Straw Construction in the Media!

The Build Well project, a project of the Ecological Building Network, has produced a stunning new video, featuring long time straw bale construction advocate and structural engineer, Bruce King, as the host and narrator. Well worth a watch, this short documentary talks about the history of straw bale construction and the use of straw as a building material. It goes on to showcase the straw bale building revival in various new forms — including straw structural insulated panels (S-SIPS) — and the future of building with straw and other plant and bio based materials, including hemp and sheep’s wool.

These natural plant and animal based products reduce the carbon impact of our buildings by harnessing nature’s own processes, plus they create healthy buildings for the people crafting them and the people living in them. A bio-based building revolution would be one of the fastest ways to draw down atmospheric carbon and help reduce the impacts of climate change! Bruce believes that we can turn the built environment into “a carbon absorber within a generation.” So let’s get to work, together!

Hemp Energy Retrofit

2026 Update:

We are excited to announce that this home will be featured in an upcoming book, Passive House Retrofit Details: Case Studies in North American Climates.

 

This 1950s home outside of Boulder, Colorado needed some upgrades for both performance and durability. The homeowners decided to use the most natural and healthy materials possible, to craft a home they can feel great about living and raising their kids in.

Living Craft offered our expertise to oversee an exterior envelope remodel that started with removing the old sheathing and insulation. We replaced the 2×4 insulation batts with new-carbon sequestering hemp based batt insulation. Next, we added new sheathing and a self-adhered, vapor-open, smart membrane air and water barrier from 475 High Performance Building Products. After that, we installed a 4″ wrap of continuous, hemp board insulation. The final layers are a rainscreen dimple mat, which will allow the wall components to stay dry, and a three coat exterior lime plaster as a beautiful and fire resistant finish.

Indoor upgrades also include a new integrated whole house ERV for keeping indoor air quality high. We replaced the old attic insulation with new R-60 blown in cellulose, plus added fire and ember resistant attic venting from Vulcan Vents into the stained cedar soffit. These changes will result in a healthy, quiet, high-performance home with reduced energy costs and increased comfort.

Architect:

Bela Design Studio

Structural Engineer:

GFE Structural

Energy Inspection:

Scott Home Services

Building and Remodeling with Hemp

There’s a lot of information out there now about hemp construction. Since the recent passing of the 2018 Farm Bill in congress, which legalizes the growing of industrial hemp on a federal level, the hempcrete building technique has gained media attention.

But what do you need to know if you are thinking about your new dream hemp house or hempcrete remodel?

hemp building in progress

How Hemp is Used in Construction

Many articles in the press have done a good job of explaining the use of hemp in hempcrete walls. This system involves hemp hurd being mixed with lime binder and then loosely packed into forms that are built around the wall framing. This is applicable in both new builds and remodels. There is lots of room to experiment, as well.

For example, the hemp-clay house we worked on uses the hemp portion of the wall solely as an infill which butts up to the inside of the otherwise more conventional wall. It serves as a thermal break and plaster substrate. Hemp can also be mixed into plasters, earthen floors, and used in creating blocks, with either lime or clay binders.

There are companies that make building products made with hemp that could replace plywood, batt insulation, and even wood framing members. For now, though, hempcrete (or hemp-lime, or hemp-clay) is the king of hemp building.

Benefits of Building with Hemp

There are many benefits to building with hemp and hempcrete systems.

Environment

First off, the environmental benefits. One way hemp is better than other building materials that it may replace is that its production (farming) and processing (making the hemp plant into hurd) can require less energy, water, and time inputs. In fact, due to its long root system, hemp plants can actually improve soil health by increasing organic matter in soil over time and naturally loosening dense soils.

A hemp home may use less lumber, since the wooden frame of the house can be designed with greater spacing than if the home used more conventional insulating batts that are designed for 16″ or 24″ spaces. And since hemp grows much faster than trees, it requires less water and energy inputs, and a smaller area of land to produce an equivalent amount of material.

Hemp also replaces insulation. Batt insulation like fiberglass and mineral wool are manufactured products that need a lot of energy to create and ship. If local hemp hurd is used instead, the embodied energy is much lower. Also, hemp captures carbon from the air as it grows, which is then sequestered and stored in the walls of your building for as long as it stands. This means you get to start out with a carbon neutral or even carbon negative home from the beginning!

