tag:blogger.com,1999:blog-58552769204647617982024-02-20T06:49:17.467-08:00Zero Energy FutureDIY zero energy home construction, environmentalism, green technology and a new social paradigm.JStemhttp://www.blogger.com/profile/00824469185320678774noreply@blogger.comBlogger3125tag:blogger.com,1999:blog-5855276920464761798.post-532922653906527952013-07-28T11:55:00.002-07:002013-08-22T13:29:12.167-07:00Choosing a Construction Method: Insulated Concrete Forms and Monolithic Domes<!--[if gte mso 9]><xml>
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<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
We need
to begin construction of our zero energy house by deciding how it will be
built. This decision will impact our design, materials and process. In making
this decision there will be tradeoffs and consequences that must be carefully
analyzed and understood. No design or method can be entirely perfect. After
examining our options, we will choose the method that works best for the goals
of this project.</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
In <a href="http://zeroenergyfuture.blogspot.com/2013/07/choosing-construction-method-rammed.html" target="_blank">part one</a> we examined rammed earth construction techniques</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
In <a href="http://zeroenergyfuture.blogspot.com/2013/07/choosing-construction-method-cordwood.html" target="_blank">part two</a> we examined cordwood and strawbale construction</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
Today we
will be talking about two construction methods that make extensive use of
concrete. So before we begin let’s take a moment to examine this material.
Concrete is a mixture of aggregate and sand held together by a binder. The
aggregate is generally some form of gravel and the binder is some form of
cement. When reinforced with either rebar, wire mesh or fibers, concrete is one
of the strongest readily available materials in existence. Concrete
unfortunately has a very high carbon footprint which results from the
production of cement. The main compound in most cement mixes is calcium oxide
(CaO). This compound is produced from naturally occurring calcium carbonate
(CaCO3). The extra carbon dioxide molecule (CO2) is given off in the process. Concrete
is generally used as the foundation for most buildings. Its high compressive
strength allows it to carry and evenly distribute the load of the structure. Insulated
Concrete Forms and Monolithic domes use concrete as a structural element to
construct the entire building.</div>
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<br /></div>
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<b style="mso-bidi-font-weight: normal;">Insulated Concrete Forms</b></div>
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In this
system, modular blocks or ‘forms’ are stacked to create the formwork for a
wall. This formwork is then filled with concrete which sets together with the
blocks to form the wall. Concrete has high thermal mass but poor insulation,
thus insulation is generally built into the block forms. The blocks themselves
and the accompanying insulation can be made in a variety of ways from a variety
of materials. Many different companies offer a variety of insulated concrete
forms. Generally the forms are made from either expanded polystyrene or a
cement bonded composite material. The insulation can be provided by the
polystyrene form itself or by additional fiberglass or mineral wool insets.</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://www.insul-deck.org/product.htm" target="_blank">ICF roof panels</a></div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://www.youtube.com/user/ICFbuildings?feature=watch" target="_blank">Quad-Lock Youtube Channel.</a> Contains many tutorials and overview videos.</div>
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<br /></div>
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<br /></div>
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<b style="mso-bidi-font-weight: normal;">Monolithic Concrete Domes</b></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
In this
system concrete is sprayed onto a dome shaped form to create a single, monolithic
concrete dome. An inflatable airform is generally used as the starting formwork.
A grid of rebar is then placed around the airform. Typically, polyurethene foam
is then sprayed over the rebar grid. This foam shell serves as insulation and
as a more complete, rigid form to which the concrete can be applied. Concrete
is then sprayed to complete the structure.</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://www.youtube.com/watch?v=BtUs_DGxQAQ" target="_blank">Overview of small monolithic dome construction</a></div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://shop.monolithic.com/pages/airforms" target="_blank">Airforms for small monolithic domes</a></div>
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<br /></div>
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<br /></div>
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<b style="mso-bidi-font-weight: normal;">Pros/Cons</b></div>
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<br /></div>
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Pros<br />
</div>
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Strength
and Longevity:</div>
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Since
these structures are made of mostly concrete they are extremely strong.
