Build a full size 3D Printed Hempcrete Structure to demonstrate Hemp/3D Printing as a sustainable alternative to traditional construction.
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We are currently in the design and development phase of a 100% hempstone construction project.
All structural and architectural elements will be constructed of either hemp fiberboard, hempcrete/hempstone, or hemp plastic or resin composites.
All hempcrete/hempstone components will be printed in smaller single-man-manageable blocks with a waste-less "skeleton" form, not unlike the way bone is structured, only applying material where it's needed. These blocks can then be stacked together to form the body of the house, and will include space for utilities and wiring etc in the blocks design.
We plan to create a set of standardized blocks that could be used to build almost and shape or size of structure desired.
For larger structures, tension cables or clamps can help hold the seams and joints together firmly.
As hempcrete "petrifies" after a few years in the elements, we are excited about the possibilities presented by constructing structures that will evolve from plant into stone, will actually absorb more co2 than they release during construction and during the petrification process, and can be made from a completely renewable material using minimal waste methods for construction.
We intend to produce a hempcrete mixture that I am calling "Hempstone", made of micronized lime, and specially milled refined hemp fibers with incredible strength using a (currently functioning and proven) proprietary technology that breaks down materials utilizing resonant frequency and negative air pressure rather than friction and heat to tease the materials apart long natural structural boundaries.
What actions do you propose?
Gather materials, (hemp, lime, binder etc.)
Micronize the lime using our Comminution Reactor. (Milling system). http://www.google.com.ar/patents/US20130126647 This creates tiny particles, with incredibly active surface area that should petrify quicker than lime powders produced using other methods. Also the greater compaction qualities of these smaller particles should significantly enhance the compressive strength of our hempstone.
Process hemp fibers using the same system. The fibers we have processed using our system have very active surface area as having very frayed ends which enhances their ability to cling to one another, and to surfaces they are being sprayed or printed on. (Same note re: smaller particles, compressive strength. Additionally, our milling system creates very active frayed ends on the hemp fibers, which allows for greater adhesion when being printed or sprayed into,place.
Mix the processed hemp and lime together, pour some basic sample structures, and conduct structural, thermodynamic, environmental and other conditional tests to determine/prove the efficacy of the resulting hempcrete mix.
Utilize an algorithm such as: the Softkill-algorithm. http://www.fastcodesign.com/1671102/a-3-d-printed-house-that-grows-like-human-bone#8 To create smaller blocks with a structure not unlike the interior structure of bone, that can then be fitted together to form the skeleton for a building. The wiring and plumbing can be factored in, and threaded through the open mesh like structures of this frame. Then the inside of the structure can be filled in.
Create the "skeleton blocks" (some structural/load bearing, some for fillers etc) needed to build the house design. Including in their design, grooves for installing conduit and plumbing and utilities etc.
Deliver "skeleton blocks" to site, (with pre poured foundation). Begin assembling frame/structural sections.
Add filler skeleton blocks to completely encapsulate structure.
Add outer shell. Add windows. Add utilities, appliances.
Finish interior. Furniture etc.
Ideally, the bone like frame structures would be made of a hemp resin or hemp plastic, and then hempcrete would be poured over the frame etc, to fill in the gaps, and provide the strength and filler needed.
For the sake of this first test however, we intend to make everything from hempcrete. To prove out the basic concept.
The benefit of the hemp resin or hemp plastic frame would be that they would be very light weight, and could easily be shipped or otherwise transported. Also, the assembly of the smaller hemp plastic frame structures would be very easy, and could most likely be managed by just a few people. Eventually I would create sets of standardized hemp plastic frame segments that could be easily selected and combined to build almost any size/type/shape of building that someone wanted.
Even the wiring and residential battery banks could eventually be replaced with interchangeable modular panels containing grooves filled with conductive hemp graphene, and hemp supercapacitors (ala https://www.asme.org/engineering-topics/articles/energy/hemp-carbon-makes-supercapacitors-superfast).
We will document the entire construction process, (with the help of Brainship Media at www.brainshipmedia.com).
We will then of course have the structure inspected by green building experts familiar with current green building methods, costs, codes, LEEDS etc etc. with their comparative analysis of our creation vs. the current popular building methods will be a great tool for illustrating the many of the benefits of a hempcrete/hempstone based construction industry/process.
Once the structural elements are completed, we will outfit the rest of the house using current but un-commercialized green technologies. Giving inventors a chance to showcase their world changing innovations as a part of the "possible-future house" we are constructing. So-as to prove the tangible reality of the world we could live in once the veils of suppression and doubt are pulled back and the People see how we can use what already is, to create what will be.
"Est SIcut Cogitavi, Erit Ut Putatis"
Onward and upward.
The house will be designed specifically to combine beauty and functionality, both as an "off grid" or "plugged in" home.
(one of the ideas for the structure:)
Features such as rainwater collection (including filtration, and micro turbines to generate some power during heavy rains), photovoltaic glass windows (to generate more passive power), not to mention of course the outstanding thermodynamic qualities of Hempcrete...(http://www.slideshare.net/limetech/thermal-performance-of-hemcrete-with-photos).
Traditional hempcrete has relatively low compressive strength, however according to studies such as: http://www.bath.ac.uk/ace/research/cicm/news-and-events/files/BIOMATERIALS_AND_BINDERS_-_Lanos.pdf, the compressive strength is significantly improved as the hempcrete becomes more compacted.
The hempstone mixture I intend to produce would have incredibly smaller, more irregularly shaped particles that should compact together more solidly, which should result, in vastly better compression test results. Of course the first phase of my proposal would be the acquisition of hemp, lime, and binder to Micronize, mill, and mix, then to conduct the needed tests to determine our new materials strength, then tweak the formula as needed to achieve the desired result.
