Calton Foundations now offering Rammed Earth Construction

Rammed earth in green building (from Wikipedia)

Rammed earth structures are beneficial for natural building because they can utilize locally available materials with little embodied energy and harmful waste. Earth is a widely available building material with virtually no side effects associated with harvesting for use in construction.^[2] The earth used is typically subsoil, leaving topsoil readily available for agricultural uses. Often the soil can be used on the site where the construction takes place reducing cost and energy used for transportation.^[2] It is also affordable to build with, as the materials are inexpensive or free. It is a viable building material for low- income builders with help from unskilled workers, friends, or family. Today more than 30 percent of the world’s population uses earth as a building material.^[1]

Compressing the earth can be done manually using a tamper made of a heavy flat bottom plate connected to a long vertical handle. Using a pneumatically powered tamper the material can be compressed with much less manual labor. Although the cost of material is low, constructing rammed earth without mechanical tools is a time consuming project. With a mechanical tamper and the forms ready it can take about two to three days to construct the walls for a 2000–2200 sq foot house.^[1]

Rammed earth buildings reduce the need for lumber because the forms used are removable and can then be reused for different rammed earth wall construction.^[3] The forms are usually made of reinforced plywood, but sheet metal or even glass fiber can be used. The form wall faces must be externally reinforced with laterally running beams to prevent outward bending of the wall faces during the compression process. The two opposing wall faces must be clamped together and the wall edges need to be securely compressed between the form faces to withstand the high amounts of pressure created during compression.

The USDA observed that rammed earth structures last indefinitely and could be built for no more than two-thirds the cost of standard frame houses. Rammed earth can carry a heavy load and using re-bar, wood or bamboo reinforcement can prevent failure caused by earthquakes or heavy storms. Mixing cement with the soil mixture can also increase the structure’s load bearing capacity. The compression strength of rammed earth can be up to 625 pounds per square inch. This is only two-thirds the value of a similar thickness of concrete, but a rammed earth building is still a useful durable material.^[1] Termites won’t infest rammed earth walls and the material is reusable, biodegradable and highly fire resistant. The walls require no toxic treatments and have no risk of off-gassing toxic fumes, making it ideal for chemically sensitive dwellers.^[4] Properly built rammed earth can withstand loads for thousands of years as the history of rammed earth structures around the world has proven.^[5] Stucco can finish the walls in almost any color or style; untouched the walls have the color and texture of natural earth. Blemishes can also be patched up using the soil mixture as a plaster and sanded smooth.

In the UK it has been suggested that a compression strength of 2N/mm² (290 pounds per square inch) should be assumed in the absence of data derived from testing of the earth that will be used.^[6] Concrete typically used in UK construction is mixed off site and has a compression strength of 12-16N/mm² (1700–2300 pounds per square inch, from a cube strength fcu = 30N/mm² to 40N/mm²), around seven times stronger than rammed earth. However, there are many factors that affect the width of a wall, so a plain concrete wall will not necessarily be much thinner than an equivalent in rammed earth.

Rammed earth is not only an economically viable construction technique, it results in pleasant, and energy-efficient buildings. The density and thickness of rammed earth makes it so that hot or cold temperature penetration has a slow rate of thermal conductivity. Warmth takes almost 12 hours to work its way through a 14 inch thick wall.^{[citation needed]} The walls provide good thermal mass, which helps keep indoor temperatures stable, particularly in regions with dramatic daily temperature changes. The half-day rate of heat transfer and thermal mass of the material makes rammed earth a practical material for passive solar buildings. Rammed earth has been a popular choice for buildings where temperature fluctuations need to be kept to a minimum. It can be used in cooler climates but must be protected from heavy rain and insulated with vapor barriers.^[5]

Typically rammed earth walls are about 12 to 14 inches thick making them ideal for humidity control and noise barriers from traffic, furnaces, compressors, fans or ducts. Rammed earth also allows more air exchange than concrete structures allowing the building to breathe and not become clammy without significant heat loss as the material mass absorbs the temperature as the wall breathes.^[1]

By its very nature, earth is one of the best sustainable building materials as it is historically the longest used material by man. It is universally a naturally available product, with a heavy thermal mass and a natural barrier to cold winds and forces of nature including insects and rodents. The material is not rationed or monopolized, is fire proof, and sound proof.^[1] Rammed earth can contribute to a solution for much of the world of homelessness caused by high costs as well as today ecological dilemma caused by deforestation and toxic building materials.

Poured Concrete

Is a poured concrete foundation better than a block foundation?

Choosing poured basement walls over a block basement should be any easy choice to make considering the advantages of the poured basement wall. Poured basement walls are stronger, drier, more durable, and can be constructed more quickly than block basements. Even though our winters can be bad, poured walls can be constructed year-round. In addition to this, poured concrete walls are better suited for building on “marginal lands,” and with the great variety of soil types found in North and South Carolina, this is an important advantage.

Poured wall basements also offer greater design flexibility, which is important for the homes of today. Homes with poured walls will also have greater resale value, which is an important consideration when building a new home. Poured basements are also competitively priced with block once you look at the overall cost of block and working with the several sub-contractors that are necessary for block construction, which makes them an exceptional value considering their enhanced performance.

If basement cracking or leakage were to occur, poured basements can be easily treated with polyurethane foam injections. Block basement repair can be costly, and often involves excavation and disruption to the landscape of a home.

Poured walls is also the clear choice for modular home manufacturers.  If a block wall is hit or dislodged from its footer then demolition and reconstruction must occur.

The choice is clear. Choose a poured concrete foundation for your new home!

What are important factors when considering a poured concrete foundation contractor?

