Startup Builds Houses by Pumping Concrete into Inflatable Forms
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If you want a small, low-cost box structure, there are companies that will sell you one. Concrete.[1] Metal.[2] Steel frame with wood siding.[3]
[1] https://precastbuildings.com
[2] https://www.butlermfg.com/
[3] https://www.homedepot.com/p/Rose-Cottage-2-Beds-443-3-sq-ft-...
If you then have wire conduits and junction boxes built-in, you are a lot closer to a livable home. Perhaps floor assemblies with hookups for plumbing.
I'm not sure why these things aren't standardized to be the point of plug-n-play. A lot less work for the tradespeople maybe.
https://www.liebfertighaus.at/wp-content/uploads/2019/05/Ado...
https://www.google.com/search?q=fertighaus+teile&tbm=isch
There are some efforts now being made to reduce the amount of concrete and build with more sustainable wood.
You get what you pay for.
If you have the foundation already done, then the assembly of the rest of the house takes around 3-5 days
Random promo video of one company: https://www.youtube.com/watch?v=KqAxoBAE2pc.
A prefab house design will typically be replicated in several projects / cities, usually with a few customisation options. Different prefab factories have different levels of standardisation and automation. The prefab production lines I designed long ago for example used fully parametric designs to offer standard concepts sized to fit. At the time (~10-15 years ago) a novelty, by now must be pretty standard.
Do you have any links to learn more about your prefab designs and a company that assembles these designs?
Wall assembly is zip->10 inch blown in insulation around 10inch I-Joist -> OSB -> 2x3 interior wall studs to hang your sheetrock off of and run utilities. (All pre-drilled for faster running of pex and conduit.)
You do have to do all the interior work after, though.
Note: Yes, I know zoning and planning etc are still the biggest hurdle.
Building tall buildings is not a rocket science. Look at Burj Khalifa‘s construction: clever designed crane, lots of rebar and extremely powerful concrete pumps. And it’s really fast. One year to build enough space for thousands of people.
Building Tall building isn't Rocket Science, but building them fast, high quality ( comparatively speaking ) and cheap has not been done yet. And one year to build space enough for thousands of people is not my definition of fast. At least building "On Site".
Burj Khalifa does not have a severage system. Trucks are used to take the human waste away every single day from burj khalifa.
I figure the problem is basically politics. Liberal democracies typically do planning by asking 'stakeholders' (e.g. business owners, home owners, etc) what they think about proposals. Since you're asking the stakeholders in an asset class whether or not you should build more of their asset, usually nearby, the answer is usually a lawsuit.
From what I gather, a industrial-scale air-conditioning unit company basically broke the space open, since they were essentially doing large scale prefab construction already.
Just think about it from first principles. You can build large structures out of prefabricated parts, and if you design the parts sufficiently well, it's possible to fit them together fast. The problems are stuff like weight (transport costs start to dominate), volume (if there's not enough demand for skyscrapers, you don't want to be sitting on a skyscraper factory), etc.
In East China, they have a lot of structural advantages: a huge, hugely dense population, a government that loves big construction projects, a massive housing market, a great deal of experience in doing civic infrastructure fast, etc.
https://inhabitat.com/the-incredible-story-of-how-the-burj-k...
And the wonderful solitude and quiet of my old house in a dying town contrasts sharply with my college years living in apartments.
Some of it is the rhetoric about owning a home being part of the American Dream. Some of it is about the nature of the US housing market being a such an avenue to wealth (Americans have a disproportionate amount of their wealth wrapped up in their home). Some of it may be the individualistic mindset.
I would love to live in an apartment complex in, say, Sweden, but there's a huge cultural component to apartment living in America that would have to change before it matches apartment living elsewhere. Even if building codes changed tonight it would still wouldn't address the issues of city design/public transportation that hurt the very notion of living that tightly together to begin with. It's just not at all convenient to live in an apartment complex that's miles away from the nearest public transportation hub or even a strip mall.
