The Original
What does it mean to be
“The Original Manufacturer of Poplar Bark Shingles”?
From the Experts:
Marty on Manufacturing
Before we began manufacturing poplar bark shingles, no-one had used this material extensively for 65 years. There was no bark company out there. There were few old timers left to consult. The techniques had all but been forgotten and the tools were antique. Some of the old methods were outdated and unacceptable anyway as buildings are now air-tight, insulated, and of course more energy efficient. Building code issues had to be understood and addressed.
As the originator, we had to do first hand research, directly observing and recording results. We then employed impartial laboratories to gather empirical data on performance and longevity issues. We worked diligently for years to invent manufacturing processes and means of managing product. Issues such as decreasing waste, managing material dynamics, and refining product appearance had to be dealt with.
Matt on Sales and Service
Because we created every aspect of this industry, we understand it intimately. Clients benefit as we not only provide written installation guides and material resources, but we back up those guides with personalized support when individual questions arise from the field. If you have a question, we provide answers you can trust from experience, not from piece-milling what others have said.
We establish the terminology that describes this emerging industry and improves communication with clients. For example, the grading system that identifies shingles as Premium™, Standard™ or Interior™ Grade was established by us. The thicknesses associated with the grades were set by us as well. In the past three years, we have watched as “producers” of materials come and go in a market we created. Being the original manufacturer of poplar bark shingles means we had a tougher trail to blaze. That has made us stronger and amply more appreciative of what we have built and the customers we service.
Chris on Design and Marketing
It means that we work daily with many premiere developments, communities, and individual projects across the country as they begin their planning and design process. From architects and designers to homeowners and building companies, we share knowledge and experience to assist in any way to help achieve their goals. We have studied different rustic styles across the U.S. from Adirondack to High Cowboy and travel abroad yearly to study and explore other cultures’ material manipulations. We were proudly sharing the news of our waste reclamation, forest stewardship, and nature blending designs long before being “green” came into our national consciousness.
We are the pioneers of the modern Bark House® Style. In the fall of 2008, look for my new book Bark House Style, Sustainable Designs from Nature. It continues this conversation in depth with a fascinating look into the origins and history of early bark siding usage and the exciting future it holds.
How It All Began
Our rich history nurtures our sustainable future.
The history of Highland Craftsmen Inc begins with two individuals that founded the company and built an industry. Marty McCurry, President of HC, attended NC State University and studied chemical engineering and pulp and paper. He earned a living as a builder. Chris McCurry, Vice President began her career as a nurse, always interested in relatedness and systems analysis. Training in a discipline that married art and science would be beneficial in the path the two would pursue. Both were profoundly interested in the natural world and in 1986, they met. On a personal note, their first date was hiking and they were married one year later. 1986 is the year that Marty became inspired by historic chestnut bark shingles in Linville NC and the patch work of new shingles made of poplar bark. He noted that the new shingles were not manufactured well as they wrapped the corner in a round fashion which meant they were not dried before installation. This would be one of many issues he would come to address in the design, manufacturing and selling of Bark House brand shingles, the staple of the Bark House Style.
During a six year period starting in 1990, the couple invested in educational preparation, the formation of a company and starting an industry that did not exist. The issues were many, resources were very limited. Obviously the material that had been used historically for squared bark shingles, American chestnut was not available because of the blight in the early 1900’s. Although poplar bark was being used to patch the old chestnut homes, no one was manufacturing bark shingles with consistency and reliability of product for a commercial market. Tools, supply chains and basic manufacturing methods were non-existent. Construction methods had changed since 1895. There were questions about modern installation of the product relating to building codes. Although the material would eventually create a new standard for the siding industry as a whole, in the beginning there was no client list to rely upon. Locals had forgotten the material. A brand new client had to be created as the benefits of this material were explained.
When Chris finished nursing school the couple moved to Charlotte where Marty attended UNCC school of architecture and intensified his studies on bark materials, doing rubbings and textural studies as well as cellular analysis on his own. Supposing that they had the educational preparation needed, the two began practical research and development. Their ultimate goal was to minimize the impact of construction on the environment and create buildings that harmonize with their natural surroundings and were vernacularly appropriate.
The old photo that Marty saw with the poplar bark patch held one key, but would the material last? Alas, three homes of 70 years were located in a four climate environment. This repeated evidence proved Yellow Poplar would last.
Procurement and manufacturing methods did not exist, so tools, techniques methods and supply chains had to be established. Logging industries were too set in their practices to interrupt their work flow and procure this waste material. Antique tools were searched out at trade lots and antique malls to give clues. Ultimately, old tools, such as barking spuds, hatchets and knives were used. But new tools such as stack racks and weighting implements; techniques such as stacking and sticking and methods such as moving and proper timelines had to be identified, implemented and tested.
Building methods had changed with air-tight construction. This was different than the buildings of 100 years earlier that were primarily for summer holiday and showcased chestnut shingles. Air flowed from inside to outside spaces easily and the shingles could essentially dry on the structure. Drying the product to meet today’s construction methods was one of the key elements that Marty had to address. No-one was drying bark which is cellularly different than wood. The kiln type, temperatures, times and methods had to be perfected.
Once the product was deemed viable, proper installation techniques had to be identified. Marty helped his brother-in-law make poplar bark shingles and install them on his home in Highlands. It was the first modern application of poplar bark shingles that we are aware of. He spent the next several years not only studying past techniques, but installing bark shingles in the field to determine the best methods.
Marty accomplished the long list of tasks with great creativity and little waste. He built a solid foundation that would lead to a new bark house style and a new industry.
The only issue remaining that also continues today is education and marketing. Initially reminding local builders of the historic precedence of the chestnut bark shingle helped. Pointing out the similarities and differences between chestnut and poplar bark shingles was the beginning. Today’s ongoing focus is comparing poplar bark house brand shingles to other cladding products.
By 1996, the bark shingles were selling commercially and by 1999, reliably. In 2003, HC started using a brand name, Bark House to identify its product and added new, natural interior and exterior elements to grow a style. In 2005 the registered trademark was filed for as competitors were starting to sell their own version of poplar bark shingles. In 2008, Chris co-authored Bark House Style Sustainable Designs from Nature, to relay the earlier history of the squared bark shingle as well as its re-birth.