Monolithic concrete domes are especially durable. Reinforced concrete domes
have survived tornadoes, hurricanes, earthquakes and even military grade
bombs!<span style="mso-spacerun: yes;"> </span>When constructed properly they
have the potential to persist unharmed for centuries.</div>
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<br /></div>
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Energy
Efficiency:</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
In each
of these systems, insulation is naturally built in as part of the construction
process. The naturally low surface area of domes also limits energy loss
through the exterior.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
Cons</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
Environmentally
Harmful:</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
There
are many negative environmental impacts to consider. As
discussed earlier, the production of concrete creates a massive amount of
carbon dioxide. Insulated concrete forms also use either additional cement or
expanded polystyrene in production of the forms. Monolithic construction uses
polyurethane spray foam. All of these materials are environmentally damaging.</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
Specialized
Equipment/Training</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
In both
methods some advanced equipment and training is required. Large concrete
mixers or Concrete spraying pumps are necessary. Setting up the formwork and
applying the concrete properly requires special methods and techniques. This
equipment and training requires either additional preparation or additional
cost.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<b>GeoPolymers,
Lightweight Concrete and Other Considerations</b></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
The
overall design of monolithic concrete construction has potential. The problem
thus far has been either an inefficient implementation or a lack of good
materials. Lately there has been a lot of work devoted to finding an
alternative to cement binders. Such materials are collectively categorized as
geopolymers. Geopolymers have the potential to offset the major environmental
disadvantages of conventional concrete. Several companies have already made
significant advancements in this area.</div>
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<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://www.treehugger.com/green-architecture/gigacrete-an-alternative-to-concrete.html" target="_blank">Gigacrete</a> replaces the majority of cement with industrial byproduct wastes such as fly
ash or blast slag. <a href="http://novacem.com/technology/overview/" target="_blank">Novacem</a> and
<a href="http://www.popsci.com/gear-gadgets/article/2005-11/grancrete-llc" target="_blank">Grancrete</a> have
successfully used Magnesium Oxide (MgO) in place of cement which can be
produced from readily available magnesium silicates.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
It is
also possible to replace the aggregate of conventional cement with a
lightweight insulating material such as recycled paper or hemp. Doing this
greatly increases insulation value but decreases structural strength. If
insulating concretes could be used successfully in monolithic construction,
petroleum based foams would no longer be needed. Finally, simpler DIY equipment
for mixing and spraying concrete is becoming available. The <a href="http://www.mortarsprayer.com/" target="_blank">mortarsprayer</a>
for example has been successfully used in a variety of applications where more
complex concrete guns and pumps had previously been required.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
The
obvious best case scenario would be some form of easily sprayed, insulating
geopolymer concrete. However both lightweight concretes and geopolymers are
very new. More testing across a variety of areas is required.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<b>Final
Thoughts</b></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
Monolithic
Concrete construction has great potential and some very compelling benefits.
With current methods and technology however the environmental cost is simply
too great. In addition, the specialized equipment and skills currently needed
will likely drive up the cost.</div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<br /></div>
<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
An
insulating geopolymer concrete combined with an easy application method would
most definitely be a game changing development.</div>
JStemhttp://www.blogger.com/profile/00824469185320678774noreply@blogger.com0tag:blogger.com,1999:blog-5855276920464761798.post-17755151335672854042013-07-27T10:08:00.002-07:002013-07-27T10:08:58.842-07:00Choosing a Construction Method: Cordwood and Strawbale<!--[if gte mso 9]><xml>
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We need
to begin construction of our zero energy house by deciding how it will be
built. This decision will impact our design, materials and process. In making
this decision there will be tradeoffs and consequences that must be carefully
analyzed and understood. No design or method can be entirely perfect. After
examining our options, we will choose the method that works best for the goals
of this project.</div>
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<br /></div>
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In the
last <a href="http://zeroenergyfuture.blogspot.com/2013/07/choosing-construction-method-rammed.html" target="_blank">article</a> we examined rammed earth, earthships and earthbag construction.