These sound like wild assumptions with nothing to back them up.
https://basc.pnnl.gov/code-compliance/air-sealing-and-insula...
"Many builders are insulating these walls fully for sound proofing purposes per the International Building Code (IBC), Section 1207, Sound Transmission walls, partitions, and floor/ceiling assemblies separating dwelling units from each other must have a sound transmission class (STC) of not less than 50 for airborne noise when tested in accordance with ASTM E 90."
Also the comment I replied to said 'americans' not 'in america'
This is not unique to America, all the countries that went through rapid urbanization that moved millions of former farmers from detached homes into city apartments have an archetype of a rural rube unable to accommodate to communal living with strangers.
There is perhaps some platonic ideal of an apartment where you can live a similar quality of life to a house. But in the reality that we actually live in currently, living in a house usually has a much better quality of life so it's natural that people would prefer it.
My SO and still think back to how great it was to have an apartment with a park next door where we could let our dogs run. They had more space there than our current home.
I've never seen a public wood fired pizza oven but community bbq's were pretty standard at our apartments in the past.
We have a community projects place that gives us the opportunity to do all kinds of woodworking (my personal hobby) without spending tons on equipment. Plus there's always people there more competent that I can learn from. We have a seed-sharing repository in our local library and the ag school has plenty of gardening resources.
I think what you're talking about is certainly possible, but it takes a concerted approach to meet the needs of a community. I tend to think people in the US prefer housing because there is a much more individualistic mindset combined with relative affluence that gives people the option to eschew many community approaches.
There are a few European countries where >50% of people live in flats: Spain for example. In Spain, however, the reason most people say they live in a flat isn't out of preference, it's because houses are too expensive. The other thing to note is that the European countries where flat habitation is popular tend to have interesting reasons behind it. In many cases, it's because they were built during the Soviet era.
I do think those community amenities are valuable, whether people live in houses or flats. I live in London, in an area with quite a good sense of community. I have an allotment, help at the community garden, live next to a very well maintained park, etc. but it really isn't the same as having your own private space. For example with the building stuff, I used to go to a Hackerspace, but I'm getting a lot more done now that I have a bunch of equipment at home. Simply getting things to and from my old Hackerspace was a nightmare without a car. Shared spaces also have rules which may not be compatible with what you're trying to do. My allotment doesn't allow irrigation systems, for example, so my little automated irrigation project in my garden wouldn't go down too well there!
Plus there are all these small things like talking to my neighbours over the wall, being able to easily get my bicycle in and out, not having to walk up 12 flights of stairs because someone is moving in and has the lift blocked, etc. One of my favourite things to do in this past warm summer was to just work outside in my garden, in the breeze, with my laptop plugged into my outdoor sockets, fast WiFi and the ability to just pop into the kitchen for drinks.
I'm not saying flats shouldn't be made more tolerable - but aside from density meaning you can live closer to the centre, is there any case where a flat is really a better quality of life?
Also an interesting thing to consider is: how different is building vertically with elevators, versus building horizontally with trains, anyway?
In general, though, density doesn't mean that you can't have yards. Do you need a front yard, back yard, and two side yards to set up a wood fired pizza oven, grow potatoes, and build things? Nope. Just a backyard could be fine. So you could share an exterior wall with your neighbors, stick your front door right up against the street, and do all the same things as a freestanding house but at lower cost and higher density. If townhouses were more of a thing, you could have everything you want, AND not have to drive. The only problem is zoning laws.
An interesting approach we used to have was where rather than adjoining gardens at the back, we'd put an path down the back of the townhouses between the gardens, with a door into each garden, so you could easily walk/cycle and, if needed, get equipment into your back garden. Apparently we stopped doing that because those alleys turned into major crime and antisocial behaviour hot spots, and people stopped buying houses with alley access due to people constantly jumping your fence and nicking anything in your garden that wasn't tied down.
