Walter Don DeVore, Jr
480 Overlooked Way
Idaho Springs, CO 80452
303-567-2415
Fax: 909-919-1749
Cell: 303-520-4658
ddevore@cavitywall.net
Property
Executive Summary
Cavity Wall Technology Website
Walter Don DeVore, Jr
480 Overlooked Way
Idaho Springs, CO 80452
303-567-2415
Fax: 909-919-1749
Cell: 303-520-4658
ddevore@cavitywall.net
Property
Executive Summary
Cavity Wall Technology Website
Cavity Wall Technology (CWT) optimizes the attributes of regular concrete, lightweight concrete, precast, and cast in place concrete. Using superior structural shapes (narrow and deep) and economies of scale, a patented building method emerges with unduplicable durability, economy, and resource utilization efficiency.
Established methods of SIPs (structural insulated panels) and ICFs (insulated concrete forms) fall short of the efficacy of CWs (cavity wall panels). SIPs require drywall on the inside and exterior siding and have caused problems outgassing their bonding glue. ICFs squelch the exposure asset of concrete by burying it between styrofoam enclosures. CWS (Cavity Wall System) place glass smooth fireproof lightweight concrete as the enduring surface both inside and outside.
The patented CWT system employs a versatile cavity wall that serves as a one step finished exterior and interior wall, a stay in place form for cast in place column, beam, slab reinforced concrete, and many other applications. The advantages of manual assembly combined with pumped ready mix placement construct a highly durable, immense thermal mass, and well insulated building. Heating and cooling energy expenditures are largely eliminated. Vulnerability to nature's extremes is mitigated.
The claims made are supported by standard engineering calculations and common sense. Actual performance with Nature is difficult to predict. Actual results will give important fine tuning data for future design parameters.
Although I've built three structures so far, none have been equipped with the solar systems of the new designs. Developing the best techniques to take advantage of the cavity wall has been a persistent long evolution. This new phase will place these into action.
Development Plan
Putting existing molds and equipment into production as quickly as possible is tantamount. Every day the potential lies dormant, it's a loss.
Six acres of land in northeastern New Mexico, 17 miles from the major raw material, cinders aggregate for lightweight concrete serves as a rural beautiful setting to highlight the organic aesthetic of this cast cut stone patented building system. An installed 40 gallon per minute well and 200 amp power is ready to go. A dramatic National Monument featuring the Capulin Cinder Cone Volcanoe is immediately to the north. This special land is on the end of an anceint lava flow resplendent with juniper ringed lava coves and fractured lava formations. Adjacent raw land parcels are available to the west. The north and east abut ranch land. There is no zoning and the land is county approved for any combination of applications.
Building a simple dwelling for onsite worker accomodation comes first, followed by a 12 unit dormitory production facility for year around activity.
Financing Requirement
Backhoe.........................20,000
Dump Truck....................18,000
Trailer..............................5,000
Relocation........................2,400
Storage............................4,000
Solar residence...............92,000
Precast/Dorm................555,500
Total Capitalization.......696,900
Total square footage constructed = 9,192 + 882 = 10,074
Average ceiling height = 9.8'
Investment per square foot = $69.18
Construction Time...............................46 weeks
Weekly Income After Construction........12,500
Operate February through November = 44 weeks
Net annual income ............................ $550,000
Monthly net income...............................$45,833
15 years@ 10% monthly payment...........7,280
15 years@ 15% monthly payment...........9,481
15 years@ 20% monthly payment...........11,898
15 years@ 25% monthly payment...........14,467
14,467 x 15 x 12 = $2,604,060 Construction income, workshop fees, patent licensing not included.
Steps to Readiness
Cavity Wall Technology System Attributes
In the conservative building climate of the US innovation comes slowly. Standard practices in other countries, especially European, can often only be attempted here after twenty to thirty years of successful use. Anything different naturally arouses suspicion. But, is this really different?
