Sustainable Luxury – Blog

Rammed Earth Tyres 2

Well, the second layer of tyres are laid – this time filled with the local clay
Various tools were used, concrete tampers (square and round), and sledge hammers large and small.

Tyres rammed with clay

Tyres rammed with clay

The time this process takes seems to be a little over an hour per tyre and each one will take about two barrowloads of material. It’s surprising how much they fill out – rather like an overinflated tyre, even though the top surface is exposed.
My friend seems to have the superior technique – using the small sledge hammer, hitting sideways to pack the profile first but I’m hoping another method will present itself because of the heavy effort involved.
It’s a very labour-intensive process so I’m glad this is as high as the tyre wall will be.

wall 2, second layer

wall 2, second layer

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Chair Restoration & Reproduction

When I was smaller I found an old chair and had it in my bedroom for many years, but one day it succumed to woodworm and fell apart. I couldn’t bear to throw it away and so put it into storage until I could repair it.

I liked how the chair was small, efficient, recined and it’s 30′s Art Decco, almost Arts and Craft in style. Under the cerise upholstery I found a wild, flamboyant designed fabric on a ochre background (which sadly was stained with the secondary upholstery that was once on top).

A couple of years back I apprenticed myself to a local joiner who allowed me the use of his workshop. I resolved to restore the chair and duplicate it as an exercise.

Original and Reproduction Chairs

Having copied the pieces I dissasembled the rest, copied them, replaced the dowels and glued the base of the chair together. The seat and back were too far gone so had to replace them using locally grown Elm and Ash I’d seasoned myself.

I’d always wanted to sit in a house I’d built, in a chair I’d made using materials that had grown around me. I’d seen dead Elm trees standing for many years – the ‘disease’ having killed them off well before they were able to mature to any size. I reasoned that they must have dried quite a bit just standing there off the ground so brought a few in to dry some more.

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Here are some of the pieces being readied for assembly. The wood which has the red colouration I cut from a really old Jarrah railway sleeper which must have been brought over from Western Australia over 100 years ago. I undertsand it’s one of the densest hardwoods out there – it certainly is heavy!

Here we have all the framework finished. I was relieved to find that the seat reclines as smoothly as the original did.

First repro chair frame

First repro chair frame

 

I neglected to take many shots during the upholstery stage. I had ‘spring units’ made up to my dimensions, stretched hessian over that, fixing it all down with tacks, cushioned everything with recycled cotton stuffing then stretched calico over all and stapled the edges.

The second reproduction chair I made was Jarrah - Eucalyptus wood, from a railway sleeper. I like the idea that at one point this timber was brought over from Western Australia, used as a sleeper for a hundred years with thousands of trains running over it and was now a chair.

Since Jarrah is  most impervious to water damage, they didn’t bother to impregnate these sleepers with bitumen – I’d hate to have a chair stinking of bitumen!

Jarrah Chair - side panel detail

Jarrah Chair – side panel detail

Above shows the side panels which I took from a slice of the outer part of the sleeper – a part that had some slight water damage which causes the dramatic black stripes. I’d already featured Oak that had fungal damage creating the flame like side panels so it made sense to feature the stripes here.

so, right now all three chairs are at the calico stage. I have the finish fabric for the three but I cannot afford a nylon tipped upholstery hammer, they’re about £50 – anyone want to help me out?

Stuck at this stage:

Awaiting finish fabric

Awaiting finish fabric

 

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Rammed Earth Tyres

Rain got to one of the rammed earth walls (built using the shuttering method, not adequately protected during the winter).
Replacing this now cracked and crumbling wall proved to be the opportunity to try the tyre method or ‘earthship’ as it’s become known.
One of the benefits of this method is that the rubber seems to provide it’s own damp proof course.
Anyway, we’ve only just started, here are a few pics.

We put a small initial layer of shingle on the ground for fine leveling purposes then half filled the tyres with shingle, topping up with type 1.