Where I grew up was like a townhouse/semi-detached hybrid - the upper two floors were terraced, but at ground level there was a car garage that connected the street and back garden. A lot of people don't like that design because it's associated with council homes (mine was a council home), but I actually thought it was a best of both worlds.
Assume I have a detached home in the suburbs. How am I going to walk to the grocery store when it's miles away? How do I live without a car when there's no public transit? How do I get access to job opportunities, cultural experiences, dining options, and other amenities that come with close proximity to an urban core?
If your answer is "But my detached home is near the urban core!" then you're fortunate, but as large American cities have shown us that doesn't scale.
I live in London, in a suburb, but within a 10 minute walk, I have multiple pubs, doctors, dentists, restaurants, small supermarkets, library, community garden and - most importantly - a train station that takes me into central London in about 10 minutes.
The way we structure housing here tends to be arranged around lots of smaller satellite town and villages connected to a large city centre. Big cities like London will provide trains for commuters and going "out out", but in a smaller town you often live a lot of your social life more locally and might commute to work by car.
The other thing in the UK is our houses aren't particularly large. A terrace home might not be more than 50% bigger than an apartment, but you get a garden, driveway and actually own some real land.
I would dispute that "in London" actually counts as a suburbs. The real suburbs (the ones we'd need to build if everyone lived in a detached house) would be way out.
I’d love to have my own airport and marina, but I’m not sure that’s the goals we should be using to create a society.
You get neighbors screaming and fighting, playing music at 2am, apartments turned into meth labs with explosive toxic chemicals, dangerous predators can be right next door, people who don't take care of themselves and give your whole unit rats/bedbugs/insects, people who don't know you should fix water issues and cause mold, roof assessments that can be tens of thousands of dollars surprise! That you're forced to pay...
It isn't some fairy land where we all love plants and hold hands in our communal space - living close to other people IS failure.
We live in a society, and that means dealing with people. Even if you live in a place where the nearest neighbor is half a mile away, you're going to have issues with someone. We used to have issues with people riding dirt bikes and trucks on our land, kids breaking in to have parties in our woods, people with horses who shit on the streets, and lots of illegal dumping.
The world is full of shit heads.
Also a house blowing up due to cooking meth - down the street, which is not connected to your house - is a much better situation.
Dirt bikes and teenagers partying the woods is definitely the better option too, imo.
"We live in a society" - true but one of these things is clearly better than the other. It's just not very convincing to think people want to be stuffed into apartments.
In contrast, a fire chute is basically a giant convection tower that should spread smoke and heat across all the higher floors of a building immediately.
Make bigger trash chute doors, better bags, and smarter people, then trash chutes work. #1 is doable, #2 is hard because it's always a race to the bottom, and #3 is impossible.
Whatever Germany is doing, copy it.
This is also a scale where construction and maintenance is straightforward, and where the building makes sense in a walkable neighborhood (as opposed to taking 5 minutes to even leave the building).
So people focus on building houses because that is all you can build.
All this in Boston, at nearly $2,000 per month for a single bedroom, in the mid 2010s.
Conceptually, I’m on board with apartment buildings. I would like to think that the future looks more like Mister Rogers’ Neighborhood than the one that I lived in. But the people who evangelize high rise buildings must be either paying for a ritzy place or never actually lived in one.
> must be either paying for a ritzy place
Yes, a compromise for a more pleasant place to live is price. But a side-effect of more affordable housing is that nicer places also get cheaper.
Another compromise to get a nicer place to live for the same price is to move to less desirable location.
Remote work is the way to solve the housing crisis. There can be smaller regional clusters of people working in shared offices or small offices but there’s no real need for cramming people in offices in densely populated cities.
Free range chicken and cattle farms have minimum space requirements, yet human farms require people to sit in overcrowded spaces at least 8 hours a day every day usually limited to the space of a seat and a desk.