Precast concrete is not new. Neither is cast in place. Neither is lightweight concrete. This is more like a typical steel chassis, made of the same stuff, but assembled in a new manner. That manner does not invalidate the inherent material properties.
They are now pouring concrete inside of styrofoam forms. This is pouring concrete within precast lightweight concrete forms. This structural column, beam, slab system is used in high rise construction, while this application is for only low rise application (to start with). It really should be an inspector's or engineer's dream, with so much reserve strength. These are two structural systems tied together, either survivable without the other, a level of reduncdance not found in any other method. Yet, the fear of liability for innovation without by definition a proven track record, will cause most to flee.
But we are confronted now with the imperative of change. People with courage to blaze that new path will step to the forefront to pioneer solutions for the many, out of kindness and empathy for the many. I believe this is the tool to do precisely that. I have lived confronted with what to do for thirty years. No distractions of child rearing, no urban cacophany, just high altitude mountain splendor free of television to delve deeply into contemplation imprisoned by the thought of what to do. This is what ultimately resulted. No allegiance to anything other than growing and evolving that best idea.
While in Thailand and Nepal I'd observe construction sites, particularly rural ones. They seemed to be a full town or family effort, employing men, women, and children, young, old, and in between. It seemed to remind the early settler days of village barn raisings. If one is going to live somewhere, it should have the energy and support of one's neighbors, like a neighborhood insurance policy.
The precedent of official approval has been established. The 20' x 30' Lakewood, Colorado studio with a wood truss roof was built with stamped plans and a municipal building permit. The proposed 40' x 19' with a post tensioned concrete slab roof will build upon that precedent.
The installation of "unbonded post tensioning tendons" is now regulated under Building Code to be done by a "certified" installer. I'm attending a weekend workshop in Phoenix to attain that certification. That will greatly facilitate CWT progress to not need outside people for that function.
Placing the manufacturing assets of CWT into production is necessary to begin beta testing of the latest system evolution. The simplest plan is to utilize the molds to their utmost capacity. The resultant panels will always have valuable application. The startup nucleus will learn product manufacturing and gain construction experience. Finished appraised value will exceed construction investment by a large amount due to enhanced resource utilization. Low loan to value ratios benefit both lender and consurmer.
Free and clear exotic property in northeastern New Mexico with close proximity to inexpensive lightweight aggregate, abundant water, and power will be the stage for launching CWT. The land will be titled in the corporate name and cooperatively owned by corporate shareholders.
An initial 40' x 19' (inside dimensions) structure will be built first, providing a model for structural test measurements and shelter for site workers. Site shelter is then had for a crew of eight, the labor required to build an indoor full year precasting facility and 12 unit dormitory. Performance data for thermal mass and solar input will be compared and analyzed against theoretical calculations.
The completion of the manufacturing facility plan will give experience to undertake a more sophisticated residential construction. The lessons learned from experimenting with various aesthetic panel finishes in the facility will be employed to full effect in the house. Energy performances will be fully proven.
CWT will next fully prepared to undertake large scale panel manufacture and home building. A 250,000 square foot facility south of Pueblo, Colorado could provide space for precasting panels for 27 homes per day. This new superior construction method will spread its availability to everyone.
A deliberate approach to full scale operations is necessary as experience has shown one new idea can change everything. The amount of progress in technique gained so far has been considerable and things can proceed quite nicely with the current state of the art. However, as the scope increases and more people see what is possible, the probability for further breakthroughs also increases.
Currently armed with over 700 square feet of molds, the primary order of business is to be pouring the molds daily, generating system panels. The fundamental goal is to make components at $3.50 per square foot, sell them at $7.00 per square foot to build for $70 psf creating dwellings that would appraise for at least $140 psf.