Building Health

The rise of “sick building syndrome” is well documented. As homes get more energy efficient with tighter envelopes, indoor air quality can decrease. Particularly when the materials used to build and finish them and the products we bring inside are off gassing chemicals and VOCs, this can result in poor health, lowered cognitive abilities, and potential long term disease. In addition, mold can become a problem from condensation forming within wall systems or inside of poorly ventilated homes.

Hemp can help with this is a few ways. If you follow our plaster site, you may have read about how plasters can improve indoor air quality. The lime (or clay) binder in hempcrete is the same earthen material as in a natural plaster. Also, most hemp walls are finished using plaster on the inside.

Also, hemp won’t contribute to VOC and chemical off-gassing as it is a wholly plant based material which has been dried and processed before being mixed with the lime.

Finally, hempcrete walls are highly mold resistant. The lime binder has a very high pH while wet, which prevents mold. And, once it has cured and been plastered, a hempcrete wall regulates humidity and allows water vapor to pass through it in a way that won’t lead to any points of condensation within the wall. There are also no gaps within the wall through which air can move. This eliminates another source of moisture and mold, and contributes to the longevity of your building.

Boosting Local Economies

Growing hemp is seen as a healthier, safer alternative to other economic activities, like mining and large scale industrial agriculture. Because hemp requires less inputs of pesticides and herbicides than other crops like cotton, soy, and corn, it is a good candidate for replacing or joining into a crop rotation with these plants. Also, parts of the country whose economies were dependent on coal mining or manufacturing jobs could use the recent legalization of industrial hemp to carve out a new living. In Colorado, hemp and marijuana growing is already boosting the economy.

Current Challenges of Building with Hemp in Colorado

Since industrial hemp is a new crop in the United States, we are lagging slightly behind in the manufacturing of products using hemp and in the processing of the raw plant material. The equipment, factories, and machinery required for such a task are expensive and it will take time to catch up to other countries where hemp building has been popular for decades.

For example, when we built our hemp-clay project, using a unique and lower carbon version of hempcrete where clay is used to bind the hemp together in the wall instead of lime, we used imported hemp hurd. There are drawbacks to this, like increased embodied energy. However, the current consistency and quality of processed hemp hurd available locally (if it is available at all) meant that there would be more headaches and room for errors than if we bought from a part of the world where hemp building is well established. In those countries, the processing of the plant into the final product is seamless and reliable.

So, while we are still waiting for Colorado and the US to catch up with other areas of the globe, hemp building is coming to Colorado quickly, including in a studio project that we are starting later in 2019. Keep an eye out for updates!

Hemp-clay Mountain Timber Frame

This beautiful timber frame home at the edge of the mountains near Boulder, Colorado has a fun twist: a hemp-clay infill between the timbers of the exterior walls. The Living Craft team installed a 4″ layer of hempcrete to the inside of the walls, using a clay binder instead of lime to keep embodied energy down. We then plastered over those walls with custom clay plasters.

The hemp hurd used in the walls will sequester carbon for the lifetime of the building, reducing the overall embodied energy of the building. Additionally, the highly insulative extra R-value will keep the home temperatures comfortable and keep it quiet inside. Combined with tripe pane European style windows, this home is high performing and healthy.

General Contracting:

Earthrise Homes

Plaster and Hempcrete:

Living Craft

Custom Interior Carpentry:

Grimes Carpentry

The Hemp Clay Experience

We’re working in a home where we used a hemp and clay mixture between timbers to add insulation and thermal mass. Why did we choose this, and how is it different from the hemp-lime or hempcrete building processes?

Typical Hempcrete

Hempcrete, or hemp-lime, as you may know, is a popular form of wall infill that’s a mixture of hemp hurd, hydraulic lime, and water. As it cures, the lime in hempcrete chemically changes back into the same composition as limestone, making it rock solid. Frank has taught at a few hempcrete workshops around Colorado with John Patterson of Tiny Hemp Houses.

hemp building workshop
At a hempcrete workshop Frank co-taught at in Colorado.

The Good:

Hemp! It’s great. It grows fast, and needs less chemicals while growing: all reasons it may be more ecological than other building materials. Hemp is also better for soils than most other plants, with its deep roots that aerate soil. Additionally, the hemp stalk is composed of about 50% carbon by dry weight. This means that the carbon sequestered from the atmosphere during photosynthesis can be locked into our building like a carbon sink, not being released until the building is demolished much further down the line. This enables us the possibility to build a “carbon negative” wall system. If you’d like to learn more about carbon sequestering and building for climate change, we will be posting a blog soon.