This isn't always the case even in smaller cities, let alone truly rural areas. I live in a suburban area of a small city and empty lots around here go for under $100k, and only the very cheapest houses built on top of them cost less than that to build.
Remote work is nice, but only a minority of jobs can be performed remotely; and there is a certain degree of economies of scale in "human farming" (nice phrase!), so I think the majority of jobs will always remain in denser areas.
Housing got totally out of control after this started. RTO is going to bring housing back down to earth.
Plus, an unreinforced concrete dome has to be one of the inherently least population dense structures, and density potential is probably as important a consideration in sustainability as actual construction techniques.
Edit: not necessarily a dome, but also not able to safely scale the structure very high with this technique without losing the only purported advantage, the low labor cost.
We're phasing out our 60 year old coal station given the sheer amount of solar power we now generate in W.Australia - but we still have 60 years of fly ash to deal with.
[1] https://www.abc.net.au/news/2021-09-18/geopolymer-concrete-c...
[2] https://www.mediastatements.wa.gov.au/Pages/McGowan/2022/08/...
> Plus, an unreinforced concrete dome
This is not a dome. It could conceivable be more population dense if/when they figure out how to magically get rebar into it :P. But that's not going to happen; and the real future benefits are likely going to be along the "working with nature" approach (where you use natural growing/expanding processes and direct them to suit your needs).
In terms of future human survival, I'm surprised there's so little shown or seen regarding underground living. While obviously more complex due to the excavation and reinforcement processes, the survival and energy benefits are much higher. And with modern light gathering/direction tech, it doesn't have to be devoid of daylight.
Thanks for the correction, I read the page without enabling JS on it, so the images didn't load, and every previous iteration of this technology I've seen has been limited to producing domes or arches. Nonetheless, even if you could, in practice, stack multiple floors using this new form, no developed country with any potential seismic activity or hurricane/typhoon threat will let you build multi-story structures like this (or perhaps even single-story ones), and I think you're right to use the word "magic" about using rebar with this, since installing rebar is a very labor intensive process, thus negating the only alleged benefit of this technique.
I’ll take tyvek and wood :)
Sustainable, innovative building structures that don't require energy-intensive and corrosive steel will depend on a convergence of strengthening technologies and archtectural techniques, maybe even including ones like described in the original article.
Considering all the environmental and social problems we have with modern housing and construction, this is a prime area for innovation!
https://www.architectmagazine.com/technology/two-natural-reb...
https://www.sciencedaily.com/releases/2021/01/210113090920.h...
Practical Engineering has a good video about it: https://www.youtube.com/watch?v=qL0BB2PRY7k
That 'V' in 'HVAC' must have an industry-specific meaning beyond "Ventilation" then.
Look at Passivhaus for the most extreme version of this. But even regular new build houses in the UK now have to meet air tightness regulations.
There’s all sorts of research into how to reduce air movement while still allowing water vapor to escape.
Ideally you'd have an airtight house and bring in fresh air through an ERV or HRV to save energy and filter it but even if it's just fresh untreated outside air brought in straight from a vent you'd still eliminate the moist air moving through fiberglass batt insulation and the occasional condensation on the paper backing of the drywall. One thing I really like about spray foam insulation is that your insulation is your air barrier and thermal barrier and you don't have to deal with air passing through your thermal barrier and potentially causing condensation. In southern climates the air barrier is always on the outside of the insulation and in northern climates from what I understand they put the air barrier on the inside. Spray foam effectively puts it on both sides so you're not compromising based on what location is more often going to prevent condensation.
Think about what an air filter looks like after a few months. That's what happens inside wall cavities in leaky homes only there's no way to change them and it builds up slowly over decades. There's a lot more surface area, but that only delays the problem, if you look at any renovation photos when a wall is opened up after a few decades they're typically filled with dust and grime. Even if you just had a 6 inch duct with nothing but some louvres separating inside from outside you've still eliminated most of the potential buildup.