Minimum People Required Labor Intensive Slab Pour and Finishing:
One on screed
Two each side screed bar leveling concrete
One on concrete pump hose end
Two with floats
Two with power trowel
Total eight workers
Property Specifics
6 acre parcel
40 gallon per minute well
200 amp electric service
No zoning
Exotic setting by Capulin Volcano National Monument
Land purchase by corporation per unit = $4,000
Total purchase price = 13 x 4,000 = $52,000 payable to seller by corporation
Property Survey
The attributes of the area, site, and construction are extremely positive. Hiway 64-87, between Raton, NM, and Amarillo, TX is a designated NAFTA super highway, in the process of being four laned from two. A two lane road, Hiway 325 heads north from 64-87 in Capulin to Folsom, a small picturesque area, next to the geological site where the oldest artifacts of ancient North American habitation are found. The property is 38 miles from the New Mexico-Colorado border at Interstate 25, known as Raton Pass.
The property access is an inconspicuous path 0.8 miles from 64-87 north along 325. The access is flat except for a hundred yard steep up ramp where higher clearance and four wheel drive may sometimes be necessary. Besides being my easement for access, a local rancher uses it occasionally for access to his adjacent pasture land. Full size rv's, well drilling trucks, and ready mix trucks have no problem with access. During a heavy rain, the soil becomes slick and muddy, but dries out quickly. The steep ramp is rocky and not subject to becoming muddy, as it's the leading edge of a lava flow mainly composed of fractured "malpais" (a synonoum for lava). The distance from pavement to the property is one half mile.
An established forty gallon per minute well with a three acre feet annual water right, natural beauty, bordering a large ranch, freedom from zoning, two hundred amp utility electric service, and proximity to a cinders pit for lightweight aggregate are the property's main attributes. The north third is flat, then descending down the rim of a lava flow, to a scenic "cove" area defined by juniper and pinion trees growing out of the defining lava wall. A tennis court is roughed in for recreation.
Property Development
The Cavity Wall System will be employed at its latest stage of development on 6 acres of land in order to gain knowlege and experience for training skilled professional crews.
Invested funds are transformed to increased real estate equity through developing the property.
Due to the efficiencies of the development, the equity is planned to increase two dollars for every invested dollar.
By implementing solar energy, wind, gray water recycling, composting, peat filters, and greenhouse gardening the focus will be advanced simple living.
A simple one way slab designed 40' x 19' cabin (a concrete cabin?) will be built first to gently set the legal precedent for this system in New Mexico. That should either ease most doubts and give great breathing room for progress or shut the effort down as a well intended but not good idea. Counting on the former, then a production and dormitory facility will be built for year around panel production.
Divisions (after completion of precasting dorm facility)
A manufacturing division precasts lightweight concrete building components that work with a simple geometry for versatile applications.
A Design/Engineering division designs structures utilizing the precast components.
A Construction division builds out the projects.
The combined company will operate as a "C" corporation. This will allow it to operate initially in an owner built fashion that will streamline and economize moving forward.
Ownership
Consultation with lending institution to form most desirous entity.
If C corporation is decided, ownership will be apportioned to shares held by contributing parties representing contributions of professional services, cash, real estate, and assets comprising the corporation.
Marketing
Initially, the best marketing tool will be a third party building professional confirming the virtues of the system. This will be evidenced by the approval and sealing of the plans by a New Mexico licensed professional structural engineer.
The lowest common denominator is still seeing is believing. This is an innovation that will crawl before it walks, walk before it sprints. Marketing will first depend on artistic technique to maximize the aesthetic potential of glass smooth cast concrete. An attunement to popular taste needs to be formulated. With the booming new business of decorative concrete there are becoming more and more interested experts. I have visions of appearances but have not been able to fully develop the talent to bring them to fruition. Basically the appearance of sliced and polished petrified wood is what I seek. A mottled coloration akin to a Utah sandstone landscape is soft blended natural pastels, like looking into Canyonlands. Concrete needs to go from an institutional association to a natural organic perception.
In the west with higher elevation and colder winters the south facing wall will be encased within an attached solar greenhouse. That wall ideally would be a flat black. To maintain artistry variations into purples, browns, and other dark colors for some type of exotic swirl effect offer minimal drop off in heat absorption. To achieve the appearance of striated mottled natural stone is the goal. The only sure fire route to optimal success is experimentation. Besides being highly functional, the system is capable of stunning presentation.