The two methods on our list for consideration here are cordwood and strawbale.</div>
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<b style="mso-bidi-font-weight: normal;">Cordwood </b></div>
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In this
system small, debarked pieces of wood between 12 and 18 inches long are stacked
to create walls. A mortar mix is used to bond the pieces together. This mortar
can be something more conventional using cement or something more natural such
as an adobe or cob. Generally sawdust or some other light weight filler
material is used within the wall or mixed in with the mortar to provide some
insulation. Cordwood is similar in many ways to the rammed earth methods
discussed earlier. They both make good use of natural materials to create an
extremely environmentally friendly building. Unfortunately additional wood
framing is usually required to support the load of the roof. The roof itself
must also be designed separately. </div>
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<a href="http://www.home-n-stead.com/blogs/homenstead_files/035fa61c088d68ecede411a320e61f89-15.html" target="_blank">Cordwood walls being built</a></div>
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<a href="http://www.buildnaturally.com/EDucate/Articles/Cob.htm" target="_blank">Information on how to mix cob</a></div>
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<b style="mso-bidi-font-weight: normal;">Strawbale</b></div>
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This
method has become a popular due to the tremendous insulation value of
strawbales. Since they are so thick, a wall filled in with strawbales can
easily achieve an R-40 insulation value. This high insulation is very valuable
in the design of a zero energy home. However, like cordwood the bales
themselves are not load-bearing. Although this is possible, it is limited to
certain areas and requires a very careful and well engineered design to be
successful.<span style="mso-spacerun: yes;"> </span>A separate roof structure is
again necessary.<span style="mso-spacerun: yes;"> </span></div>
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<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
<a href="http://www.strawbale.com/" target="_blank">The definitive straw bale construction website.</a> Contains videos, tutorials and
additional information</div>
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<b>Pros and
Cons</b></div>
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The
first important thing to realize is that both cordwood and strawbales are
generally only used for non-load bearing sections of walls. We would prefer our
method to be more all inclusive as was the case with earthbag construction.
Since additional wood framing is necessary, our design becomes more complicated
and more costly. Cordwood and Strawbale are both environmentally friendly and
low cost, although not to the same extent as earthbag construction. Since
cordwood and strawbale make extensive use of adobe and cob, there are also some
climate issues to consider. These designs will be more difficult in areas that
experience a thaw/freeze cycle or in areas that have perpetually high humidity
and precipitation. These methods are also extremely labor intensive. While
being superior in this regard to rammed earth and earthships, they again lose
out to earthbag construction. In most cases we will again have trouble with
conventional building codes depending on the extent to which we utilize
conventional wood framing. The one area in which strawbale construction
undeniably excels is in its extremely high insulation value.</div>
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<b>Final
Thoughts</b></div>
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These
methods are just too limited in their use and applicability. They are also
inferior to earthbag construction in most cases. As insulation however, straw
bales are very appealing. Moving forward, we will keep this in mind and try to
look for places where it might be possible to utilize straw bales as
insulation.</div>
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JStemhttp://www.blogger.com/profile/00824469185320678774noreply@blogger.com0tag:blogger.com,1999:blog-5855276920464761798.post-50644119533145187592013-07-25T09:36:00.002-07:002013-08-22T13:17:49.651-07:00Choosing a Construction Method: Rammed Earth Variants<!--[if gte mso 9]><xml>
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<div align="left" class="MsoNormal" style="line-height: 200%; text-align: left;">
We need
to begin construction of our zero energy house by deciding how it will be
built. This decision will impact our design, materials and process. In making
this decision there will be tradeoffs and consequences that must be carefully
analyzed and understood. No design or method can be entirely perfect. After
examining our options, we will choose the method that works best for the goals
of this project.</div>
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<br /></div>
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<b style="mso-bidi-font-weight: normal;">Rammed Earth, Earthships and Earthbag
Construction</b></div>
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<br /></div>
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Let’s
start at one end of the spectrum and work our way across. These methods are the
ultimate in environmental sustainability. The load bearing structure of the
house is formed from the earth beneath your feet. Often the same soil excavated
to prepare the site can be used. In pure rammed earth construction a mixture of
sand, clay and silt is packed down tightly within a formwork. The result is
thick, rock hard, earthen walls. </div>
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<br /></div>
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<a href="http://www.earth-auroville.com/raw_material_introduction_en.php" target="_blank">More information about the soil mix in rammed earth</a></div>
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<a href="http://www.youtube.com/watch?v=X4Zqqj-slis" target="_blank">Building rammed earth walls using fixed formworks</a></div>
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<a href="http://www.youtube.com/watch?v=u0GLTWs0-ng" target="_blank">Building rammed earth using a moveable formwork</a></div>
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<br /></div>
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Earthships
are an improvement upon this idea. Earthships use discarded vehicle tires as a
form. Since the rammed earth has additional stabilization from the tires the
soil mix is more flexible, allowing earth from the site to be used in most
cases.</div>
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<br /></div>
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<a href="http://www.amazon.com/Earthship-How-Build-Your-Vol/dp/0962676705/ref=sr_1_1?ie=UTF8&qid=1374636545&sr=8-1&keywords=earthship" target="_blank">The definitive guide to building Earthships</a></div>