The prices of hemp are going down as the regulations are easing up state after state, and this will soon make hemp materials the most affordable construction materials as well as the most ecologically and structurally sound.
But none of this will be possible if the People at large do not know it is possible. And that is why it is absolutely imperative to not only construct, but to document and showcase this project far and wide. (the extensive media connections and experience my partners and I have will help in this greatly.)
The endgame would see concrete and cement being phased out and replaced entirely with hempcrete/hempstone.
Who will take these actions?
- We will.
- Along with you (if you are up to the challenge).
- I have spoken with Ryan Loflin in Colorado (first American hemp farmer in 60+ years). We are in contact and when the time comes to begin construction will likely be collaborating.
- My partners and I, who are the only folks with access to the proprietary milling system that will enable the unique hempstone which could be the finest hempcrete ever produced.
- Brainship Media (www.brainshipmedia.com). Handling all things marketing and branding related.
- I have also spoken with American Lime Technology to see if they are interested in assisting with the production of our new hempcrete by providing lime samples for our test batches etc.
- Eventually, I hope, that all concrete companies and construction companies could be utilizing these ideas to create the infrastructure for our nations and world.
Our major focus moving forward would be on gaining a foothold on the infrastructure construction market, rebuilding the crumbling infrastructure of cities like Detroit using materials that could be cultivated and sourced in their own neighborhoods/areas, creating jobs, healthy soil, healthier air, and longer lasting infrastructure, which also saves on the economy be reducing the repairs needed over time.
Where will these actions be taken?
Residential example project: Either in California or Washington State, or Colorado most likely. Several other locations being considered.
Future efforts: Detroit and other cities that have been ravaged by either terrible policy or natural disasters.
How much will emissions be reduced or sequestered vs. business as usual levels?
By replacing the cement industry with a Hempcrete industry, we will reduce worldwide CO2 emissions by a minimum of 7-8%.
As of 1998, 7-8% of worldwide were from the concrete industry. And that was in '98.
Cement production is growing by 2.5% annually, and is expected to rise to 3.7-4.4 billion tons by 2050.
Cement manufacturing is highly energy – and – emissions intensive because of the extreme heat required to produce it. Producing a ton of cement requires 4.7 million BTU of energy, equivalent to about 400 pounds of coal, and generates nearly a ton of CO2. Given its high emissions and critical importance to society, cement is an obvious place to look to reduce greenhouse gas emissions.
The hemp which forms the key element in these products can be grown and harvested worldwide helping to reverse the damaging effects of greenhouse gases. Our Hempcrete will lock around 202kg of CO2 per m³ of wall and provide the best value materials for sustainable and commercially viable construction.
What are other key benefits?
Lets start building a civilization that plans for the long game.
Current building methods produce structures that must be replaced fairly often...
Not only in residential applications, but in commercial and industrial especially.
David Mosrie of Push Design, who was involved in building the first Hempcrete home in US said:
“The durability is unlike anything we have seen, with the exception of stone, as perhaps even beyond that as there is no mortar joint failure possible. Studies in Europe have estimated about a 600-800 year life span for the wall system.”
Not to mention all the incredible designs and creations in architecture that are being made possible for designers today with 3D printing.
Imagine how much money the economy would save if it wasn't forced to constantly fix all our critical infrastructure every few years...
There's a reason that so many of the ancient roman aqueducts and roads are still in tact...they were built utilizing hempcrete mortar...makes you think eh?
What are the proposal’s costs?
I believe this project could be completed with somewhere between $50,000 and $100,000. The money would be used as would be expected, materials, some personnel, testing, etc. A full budget will be prepared as the project moves forward. The money would be used as would be expected, materials, some personnel, testing, etc. A full budget will be prepared as the project moves forward.
We however will be producing our own new form of incredibly high quality/strength hempcrete. We have sponsors to contribute most if not all of the building materials and technologies as this project will be the best conceivable marketing opportunity for companies and techs alike to showcase their innovations.
1-2 years. Or less. The project will continue after the first build. But let's focus on one thing at a time.
Months 1-3: create initial formula, test, refine! Repeat. Fine tune design of house skeleton blocks. Begin contacting materials suppliers, fabrication facilities etc. pick site.
Months 3-5: finalize house design. Lock down crew and materials. Produce skeleton segments, test how well they fit together. Refine, repeat.
Months 5-8: assemble structure on site. Install wiring tubes and plumbing as designed, amongst the skeleton mesh structure of the blocks. Fit the outer shell in place. Add in windows and floor and wall panels.
Months 8-12: finishing touches, appliances, furniture/interior design.
Months 12-14: conduct applicable tests to enable complete comparisons with current building methods re: cost, carbon footprint, time, ease etc...
The first construction will be complete within about a year of being funded. After which we will send out invites to major HGTV, and DIY and other such outlets, not to mention NPR, popular bloggers etc.
During this phase, we also intend to develop a project to utilize all the benefits of building with 3D printing and hempcrete to assist the homeless and impoverished people of the United States by teaching folks how to do what we have done, and providing a space for hard working willing individuals to build their own homes. (Hopefully partnering with the Open Source Ecologymovement.)
Our major focus moving forward would be on gaining a foothold on the infrastructure construction market, rebuilding the crumbling infrastructure of cities like Detroit using materials that could be sourced in their own neighborhoods, creating jobs, healthy soil, healthier air, and longer lasting infrastructure, which also saves on the economy be reducing the repairs needed over time.
Current hempcrete compression strength etc...
Hempcrete thermal tests
Creating Optimal Bone Structures via algorithms.