Demonstrated aesthetics, durability, performance, and economy will be the no brainer marketing impetus. As the economy worsens and change becomes more imperative, this will be the timely solution. The novelty of experiencing this type of house will make a powerful impression. The megamass gives a feeling of security and well being seldom experienced. The difference between nailed sticks and cast in place concrete is literally awesome.
There is also the potential for making a movie illustrating how adopting and changing to this mode of construction can provide a solution for affordable housing and climate change. Past construction emphasis on a thin veneer aesthetic, whether a coat of paint or thin gauge siding will give way to durability and performance many orders of magnitude superior to the current practice.
A good question is does one start cautiously with a minor effort or boldly with a full commitment? That answer depends on how solid the fundamentals are. Does this engineered connection system really demonstrate a superior use of materials? Can this really be understood and verified? Does it satisfy one's common sense? Can one say, "Well, but of course". It just depends on where one's aptitude lies. The case is made in simple calculations. Can they be trusted? Calculations are based on code experience derived by testing and observation. Factors of safety are built in. This system is not meant to satisfy code by barely squeaking in with some sort of subterfuge, but to greatly surpass it. Increasingly violent and out of season extremes demand this.
There are levels of safety in analyzing this system. The most safe is to dismiss it, if it's different why wasn't it thought of before? Why risk change. Don't tamper with the gravy train. We are fine. Let well enough be.
With record high energy prices and increases in all resources and commodities, maybe looking at superior resource utilization is will be a major criteria for investment. But do you understand it? Is it better to widely proclaimed or something that only the most discerning insight can reveal? The cycle of acceptance is purported to be, first, total rejection, second, a grudging tolerance, and finally, of course, we knew it all along. Can innovation escape that fate?
Pricing Strategy
Two integrated operations will comprise pricing. The first is the casting of Cavity Wall building panels. A 100% markup over costs of production, including labor and materials, will be the sales price of the panels.Currently, on a dollar per square foot of panel, a $3.75 per square foot manufacturing cost will translate to a $7.50 per square foot sales price.
The second component is the purchasing of the panels at the retail price by the construction division for use in the erection of buildings. The inherent efficiencies of the construction process will create a building that can also be valued at double the cost of materials and labor. Currently, a $70 per square foot building cost will make a building value of $140 per square foot. By no means is this documented. If comparisons are made 140 could be considered conservative. The inflationary environment we're moving into will favor bulk material procedures that minimize middle men.
History
For the past 18 years I've been developing this system. Most of the time was spent improving the molding process, which is the heart of the efficiency of this system.
I have built three structures. The first was a 19' x 16' stand alone building about 16 years ago. My begining generation molds were used. The building has required no maintenance except for renewing the roof coating one time.
The second was a 32' x 22' studio in Lakewood, Colorado. The clients prefered a truss roof to have attic storage.
The house I currently live in is an add on to my rammed earth experience and tieing into the first building.
The modular nature of the system geometry can be tricky to the designer at times. Full freedom to do what one pleases is not the case here. I've been designing buildings for this system for years. Like anything, there's a learning curve to gain proficiency. Experience has shown that no architect wants to make the effort to work with a somewhat speculative undertaking as this. That's okay. Design ideas will evolve. The system is based on simplicity for affordable housing and an escape from functional obsolescence. Basic designs approved by a structural engineer will suffice in the beginning. I already have plans for a residence and multifamily units.
Construction
Utilities Installation
Installing a septic system and well pump will be the first focus. All the necessary distribution trenching for power, water, septic, and phone will be completed and stubbed out. This will enable surface restoration as quickly as possible and minimize future excavating.
The maximum capacity to stay in a residential non commercial mode is a total of 24 bedrooms being the total for everything to be built. Currently, one bathroom is planned for each bedroom. The New Mexico design water flow rate for 24 bedrooms is 1,950 gallons per day. The three acre water foot right is equivalent to about 2,900 gallons per day. In reality, water consumption will be drastically less than that but that won't affect the design requirement.