The Not-So-Good:

Lime, while a natural and healthy building material, requires a lot of energy input to be created. Also, we import a lot of the natural hydraulic limes from overseas, increasing the embodied energy of the material. Alternately, a mix with cement is used, which also has very high embodied energy and accounts for an absurd amount of greenhouse gas emissions. There are other additives that can be mixed with lime to make it hydraulic, such as different types of pozzolans and geopolymers. These have their own benefits and drawbacks, but it comes down to manufacturing processes, local availability, and toxicity.

What about Hemp-Clay?

Colorado is blessed with beautiful and strong clay, an alternative binder to lime or cement. The best part of this is that the energy required to dig up and screen local clay is minuscule compared to burning lime.

We made a test brick with hemp hurd and clay slip, and the result was strong and lightweight – a perfect combination of insulation and thermal mass (especially once clay plaster is added).

The Installation

The hemp clay installation process went very similarly to hemp-lime. Forms were packed with wet material and then moved up. It goes pretty quickly if you can make your mix dry enough, but still sticky and workable. That way, forms are moved up and the packed in hemp-clay sticks in place without slumping.

hemp building process
Forms and the tamped hemp-clay mixture.

Drying

Since clay does not set chemically, like lime or cement, it has to dry naturally, with time. With several fans and dehumidifiers placed around the home, it still took a while to fully dry. We used a moisture meter to check deep within the walls, and later patched those spots where we had to put the probe in.

hemp wall drying
Hemp wall drying in the basement. Some forms had to stay up a little longer for extra reinforcement of thinner areas.

This step is very important because if you seal the hemp up with plasters before it’s dry, although it can still breathe through the plasters, there is a greater chance that some moisture will get stuck deep in the wall. Over time, this could lead to mold.

Another thing to note is the clay tends to shrink as it dries. This led to some cracking and pulling away from timbers. We took an extra half day to come back and fill those cracks in to prevent thermal bridges and loss of insulation in those places.

hemp clay dried
The dried hemp-clay infill shrunk and pulled away slightly from the timbers. Nothing plaster can’t cover.

Plaster Prep and Plastering

This step is again just about the same as with hemp-lime or hempcrete. We had a few places where the mix was too dry or didn’t have enough clay, as well as fragile corners around windows where we used an expanded metal lath to shore up the hemp clay. Landscape staples were used to attach the lath to the hemp, where needed.

We used clay plaster and our sprayer to get a base coat up first. The texture is perfect for plaster to stick to. Although clay plaster is the safest bet for a strong bond, a lime plaster or lime stabilized clay mix would also key in well to the rough surface.

hemp clay wall
Before

hemp plastered wall timber frame
After

We’re pretty happy with the results and process. It’s not too dissimilar to a woodchip-clay infill wall. The fact that it’s a low embodied energy and carbon sequestering solution is exciting, but the amount of time it takes to dry is a challenge. However, working in the summer could speed that up easily. We would also consider adding a small amount of cement or lime to the mix in order to create that chemical set and allow us to fill higher and faster.

We used a mortar mixer for mixing, which only allows a certain amount of minimum moisture. If you wanted the mix dryer, a horizontal drum mixer would be a better option.

Unsurprisingly, we’re not the first to try this. Check out Chris Magwood and the Endeavour Centre Blog below for their experience.  Scroll to the bottom if you just want to read the hemp-clay part. I think that the hemp-clay block shows the most promise. Because they are small, that minimizes the risks of cracking and pulling away that can happen during the drying of a large wall.

Hempcrete developments

Thanks for reading, and let us know your latest hemp building experience, or if you are interested in trying it out for yourself, or in your home, backyard studio, or shed!

Green and Low Carbon Building Interview

lime plaster skylight

Frank participated in a brief interview on green building in Colorado with Boulder, CO radio station KGNU. Both Living Craft and Rodwin Architecture were represented after our joint presentation at The Eco-Social Solutions 2018 conference at CU Boulder. Click below to give it a listen, and be sure to read the whole article at KGNU’s site, linked below.

http://news.kgnu.org/2018/02/green-building-and-carbon-reduction/

lime plaster skylight

RMNBC 2017 Recap

Living Craft owners were recently proud to be speakers, sponsors, planners, and attendees of the 2017 Rocky Mountain Natural Building Conference, co-hosted by the Colorado Straw Bale Association and Common Earth. It’s been a fun and exhausting process through which we learned a lot, both about hosting a conference, as well as all the learning opportunities from speakers and other attendees of the event.

