights reduce maintenance burden.
- Differentiate exterior cladding by architectural zone. Western red cedar on the barn wing and LP SmartSide on the main house creates visual interest while matching performance to each area’s exposure.
- Plan for daylighting early. Large windows, skylights, and sun tunnels keep interior spaces bright without relying solely on electric lighting.
The TOH 2020 Farmhouse proves that traditional farmhouse aesthetics and modern building science can coexist successfully. Every material choice, from LVL beams to smart VELUX skylights, was selected for long-term durability in a coastal environment. For homeowners planning a similar project, studying how the open floor plan for a New England farmhouse integrates structural and mechanical systems into a cohesive space provides a useful reference for their own build.