Currently, there will be two bathrooms in the 40' x 19' cabin, 13 in the manufacturing-dormitory facility, and five bed-bathrooms in a planned future residence for a total of 20. The residence will be built form funds and labor gained by training new crews. So one more 4 bedroom structure would still be possible.
Building Begins
Footing excavations will be prepared. My dirt screen left over from my rammed earth days can be used to separate lava rock and generate clean soil.
Conveyors will be set up on a flat area and immediate casting will commence. Eighteen inch square pavers will be set down to provide a mud free work area and stable conveyor support. An 18' x 11' x 12' high cabin will be constructed first for solid shelter. Currently, a 30' RV is on the property. The building experience of the first cabin will be evaluated and areas for improvement will be sought.
Besides walking through beautiful countryside, there are few recreational activities. One available outing is to bicycle to the top of the Capulin Volcano, once the monument has closed. It's an ideal pursuit for cycling enthusiasts. My favorite recreation is tennis, and a flat court area has been bulldozed in, 120' x 60'. Precise concrete flatwork will be required for the production facility. Installing a post tensioned concrete tennis court will be a perfect warmup. This will create a refreshing break to have an athletic respite located in a picturesque semi-wind protected cove.
The completion of a cabin will offer an example of "tires to kick". In the lead up to the 8,000 square foot production/dorm facility the CWS will be vetted. The casting will still be outdoors however, and testing of panels to show consistent strength will be important and more difficult to achieve. For code compliance and credibility with architects and engineers showing consistency is tantamount.
Temporary solutions from suspended tarps for covering conveyors to fend off preciptation will need to be employed. There is an assortment of accelerating admixtures (cement reactive chemicals added to the concrete mix) to aid the cause. More savvy than meets the eye is required for excellent results. The area is usually dry until August so a majority of casting should be completed by then. In my experience, only nightly subfreezing temperatures have proven to be imperative to deal with. Pozzutec 20 has proven to be the best non chloride water reducing accelerator for all aggregate type.
Building the cabin will demonstrate the natural coolness during the summer but one will have to wait for winter to learn their heating performance. Heating is based on two inputs. One is an attached glazed south wall greenhouse with trapped heated air being blown under the slab via high efficiency reverse curved impellor blowers powered directly from photovoltaic panels.
The second input is a rooftop mounted parabolic focussing solar hot water unit to circulate hot water into the water resevoir under the slab, contained by the ground at footing level and the foundation walls. This takes advantage of water holding four times more heat than rock, concrete, or soil.
The ratio of the east west orientation axis to the north south axis determines the solar input to heat loss proportion. The Phi Ratio, also called the Golden Mean, of 1.62 to 1 is a good default value. For a single span building, a two to one may be the best to allow the slab to be designed as a one way slab.
Whether building this facility should be a separate financing or stock offering will depend on the confidence of the participants. One may want to wait for lessons learned from cabin one or decide economies of scale are best served having as much concurrent work as possible.
However, issuing stock usually has six month intervals as the minimum time frame between offerings. The mode of financing will of course be a major variable.
Negotiating the quality control issue from outside panel casting is a priority throughout.However, on site testing equipment can provide close scrutiny.
An alternative would be to install a low cost steel building. However, that would not fit in with the property as it would degrade the exotic nature. The labor to erect it and dismantle it feels like it would be a waste to me. I could be wrong though. Dealing with the elements is no doubt a challenge and in this case it would provide a wider range of experience to be more knowlegeable moving forward. I've dealt with extreme environment on my mountainside at 9,000' all through the development process.
Building the facility will offer efficiencies. First, once the floor slab is completed, the casting operation can be moved upon it. At that point, completed panels can be placed directly into the walls, minimizing handling. With everyone concentrated in a single area, speed and awareness will be enhanced. The efficiency of the entire process will come into sharp focus.
