Difference between revisions of "Giant Compressed Earth Blocks"

Latest revision as of 09:21, 20 September 2010

Giant Compressed Earth Block (GCEB)^[1] provides a low cost, environmentally friendly, natural alternative to conventional building materials. GCEB are formed using a technology developed and patented^[2] in 2008. The objectives of Giant Compressed Earth Block construction are to simplify the construction process, increase the speed of construction, reduce overall construction costs,^[3] increase thermal mass and energy efficiency,^[4] and increase structural strength.

Giant Compressed Earth Blocks are made of raw earthen materials that are similar to those used in compressed earth block (CEB) and the materials are compressed, hence the name Giant Compressed Earth Block. Giant Compressed Earth Blocks are, however, vastly different from CEB in three significant ways: the size of the blocks, the manufacturing method, and the placement method.

Size: CEBs typically weigh less than 40 pounds per block and must be placed into a wall system using manual human labor. GCEBs weigh more than 500 pounds and heavy machinery must be used to lift and place the blocks.

Manufacturing Method: CEBs are formed in a mold and, with each compression stroke, a CEB block is created and ejected. Giant Compressed Earth Blocks are formed within an elongated chamber as raw materials are compressed together in small increments and extruded until a giant monolithic block of the desired length has been manufactured. The patented machine process is trailer mounted for onsite manufacturing and the resulting blocks are very large, modular, smooth sided, highly compressed, and very strong. These characteristics make the blocks ideal for construction purposes.

Placement Method: CEBs must be placed into a wall system with manual labor. GCEBs must be placed using a specialized lifting device powered by construction equipment. The types of equipment that may be used include skid loaders, backhoes, excavators, 4X4 wheel loaders, and hydraulic truck cranes among others.

Two of the main objectives of GCEB construction are to simplify the construction process^[5] while increasing the speed of construction. The GCEB building process can be compared to building a structure with giant “Lincoln Logs.” Building with giant modular blocks simplifies and speeds construction by eliminating hundreds of manual activities that are necessary for conventional construction.

To understand the size difference between CEBs and GCEBs, see the standard 10 inch by 14 inch by 4 inch, 40 pound CEB in the photo below. The CEB is lying on an 18 inch by 12 inch by 14 foot GCEB.

Economies of Scale

Materials account for a relatively minor percentage of the cost of GCEB construction; therefore, using the largest suitable block size for the project is the most cost effective way to build. Use of larger blocks can reduce construction time by half and significantly lower construction completion costs.

There are three methods of stacking the GCEB when building. Because GCEB are extremely smooth, the blocks may be “dry stacked” which means that they may be stacked one on top of another with nothing between the blocks. This will likely be the preferred construction method in California and other places prone to earthquakes. Dry stack placement requires the least amount of manpower. The second stacking method is to wet the blocks with water between rows. Wetting the blocks causes the GCEB to bind together into a monolithic wall structure. The third method is to apply a thin slurry between layers. Slurry will be used most often when foundations are not level.

GCEB blocks are ready to be placed into a wall system immediately after being manufactured. No curing is necessary. The vertical joints are mortared just as with CEB or brick, but the small number of large blocks reduces the number of mortar joints and thus reduces the amount of time required to do the mortaring. Manufacturing GCEBs to specified lengths facilitates placement of windows and doors.

GCEB blocks are easily shaped into columns, nooks, and arches, and can be incorporated into any architectural style, which allows maximum flexibility to meet changing floor plans or conditions on the job site.

Uses of Giant Compressed Earth Block

• Energy efficient housing – GCEBs provide excellent thermal mass and work well with passive solar designs. GCEB construction minimizes air conditioning and heating requirements.
• Robust housing – GCEB construction is resistant to high winds making it highly suitable for areas that are subject to hurricanes and tornados. GCEB do not burn making it highly desirable as a building material for areas prone to wildfires.
• Commercial buildings – Large projects can be quickly constructed. Taking advantage of local soils for onsite production of GCEB results in significantly reduced shipping and construction completion costs.
• Military applications – GCEB can be used to construct housing, blast walls, force protection structures, and hardened command centers. Using local soils avoids shipping construction materials around the world.
• Infrastructure – GCEBs work well for highways and airport subgrades, highway safety barricades, fences, dams and levee construction, retaining walls and slope stabilization, and hazardous waste and low level nuclear waste containment.

Advantages of Giant Compressed Earth Block

• On site manufacturing process uses local earthen materials
• Very energy efficient manufacturing process
• Synchronized manufacturing and placement process – GCEB is placed into a wall system immediately after being produced.
• GCEB block length is instantly variable to fit varying construction demands
• The GCEB building process is simple and requires very little manual labor – 99% of the manufacturing and placement work is done by machines.
• Resource efficient – GCEB construction helps to conserve other resources that are currently being over consumed.
• GCEB production and placement capacities are designed to fit particular projects. GCEB systems can be designed to produce from 20 tons to more than 200 tons per hour.
• GCEB construction is well suited to large commercial projects. As production and placement capacity increases, costs drop significantly.
• GCEB construction can be very energy efficient. Energy efficiency reduces the need for electricity and thereby reduces the amount of pollution that would be emitted with electricity generation.

Notes

1. ↑ http://earthcomegablock.com
2. ↑ U.S. Patent #7,311,865
3. ↑ http://www.nsti.org/Nanotech2008/showabstract.html?absno=70411
4. ↑ http://visionisgreen.org
5. ↑ Clean Technology 2008, Chapter 3, Green Buildings and Construction