This year’s event was a blast, where we finally had a chance to meet other straw bale and natural building enthusiasts and reconnect with our mentors and friends from past natural building endeavors. The scope of the conference was broader than similar events put on by COSBA in the past, as we were striving to connect straw bale with other building techniques and ideas which can offer their own unique benefits. Speakers and attendees included earthen and adobe builders, hemp builders, building scientists and passive house experts, timber framers, architects, permaculturists, and landscape and greywater systems designers.

Frank was the emcee for the event, and Ben and Frank gave a presentation titled: Natural Building in the Urban Environment – Low Hanging Fruit. Cheryl was on a panel with several of her mentors and peers, discussing Intergenerationality in Natural Building.

Other highlights were Deva Racusin of New Frameworks Natural Design Build discussing building science and the important role of natural building materials and techniques in the green building movement. There is a huge opportunity for natural builders to promote building homes that not only have low energy use during their operation, but are also made of materials that sequester carbon within the structure of the building itself. By using plant based materials like straw, wood, cellulose, and hemp, instead of carbon emitters like steel, concrete, and mineral wool, the immediate carbon footprint of the building is significantly lower. This is absolutely essential to fight climate change in the moment, rather than waiting for benefits to offset inputs after 20-30 years or more. His business partner wrote a great article that goes into more detail about sequestering carbon in buildings.

The Friday night panel discussion with Deva, Mike Wird, Brian Fuentes, Emily Niehaus, and Derek Roff was also a really fun and informative discussion. The crowd was able to get involved by asking question via a website, which other audience members could vote on to lead the topic of conversation to areas of highest interest. Mike’s discussion of leverage points was inspiring and artful, as was Emily’s reminder that we all have more to give, as her upcoming role as mayor of the town of Moab illustrates.

An impromptu 5×5 panel on Saturday night allowed some of our friends for CASBA (California Straw Building Association) to share the results of wildfires on several straw bale homes which were impacted in recent wildfires across the state. We are truly impressed again and again by the durability of straw buildings with lime plaster, as several homes were left intact even after other non-straw structures nearby were damaged or destroyed.

Finally, COSBA and other anonymous donors, along with event attendees, were able to raise a significant donation to Liz Johndrow’s Pueblo Project, a non-profit that teaches local Central American people how to build with adobe and clay, and improve their homes’ durability, beauty, and comfort with these simple and affordable techniques. She’s hosting a natural building conference of her own in Guatemala this year.

There was too much fun to fully recount here, but Living Craft would like to fully extend our gratitude and love to our community for joining us on this amazing weekend. We hope to continue to work with all the folks we met and those we didn’t get a chance to talk with.

‘Til the next one, friends! #RMNBC2017

The Philosophy of Natural Building

What is Natural Building?

This is a hard question to answer, and has been the topic of many classroom and late night bonfire discussions. For us, it breaks down to a few basic principles:

Local

We try to use materials that are found or produced locally and have as little embodied energy as possible. We want to support the local economy and the people within it. I would love to use bamboo, but if I have to ship it across the Pacific, it’s probably not the best material to use.

Non-Toxic

We use materials that are not harmful to the people producing, installing, or living among them.

Healthy

Not only do we want the inhabitants and the environment to be healthy, but also the building itself. Too many of our new homes are riddled with moisture issues and bad air quality. By creating a vapor permeable wall system, we don’t trap moisture where it doesn’t belong. Instead, we allow it escape harmlessly, without negatively impacting the performance or longevity of the building.

Low Impact

Low embodied energy, with the least extractive methods possible. This allows an efficient building to begin immediately having a positive effect on slowing down climate change, rather than having to “pay back” the energy that went into and emissions that were produced while creating the materials.

Sustainable

This term gets thrown around a lot, and seems to have lost some of it’s true meaning. There are three tiers of sustainability: Economy, People and the Environment.

Economy

We want to use products that are literally dirt cheap. With cheaper materials, the customer saves money. Sometimes these materials require a little more labor, which puts more money into the pockets of local tradesmen instead of going to the large corporation.

People

We prioritize the use of local materials that help support people in our community. We also try to make sure these materials are non-toxic to anyone who comes in contact with them.

Environment

Our focus is on finding and incorporating into our design the materials with the lowest embodied energy possible. We also try to think in a cradle-to-cradle mindset. We want our buildings to last forever, but at the point it reaches its end of life, it shouldn’t contribute to the waste stream. With natural materials like clay, hemp, and straw, much of the building is compostable or can be put back into the natural environment after its disassembled.