Upon completion, the gained data and experience will enable accurate estimating for future projects. Rapid expansion will be possible. The facility will serve as training quarters to empower satellite operations. Before, or concurrently, the first real house can be built on the property. That will yield the first real "model home" to show precisely what clients can expect. Performance and economy will propel marketing. When that proves successful, the company can issue a public stock offering which should greatly reward initial investors.
These are "forward looking" statements based upon best available current insight. There is a chance that ill timed circumstances will thwart the execution of this plan. However, the real property equity achieved by the planned improvements should maintain as sound collateral, but maybe not.
Business Organization
Initial Equity
The initial equity is the patented system, property, equipment, designs, and experience that I bring. However, that is of little value without the understanding and support of a licensed structural engineer. His/her comprehension will define the precise applications most suitable for the CWS. It is the structural engineer's approval that gives value to the inventory of product. Generating product daily knowing that application of the product is legally sanctioned gives a robust attitude to the success of the operation.
Financing
My great preference is to initiate this as a grass roots movement without needing "outside" investors. Effectively the startup will be generating 14 living units necessitating an investment of approximately $560,000 = $40,000 per unit per investor. Because expansion may come quickly, the experience will prepare one to operate on their own subsequently. The investment would be secured by shares of stock in corporate ownership of the real estate and improvements. Share amounts would be weighted to maintain control in the hands of the CEO and structural engineer but initial investors would comprise the board of directors to give everyone voice. Savings and efficiency in everyone being an "owner builder" and minimizing insurance obligations allows full focus on the task at hand.
The validity of this investment opportunity is based on my experience with the system with the belief that is truly a superior tool to meet the demands of the future. I'm not experienced in other methods and may be understating competitive products and systems. A large component of system endorsement beyond myself would hopefully come from the structural engineer with from knowlege of other systems. My assertion is that the structural strength (stiffness or moment of inertia) from this system is greater than any other system. With that advantage, success should be greatly enhanced.
Another financing option is bank financing with a partial loan amount guarantee from a USDA program. This option would take on greater weight if it becomes too difficult to attract owner operator corporate investment.
Income
The most immediate income would be from licensing the technology specified in patent number 5,802,793. The conservative nature of American construction makes this a long shot as attempts to present the opportunity have not been successful. It will most likely require a track record to garner interest. That's too bad for potential constructors as change should be sought out and nurtured.
Two main income streams will be from precasting wall components and building with them. This should come as soon as the precast facility is completed. Seeking fourteen hands on corporate share holders will contribute eight to the physical working leaving six to promote the business. This promotion will be to book workshop seminars to train people for expansion. Normal fees for this type of hands on training will help generate cashflow for continuing operations and funding new construction.
Fees for professional design and engineering services will assist.
Original investors will receive dividends on their units being rented out to workshop participants.
As the group progresses, a movie will be planned and made illustrating successful applications utilizing the system to bring about change in the green and self reliance field. Competitions can be staged for the fastest crews.
The model of 100% markup on wall system precasting and similar margin on construction will provide ample profitability to attract more investment for expansion.
Structure
Prudent business structure would probably dictate a "C" corporation to hold all assets, and a separate corporation to which the assets would be leased and business operations conducted. This would isolate the assets from liability incurred by the business operation.
Personal Credit
I have a current debt of about $18,000 which mainly consists of patent fees and property improvements. My current residence needs roofing work and rammed earth wall repair of about $7,000, necessitating an immediate cash infusion of $25,000. My credit score as of July 2008 is 762. Part of the fourteen $40,000 individual investments would include $3,000 to purchase the property from me to the corporation. The resultant $42,000 would allow me to do maintenance on my present homestead to be distraction free in New Mexico. It would also cover the relocation expense of materials and equipment.
Management Structure (hypothetical at this stage, subject to opinions from initial investors)
CEO
Board of Directors
Casting Manager
Construction Labor
The simplicity of CWS allows a wide breadth of people to work. From couples, families, educated, and uneducated, a positive attitude can qualify most everyone. Despite the basic mechanics of the work, extremely competent supervision is required. A single mistake in panel placement can cause problems. The supervisor needs to fully understand the plans, and assure that plumbing and wiring is done correctly.