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<a href="http://www.youtube.com/watch?v=Qwp0kxazw5g" target="_blank">Making a rammed earth tire</a></div>
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<br /></div>
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Earthbags
are probably the best application of these ideas. In this system polypropylene
bags serve as the earth formwork. Using bags makes filling and compacting much
easier. Additionally, earthbag buildings are often formed as domes, allowing
earthbags to form the entirety of the structure including the roof. This is not
possible in either rammed earth or earthship construction.</div>
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<br /></div>
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<a href="http://www.earthbagbuilding.com/" target="_blank">More information about earthbag construction</a></div>
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<a href="http://www.youtube.com/watch?v=DPz61MWn8xw" target="_blank">Time-lapse of a small square earthbag construction project</a> (set to speed metal music??)</div>
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<br /></div>
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<br /></div>
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<b>Pros and
Cons:</b></div>
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<br /></div>
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Pros</div>
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<br /></div>
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Environmental Benefits: </div>
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The
materials used are completely natural and usually taken from the building site;
there is virtually no environmental damage whatsoever. In the case of
Earthships, there is actually a large environmental benefit since large
quantities of discarded tires are upcycled.</div>
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<br /></div>
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Low
materials cost:</div>
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The
materials are earth and formwork; there is virtually no material cost.</div>
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<br /></div>
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Low
skill requirement</div>
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The
process is simple, easy to learn and quite tolerant of small mistakes.</div>
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<br /></div>
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Strength
and Longevity</div>
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Rammed
earth style homes of nearly any style are essentially indestructible. Earthbag
buildings even perform well in earthquakes making them resistant to all but the
most catastrophic natural disasters. I would not be surprised to see most
rammed earth style buildings able to survive small explosions. These structures
will last centuries without significant damage.</div>
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<br /></div>
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Cons</div>
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<br /></div>
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Labor:</div>
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This is
by far the most significant drawback. The time and labor required to build any
of these variants is quite intensive. You need either a large volunteer crew or
some other way of getting a workforce together.</div>
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<br /></div>
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Insulation:</div>
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While
rammed earth has excellent thermal mass, it has poor insulation value. Thus
for climates that experience prolonged periods of either hot or cold,
additional insulation is needed. </div>
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<br /></div>
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Scalability:</div>
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Due to
the extremely high mass of rammed earth walls, any sort of multi-story building
would require extremely thorough engineering that is beyond our expertise.</div>
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<br /></div>
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Building
Codes:</div>
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Unfortunately
we need to consider the well established building codes that dictate home
construction. In most cases, getting approval for these structures will take a
significant amount of time, stress and money. In some cases it may be
impossible to get approval altogether.</div>
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<br /></div>
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<b>Final
Thoughts:</b></div>
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<br /></div>
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Labor
and building codes are the defining challenges here. We want our design to be
as easy and adoptable as possible. The bottom line is that getting approval and
securing the necessary labor will be challenging for most. The builders of
rammed earth style homes tend to be dedicated in a deeply personal way. They
are willing to put forward an incredible amount of time and willpower.</div>
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<br /></div>
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I want
to end by taking one last look at the potential of earthbag construction. The
ingenuity and functionality of these structures are difficult to ignore. In
addition some of the conventional difficulties with rammed earth listed above
are beginning to be addressed through earthbag construction. Instead of filling
bags with earth, naturally insulating materials such as basalt, scoria or
pumice have started to be used. These materials are widely available under the name ‘red lava rock.’ This solves the majority of the insulation problem.
There are also existing and emerging methods to offset the significant labor
needs. Devices known as pneumatic tampers make the compacting process much
easier and are available to rent. In addition, there are emerging technologies
that automate the process of filling the bags. <a href="http://www.earthbagbuilding.com/articles/bagmachine.htm" target="_blank">This machine</a> by Ensor Equipment
is one such example.</div>
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<br /></div>
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Should
these kinds of machines become more widely available earthbag construction may
prove much more viable than originally thought. In any case, the earthbag style
of construction will be a significant contender for our final decision.</div>
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JStemhttp://www.blogger.com/profile/00824469185320678774noreply@blogger.com0