And with the amount of ventilation needed to make a PVC lined box into a healthy living environment, your kids will be conducting airfoil research at the dining room table.
I imagine someday there will be a combination of organic growths which will be combined in a creative way to produce something greater than the sum of parts and which also suits our needs. This might involve fast growing things, things which can be grown in a directed fashion, and combinations of organic substances which react in a beneficial way (such as improving durability or strength characteristics).
Hemp grows really fast and has really strong fibers. Bamboo does as well. Fungi grows fairly quickly and is directable. There are probably many more things out there which can be used. Then it's a matter of refining the processes to get the results we want and then testing and developing combinations.
https://www.concretecontractornc.com/a-house-built-with-styr...
https://www.goodreads.com/book/show/621986.Barbapapa_s_New_H...
Ikea style flatpacked prefabs still seems like a vastly better option to me.
Why not 3d print homes at that point? At least you can get the rebar and other forms in place ahead of the print, and you get more flexibility in the final design of the structure.
This article mentions 100 and 200 square feet buildings, so I don't think there's gonna be much in the way of internal structure. I could see an inflatable structure with 'tubes' at certain places for wiring and plumbing to pass through, which would save cutting holes later.
But like everyone else says, there's easier ways to get the frame up faster. What makes construction slow is coordination between the many different trades that need to work in the same area. With many parts in sequence, and each trade having high utilization, scheduling is difficult --- either you plan with large gaps between trades, or you blow up everyone's schedule when one trade falls behind for whatever reason.
The work around internal plumbing and wiring is messy, though. A lot of abrasive brick dust is generated. I wouldn't want to be the guy doing this stuff. In a 3D printed home, nice empty spaces could be left in the wall while printing for all the necessary networks.
Most of the time, every connection coming from the exterior are coming through the floor in a little room that we can use for storage and from there, everything is dispatched through inner walls which are basically empty (except around bedrooms if you want acoustic isolation). This allows to maintain everything from the inside.
I wouldn't call it a mess but I'll acknowledge I'm talking about modern constructions.
None of the walls were empty, all were solid brick with no empty space.
It was quite a mess, though the guys doing the job were very professional and handled the dust disposal very well.
I've never seen something like this in France.
Granted, it is a small set, N < 10.
This might be one of the reasons why Czech construction costs are so high. Expensive material everywhere.
But without reinforcement, this is only a toy. But I find it interesting nonetheless.
Housing construction is pretty cheap. The materials are mass produced on thin margins and in the US we’ve insourced the cheapest labor available on the continent to put it together. If you’re really on a budget, you can get a pre-manufactured mobile home for very little. Even living in Soviet style concrete multi-family housing, like a human factory farm, is actually an option for most of us if we’re to move. People seem to avoid these choices when they have the option though.
I find it very conspicuous that in the commentary around this issue, finance and the market distortions they create never seem to get any blame.
Difference is that they produced a canvas containing everything needed for the concrete, only requires to add water and blow it up.
edit: point being - it seems easy to pump concrete into a form, but the problem is making forms - at scale - that look/function a certain way, and in this case are made from an inflatable.
I'm not at all impressed in this particular one, but in general it matters not what the aesthetics are when it's a survival issue.
For anyone interested in building materials, ICF & SIP seem to be the most interesting methods to me.
I'm also not entirely clear what the saving is here - you still have to get concrete from somewhere to the construction site, to somewhere that presumably already has some local material that could be use instead?
Also if it's just making a box, that's not the problem - people have already have shelter. Where things break down are access to clean water, food, and similar. But I guess those don't sound sexy and so don't get funding.
Surely it would be better to call these injection moulded homes?
It's got a nice ring to it. Don't you think?
Without these you have a weak shell not a liveable structure. Concrete doesn't have tensile strength for shear and compressive loads.
I watch a new building go up nearby. It was 4-5 days of welding rebar and pouring concrete took 4-5 hours.
Startups like this are extremely guilty of offloading massive externals costs on the communities they sell to