Because of the extraordinary accomplishment and progress building with the CWS offers, it's an excellent tool for instilling worthiness in people whom life has shut out from opportunity. People released from jail I feel could be greatly rehabilitated by seeing for themselves the productivity they can manifest. Veterans returning from military service can process the trauma out of their system by pouring themselves into building what will give great benefit for a very long time. The physical nature of handling these materials will be a great physical workout everyday, and in my belief and others, if it's physical, it's therapy. The repetitive experience of accomplishment does more to reinforce self esteem than anything else I know. As the workers gain experience of coordinating housing systems (electrical, plumbing, etc) into their work, a thoughtful multi-tasking ability will develop.
On the concrete construction side, the ability to form, pour, and finish a flat level concrete slab very quickly grows to become a most worthy art form. The successful completion of that job is the most critical aspect for efficient wall building afterwards. Learning to imprint and color concrete, along with acid staining, offers excellent opportunity to discover artistic talent. The artistry applied to this restrictive building system will be a key ingredient as to its' perceived value and profit to the company.
Insurance
Besides required workmen's comp insurance if required, (other than shared corporate ownership owner builder status) there is little else to be insured. The inherent strength of reinforced concrete will protect against natural climatic hazards. Starting out in a remote area with full time presence should eliminate theft and vandalism vulnerability.
Construction accidents have been on the increase in standard construction, especially blowouts when pouring concrete. These have been due to faulty supervision and design of the forming and shoring (vertically supporting loads) for concrete slabs. This form of temporary support, not having a rigid enclosure bracing the forming system allows for lateral shifting. The forming system employed by the CWS is secured to already poured reinforced concrete beams. Special techniques unique to the system will provide extra strength and safety.
The CWS is a different superior approach. Concrete columns are poured within a super strong stay in place concrete form. After adequate strength gain, a top bond beam is poured within the same enclosure, already strengthened by the column pour. After this reinforced concrete monolith has strengthened, the ceiling slab is formed, supported and braced by the existing concrete framework. Already very solid, the ceiling slab pour has superlative strength of containment with the possibility of lateral shift eliminated.
A construction process offering levels of enhanced strength and safety throughout the sequence relieves worker stress and allows a more focused application of effort.
Since the panels in their uninstalled state are cement based, exposure to weather does not degrade their integrity. In fact, cement products each time they're exposed to moisture become stronger, as the fraction of unhydrated cement lessens. That means that even in the highest quality concrete, there is a small percentage of unreacted cement that is hydrated (cement's reaction with water that gives it its' strength) with a subsequent exposure to water.
Fire Risk
The longest fire rating available, 4 hours, is given to a two inch thickness of lightweight concrete protecting concrete steel reinforcement. The reason is that in normal weight concrete, the density eliminates capillary passages from which a heated air pocket would be able to discharge its accumulated pressure as the pocket heats up. This pressure can blow out a chunk of the concrete, immediately weakening the structural integrity. The more "popcorn" irregularity of lightweight concrete provides a capillary route to the outside, allowing any pressureized areas to "bleed" the pressure away.
In many rural areas, proximity to a "rated" firehouse is too far, resulting in exorbitant premiums greatly damaging residents' budgets. It's now possible to have a peace of mind knowing that one has a residence secure from devastation. The threat of wall electrical fires is eliminated. Rodents are not able to penetrate through. This degree of structural soundness virtually makes insurance obosolete. One only needs to be prudent with flammability choices of contents for one's home.
Daily Operations
Daily Casting Operations
One is greeted in the morning by all the molds cast the previous day. Panels are removed from the molds, with the panel being placed on the slot sawing station, while the mold is cleaned, sprayed with release agent, and placed in queue to be filled. It's a routine and easy procedure. The completed panel is placed on a pallet, and once full the pallet is taken outside for its curing and drying process. The high water retention in the lightweight aggregate assures a thorough moist cure.
