Bunkhouse by Material Design Build LLC: A Modern Rustic Retreat in Sullivan County, NY

The Bunkhouse by Material Design Build LLC is a stunning example of modern rustic architecture, blending historic timber-frame construction with contemporary design sensibilities. Situated atop a steep slope in the rural landscapes of Sullivan County, New York, this retreat reimagines a 19th-century barn into a flexible, high-capacity living space, perfect for hosting large groups throughout the year.

Context and Design Vision

Selected to design and build this unique retreat, MDB collaborated closely with the client and specialized subcontractors to create a space that balances modern comfort, robust materials, and flexible functionality. The intent was to design a “bunkhouse” that could accommodate numerous visitors while expressing a refined, thoughtful aesthetic. Every architectural decision reflects the client’s appreciation for honest, durable materials and sustainable design practices.

The site posed notable challenges. Positioned on a steep hillside, careful grading and the installation of a substantial retaining wall using local stones were required to ensure stability and longevity. At its core, the structure retains the charm of a 19th-century timber-frame barn, built atop a poured concrete foundation and partial basement. MDB adapted this historic frame to incorporate large, strategically placed windows, maximizing natural light and offering panoramic views of the surrounding landscape. Unlike the barn’s original purpose of housing animals and hay, the interior floor plans were meticulously designed for human living and comfort.

Materiality: A Blend of Rustic and Refined

Material selection plays a central role in the Bunkhouse’s character. The project masterfully combines reclaimed, regionally sourced materials with sustainably harvested new elements. Highlights include:

• Yellow pine beams salvaged from Brooklyn warehouses, repurposed as stair treads, kitchen cabinetry, and countertops.
• Antique barn flooring from Pennsylvania, planed on one side and installed as flooring on the second and third levels.
• Leaded glass windows rescued from a defunct Singer Sewing Machine Factory, adding historical charm.
• White pine shiplap boards from New York sawmills, painted white, for interior wall cladding.
• New timber rafters, milled from trees cleared during construction, replaced damaged original elements.

This thoughtful mix of materials creates a rich, layered aesthetic that celebrates both history and modern craftsmanship.

Innovative Systems and Energy Efficiency

The Bunkhouse integrates advanced energy-efficient technologies while maintaining a visible connection to its historic structure. The timber frame is clad with structural insulated panels (SIPs), achieving an impressive R-40 insulation rating. Heating is provided via a high-efficiency condensing boiler warming radiant floors in the basement and first story, complemented by flat-panel Runtal radiators throughout the upper levels. Fresh air is delivered by a Zehnder heat recovery ventilator (HRV), ensuring continuous ventilation without compromising energy efficiency.

MDB intentionally showcased many of these systems within the building’s exposed frame, creating a visually engaging, architecturally expressive environment. A standout feature is the custom hanging steel staircase and mezzanine, designed in collaboration with a skilled metal fabricator, blending functionality with sculptural elegance.

Functionality and Experience

Today, the Bunkhouse comfortably accommodates up to 25 guests, serving as a versatile retreat for family gatherings, creative workshops, and seasonal escapes. The project’s success reflects the seamless collaboration between MDB and partners, including Baukraft, American Joinery, and Recycling the Past, highlighting an ethos of craft, sustainability, and thoughtful design.