 

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Straw Bale Wall Experiments

Since I am warming up to replacing my parents house with one made using straw bale, it seemed like a good idea to familiarise myself with the technique.
I’d read a fair bit and was most struck by the houses in America that had been built of straw that were still standing 100 years later.
We replaced the wall of one outbuilding, used the ladder technique on top and below to allow ventilation (below protected from vermin by a stainless steel mesh) and featured arch-topped ‘window’ elements.
Bales are laid in courses like bricks and staked using hazel stakes. Short end bales are made using a ‘bale needle’ to make two shorter bales of appropriate length.
The top of the wall is protected from the elements by a cedar shingle ‘short roof’

 

 

 

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Rammed Earth Experiments

I’d read that the western end of the Great Wall of China was made using the rammed earth method (not sure about the accuracy of this, they certainly seem to have used earth bricks).
The RE method seemed good in a number of ways but to me, mostly because it was a free building material. I understand the cost of building a structure is roughtly 30-50% labour and the rest is materials. So if I wanted to build a house myself, that’s a 50% saving and if I could get free materials then great.
I’d read about the benefits of having a certain mix but I didn’t want to increase the already high amount of labour involved so opted for a straight mix of the local material – clay.

Since it was an experiment and I didn’t want to risk a new dwelling, I opted to modify one wall of the generator shed, hoping at the least it would help improve soundproofing and reduce vibration.

generator shed

generator shed

the rough method is to shutter an area you want to be a wall at a fixed width, this width is determined by putlogs which hold the plank shutters top and bottom and provide a fix for the next layer of shuttering, thus:

Rammed Earth Experiment

Rammed Earth 2nd layer

Then, fill the shuttered space with earth and ram it using, well, on this wall I used a sledge hammer because the roof was already in place and I didn’t have space to use a cement tamper. Since this time I’ve bought a sand rammer (usually used in ramming sand into moulds for casting iron) with varying degrees of success and later, better results with a pneumatic chisel using a tamp head.

I am given to understand that the removal of the putlogs after the wall has been built accounts for some of the holes that may be seen on castle walls about this country (not to be confused with the more obvious beam holes for floors, etc.). Some architects(?) choose to leave these wood putlogs in to assist later maintenance as in the mosque at Djenne

Rammed Earth

Rammed Earth fifth layer

Because I wasn’t going to mess with the original roof of the shed, it rather got in the way of the ramming so I finished the job by using the straw bale wall method:

Composite rammed earth/ straw bale wall

Composite rammed earth/ straw bale wall

Then we rendered it with lime-putty plaster:

Lime Putty Plaster rendering

Lime Putty Plaster rendering

The plaster filled the cavities in the somewhat dry and crumbly wall, really solidifying it.

composite, plastered wall interior

composite, plastered wall interior

We left the interior intentionally lumpy so as to best absorb and deflect the noise waves coming from the genset.

 

Finished Composite wall

Finished Composite wall

I unfortunately lost some shots about the time this wall was finished, this is the closest to that time I could find.

The horizontal slates mask the DPM along the bottom.

 

 

 

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Power Generation

Electricity is somewhat a contentious issue here
I’d really like to say that it was provided from all renewable sources
It isn’t but I’m working on it.

A little history:

Since we’ve lived at this secluded site there has never been and never was any mains electricity hooked up.
The generator left here by the previous occupants was a Lister-Perkins diesel job, the rest of the specs of which are unknown to me. It was mounted on a concrete plinth in a ‘generator house’ and may have been there since the war. I do recall that it couldn’t manage to run an electric kettle – we plugged one in once and all the lights went out!
It had no electric start, I used to have to come home from school and crank-start that thing – it was the cause of many osteopath visits in my youth.
Next up was another Lister. This had an electric start which worked intermittently.
Please bear in mind that none of us had any previous experience of generators so maintenance was reluctant and infrequent.
Our third set was an Iveco, it was a 3-phase, 3 cylinder, 25amps per phase, a real beast, uneconomical and expensive to maintain.
Iveco 3 Cylinder with a Cummins alternator
I learned quite a bit from this machine, changed the water pump, took the head apart and so on.
The Iveko died after about 150000 hours. We had reduced our diesel consumption by fitting a battery and inverter system but not soon enough for that genny.
Right now we’re running another Lister. It’s great, a single phase setup, this time with 83.3 amps but it’s reliable. It’s previous incarnation was in a government fish hatcheries agency and had only run for 10 hours as a backup.
Lister-Perkins 3 cylinder single phase 83.3amps
We run it for 4 or less hours a day to mainly charge the batteries.

 

 

 

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First Post

Ok, after a fair bit of hassling, pressure and kind encouragement I’ve finally got this blog working.

I’m hoping this will be an outlet for and encourage areas of creativity which I’m interested in.
Right now, these include:

furniture making,
straw bale house building,
rammed earth walls,
alternative power,
wood gasification,
rocket stoves/mass heaters,
off-grid living,
sustainable lifestyles and other areas I can’t remember to mention right now.

 

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