Concurrently, the mixer is kept supplied with 5 gallon buckets of lightweight aggregate and sacks of cement. Enough manpower is supplied for smooth proceedings, somewhat depending on the awareness of the workers to be flexible to give assistance where needed. The determinant of pace is set by the mixer. On the average, a mixer load will fill about nine molds. The mixer hopper loading feature allows immediate refilling with only about two minutes mixing time before discharging and mold filling can resume.
Construction
During the first phase of development, casting and construction occur together thereby allowing completed panels to be immediately placed into walls. Two people should be able to install the panels as they're generated. Otherwise, on remote sites, pallets of delivered panels will be handled by a crew to meet the time frame of the project.
Design
An important component of ongoing evolution will be the creation of more panel designs for various applications. The development of new panel pieces for arch window and door ways and other decorative flairs will assist aesthetic enhancements. However, the inherent simplicity and economy of the system will not be diminished.
Plumbing, electrical, and other systems don't happen succesively but concurrently. Precise planning in the design phase is required so these operations are understood and successfully installed. One does not simply frame a building and rely on plumbers and electricians to make their installations one way or the other. Plumbing runs with pex pipe are made through conduit through slabs. Electrical runs are made through specified sleeves cast in columns and beams.Completed designs are best constructed on a volume basis so familiarity enhances efficiency and the extra time spent detailing is amortized over many units.
An architect, designer, engineer will form a critical aspect for the expansion of the building system.
Transportation
A maximum standard load is 48,000 pounds. Using a panel weight of 15 pounds per square foot 3,200 of panel may be shipped per truckload. I've received a quote of $1282.71 to ship at a 300 mile radius from Capulin, NM. That's 29 miles east of Raton and 38 miles away from the New Mexico/Colorado border on Interstate 25. That works out to 40 cents per square foot of panel. Per mile, it is 0.00133 cents per mile. Extrapolating, a thousand mile transport would be $1.33 per square foot. With a sales price of $7 per square foot, transportation adding $1.33 for 1000 miles, that's a 19% transport overhead. The longer the haul, there may be a discounting of that number.
An approximate rule of thumb is 3.5 square feet of panel per square foot of floor space, using a 9' 4" interior ceiling height. Shipping can be estimated at:
house square feet x 3.5 x 1.33 = $4.65 per square foot of floor area per 1000 miles (with rising fuel prices this may need increasing 15 to 20%)
Conclusion
The emergence of this system has come from the rarest of circumstance. My dogs and I started out in a tent and "just did it", establishing a toehold and moving forward. It's now or never to harvest the fruit of the adventure. I'm truly "painted into a corner" with this. A favorite quote of mine is from C. G. Jung, "Not out, but through!". The meaning of my life is wrapped up in this so I'm more than determined to see it through. In a strong way I've intuited this time of profound change since graduating college. This was not an intentional outcome. It revealed itself through a continuous period of persisting in what was under my nose.
I don't see any down side to this, for the worst possible outcome will be to have high performance low cost buildings that nobody likes nor understand. That won't diminish from the building however. The humanity of life is having a substantive thing to do and sharing it with all takers.
Being more dependent on Nature brings environment back to the forefront of awareness. Living in stewardship with Nature I believe creates a saner more fulfilling life. This is in contrast to dominion over Nature where we mechanically and energetically find ways to trump Nature's offerings. I believe this alienates us from our ancestral history and instills a lonely form of disconnect.
Time I spent in Nepal allowed me to witness "third world" construction practices. The involvement of villages and extended families engaged in a "beehive" of activity was very impressive. It was virtually silent as everyone performed seemingly automatically. I hope my system can empower a similar quality of productive social interaction.
The bevel cut stone motif of this system can become a symbol of eternal vigilance to the environment and each other. My fervent hope is to offer a tool to raise the lower end of humanity. It simply requires a tool that everyone can handle which makes the most efficient use of resource and bulk materials from any locale.