Shortly after Aaron and I
got married, we bought a piece of land. Dreams of building our own
house morphed into the reality of home construction in early 2008.
This is the short version of the story of our home; I hope it will be
useful to anyone considering building a more-or-less green home. We
made a lot of difficult choices and compromises about materials and
designs, and ended up with a very happy hippie home that we adore.
Aaron is a soil scientist, and we knew we’d build our house out of dirt. While there are more
high-tech materials out there for energy efficient homes, we never
seriously considered anything else. Aaron found a compressed earth
block (CEB) machine for sale in Mexico, where it had been used to
make hundreds of thousands of blocks for an eco-resort. We bought it,
had repairs made by the
manufacturer, and then brought “Mariana” home.
Pros of building with
dirt: all-natural material, found locally,
low
embodied energy, excellent thermal mass, fire- and mold-resistant,
and easy to build with as an owner-builder. They’re even easier
than adobe, because the bricks are extremely uniform and don’t
require a thick mortar layer between each course.
Cons:
not amazingly insulating (R-value of around 0.25/inch for CEBs).
Because of the low R-value, additional insulation may be a good idea,
depending on your climate. We used 3 inches of spray foam (not a very
green building material at all; does that negate the greenness of the
rest of the house?)
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Bricks coming off the machine at 8 per minute. |
Our blocks were made
simply of a mixture of native dirt, lime, and water, compressed under
very high pressure. The lime is not necessary, but it helps stabilize
the bricks against water damage during building. The dirt has to have
some clay in it, but the required proportions of clay to sand are
fairly forgiving. We had dirt on our property that worked.
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Aaron checking out some dirt. |
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Combining dirt, water, and lime in the mixer. |
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The downside of adding lime is that another machine is necessary,
a mixer, but it may be needed anyways for getting the required
moisture well-mixed as well. We were able to rent the mixer.
The blocks for exterior
walls are 10” x 14” x 4” (so the walls to our house are 14
inches thick). The press can also make 7” x 14” x 4” blocks for
interior walls. We rented a forklift to move pallets of bricks
around. I got pretty good at driving the forklift.
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Amy driving the rented forklift. |
Because we went with lime
in the mix, the blocks need time to cure; we wrapped the pallets of
fresh bricks in plastic and let them sit for a month. If you don’t
add lime, the blocks can be used straight from the press.
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Amy and Brendan wrapping bricks in plastic to cure for a month. |
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Aaron. |
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Bricks curing. |
It took
about a week to make an estimated 9,000 blocks. We used about
two-thirds of the bricks in the house (we had way
less brick breakage than we assumed). The remainder of the blocks
have been used for all kinds of walls and sheds and other projects,
but a few pallets of slowly decaying bricks are still sitting out
there in our “yard,” embarrassingly. Because of the lime
stabilization, some of the bricks are still in excellent shape and
totally useable after 6 years of being outside and inadequately
sheltered!
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Beautiful bricks, ready to use. |
After making the bricks,
it was time to build the house. We didn’t have really any experience in home
construction, but we had great friends who helped out, both with
labor and expertise. We contracted out for: the concrete slab, the indoor plumbing and solar
hot water, electrical, a bit of framing, stucco, and some of the interior wall
finish work (drywall and plaster). (The framing in our mostly-block
house was only for the upper half-story, a few closets, the roof, and
the “wet wall,” the single two-story wall with all the bathroom
plumbing; the two bathrooms are stacked on top of each other for this
reason. You can run plumbing in block walls by channeling.)
That left for us to do
(with help from our friends): the making of the bricks and the
mortar, building the CEB walls including window and door bucks,
installing the septic system, a bunch of the finishing work (all the
tile, wood flooring, installing the stairs and kitchen cabinetry,
etc, etc, etc), and acting as the “general contractor” and
coordinating subcontractors and pulling permits and dealing with
paperwork. Since neither of us quit our day jobs, this felt like
plenty on our plates. The home took from April 2008 (making the
bricks) to November 2008 for us to get a certificate of occupancy and
legally move in. In retrospect, this seems
fast,
but we’re still not done with all the inside finishing work, six
years later (who really
needs
trim?).
I learned to use Google Sketchup and made a model of the house, which helped us visualize the interior. You can do a person's-eye-view "walk-through" of the house model, which is pretty cool. The house really does look like this!
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Google Sketchup model of the house. |
To raise the CEB walls, we
held an old-fashioned barn-raising party (in this case, a
wall-building party) and our amazing friends came out and helped for
a weekend.
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Sifting the dirt for the mud slip between bricks. |
After about two weeks to
build the CEB walls, not including the time to make and cure the
bricks, our contractor knocked out the framing in, like, two days.
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Roof and upstairs framing. |
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Inside the garage, which houses our
little climbing wall. |
In another post I’ll
talk about the energy-efficiency and water-saving systems in our
house and discuss how they have performed over the years, and perhaps
another one will show off the hard work we did to finish off the
place and make it look presentable.