You must look at their experience, and ask questions regarding the adjustments made for pouring walls in the different seasons. The strength and variations of the concrete mix should be adjusted throughout the year, so you should look for a contractor with an extensive knowledge of this practice. Your contractor should utilize admixtures, have a good knowledge of engineering factors, and should have a close relationship with concrete suppliers.

The use of both vertical and horizontal steel should be considered. The proper steel reinforcement reduces the chance and severity of shrinkage cracks, and also adds the tensile strength that concrete lacks.

You should also choose a contractor at the forefront of his peers in both business and technology. If your foundation contractor is not around in the future, your chance of getting technical help later is very marginal. Also, if the equipment and business looks professional, you will likely receive a professionally handled job.

How easy is it to fix a leak in a poured foundation wall (although it is rare)?

It is very easy, and can be done from inside the basement. After being sealed with a 2-part epoxy coating, an expanding polyurethane foam is hand-pumped through special fittings which are inserted into the wall. The fittings are left in the wall and are sealed over, leaving the wall smooth and the crack filled. If done correctly, no excavations or disruptions to the existing landscape are required.

Why Use Poured Foundations?

Remember, we provide free estimates and proudly offer you our more than 35 years of experience in the business. Why wait? Contact Us today!

Solid concrete basement walls save you time and money.

Pouring concrete basements takes considerable less time than block construction. “Roughing in” can begin sooner. `Ready-Mixed concrete can also adapt to cold weather construction, giving builders an extended construction season.

You can use poured concrete walls in any home design. Poured wall construction is adaptable to all home styles including ranches, duplexes, and split levels. It can be finished in a variety of attractive choices such as smooth, stucco, brick, board and batten, fluted, and many others. Poured concrete fits in perfectly with today’s diverse life-styles.

	The site is excavated, the concrete footings are formed and the concrete placed.
	Set the concrete forms and pour the walls.
	Concrete foundations, any size-any, shape.

Benefits for Government Agencies

Every homeowner has a right to a safe, well built structure. Whether it’s a Habitat home, low-income, government, military housing or in a flood, hurricane or tornado impacted region – concrete construction is perfect for any community or government agency to consider.

Why consider concrete homes?

Rock Solid Construction for Unparalleled Safety and Security
A solid concrete home can withstand fire, infestation, and forces of nature like tornadoes, hurricanes, and earthquakes better than homes made of other building materials – for greater peace of mind in protecting homeowners and their property, and their families.
Environmentally Friendly / “Green Building”
As ENERGY STAR® homes, a solid concrete home places an emphasis on energy conserving energy and reducing indoor air pollution. A concrete constructed home follows the “Green Building” objectives and also significantly conserve trees by reducing the need for lumber. In countries where lumber is scarce and with the conservation of our natural resources a priority, homeowners have enjoyed the benefits of concrete, stone, and masonry homes for thousands of years. In recent years, more and more Americans have discovered the many benefits of concrete construction.

Extremely Energy Efficient
Because of concrete’s incredible thermal storage capacity, a solid concrete home stays warmer in the winter and cooler in the summer than traditional houses. Airtight construction and rigid insulation also eliminate external air infiltration to keep inside temperatures consistent and comfortable. The Environmental Protection Agency (EPA) has consistently awarded concrete homes a Five-Star Rating for energy efficiency through its ENERGY STAR home program. Homes with the ENERGY STAR label are designed to use at least 30% less energy, help homeowners save money on utility bills, and help protect the environment.

Flood Mitigation
Homeowners in flood regions and government agencies responding to these areas can be more prepared because the overall flood damage is kept to a minimal. Clean up is reduced to disinfecting of the concrete walls, floors and ceilings.
Healthy Interior Environments

A solid concrete home and its airtight construction is a healthy interior environment especially for a number of homeowners concerned with indoor air quality or air related health issues.

You can now view our add in Homes&Land

And our Website associated with Homes&Land

Benefits for Builders/Developers

taken from: Concrete Homes Council

Benefits for Architects/Engineers

from Concrete Homes Council

Taken from the Quad-Lock January Newsletter!

“Green” is a word that today in some minds is overused and abused. Ten years ago, “green” was a word for a wildly right-wing party, for people following a seemingly stout agenda, and in general a word for a philosophy that had very few followers, at least in North America.

So what will be the meaning of “green” tomorrow and in the future?

As you all know, the ‘Greenhouse Effect’ and all its consequences is not speculation anymore, but a fact. As a mining engineer, I denied its existence for quite a while for certain reasons – mining and oil production are big carbon dioxide producers – but I’ve since been converted to the “green” camp.

Thus, “green” today is being defined as limiting or eliminating carbon dioxide output. The average Canadian has a CO2 output of five tons per year, of which about 50% are attributed to travel by car and airplane, and about 50% are attributed to heating and cooling. The Canadian government has set the goal for each citizen to reduce their CO2 output by one ton per year, in essence a 20% reduction.

Such a CO2 output reduction can be attained by several measures like reducing your travel, buying a more energy-efficient car, installing energy-efficient boilers, light bulbs etc. The reality is, even doing all these actions at once, will probably not get you to a 20% reduction in CO2 output.

What will get you there for sure is using Quad-Lock products.

Quad-Lock provides a building envelope solution for new construction that will lower your heating and cooling costs on average by 50% compared to conventional construction (which will give you a 25% reduction in CO2 output in the above 5 ton example).

“Go Green with Quad-Lock” is our motto, and it is well justified by the products and services we offer. My conviction is that “Green” in the future will be associated with Quad-Lock and its products.

Best regards,
Hubert Max Kustermann

Apartment Complex under Construction

Finished Apartment Complex