The White Gold Rush?! The Video That CHANGED Aircrete Forever!
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Welcome to the self-sufficiency revolution! Our channel is your go-to source for sustainable, eco-friendly building techniques using styro aircrete, a lightweight and versatile material made from a mixture of cement, water, and styrofoam. Our channel focuses on alternative building methods and natural building materials, including aircrete blocks and styrocrete. Our expert hosts share valuable tips and tricks for building with aircrete, whether you're looking to construct an aircrete home or incorporate aircrete walls into your renovation project. We also explore off-grid living and minimalist homes, highlighting the benefits of modular and prefabricated homes for energy-efficient and passive solar homes. Our content is perfect for DIY enthusiasts and those interested in alternative building materials, especially green building materials. Follow us for inspiration and advice on building your dream home with sustainable living in mind.
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The information provided in this video is for general informational purposes only. It is not intended to be a substitute for professional advice or instruction. Viewers should always exercise caution and take appropriate safety measures when attempting to build or construct something. The creator of this video is not responsible for any injury or damage that may occur as a result of following the instructions or information presented in this video - Jak na to + styl
In Engineering School we used styrofoam and fly ash (coal ash) to design and build a concrete canoe for competition. It was pretty light weight it only took 4 people to lift it, very similar principal here. Reduce the portland by replacing it with fly ash. I'm always looking for building alternatives, I have done many non conventional builds. 24x24 clear span with 9ft walls all from white cedar pallets simple to insulate, wire, and very strong. Held 8 inches of snow and the ice that followed.
Good Job👍!
Great to hear! How waterproof was your canoe and what would you recommend?
Fly ash is a by product of Coal power plants. Due to 8 years of an administration coal plants are being shut down. The concrete became more expensive due to the scarcity of fly ash in U.S. Fly Ash in concrete is being replaced with something else. The domino effect! Fly ash was a filler ingredient in concrete to take up space and increase volume.
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Sounds interesting!
People like you are the best man, number 1 you show us we can think outside the box on building a home or whatever, save money etc. And on top of that you share your knowledge with everyone for free after no telling how much R & D is rare these days.! Thank you
You're welcome!
Hi Steve I’m a builder for many years! I’ve been see and experimenting with different materials my whole life! I see ur solution bonds pretty well, I’d bet adding paint would help even more in some applications? Even rubber paint like on exterior walls or just around the foundation where the materials meet would greatly help in bonding and water proofing if needed? I’ve got so many different building ideas, I pretty much been building my whole life! And you are definitely on to a huge breakthrough? God knows the world needs it as our so calls LEADERS shaft the system in order to jack up material cost just to manipulate the masses? Good job 👏🏼 and thanks for sharing!!!!
dried out hemp stalks as an aggregate media combined with this would probably be pretty lit
@@sinvex2224 yes similar to a fiber mesh which is always used when you don’t use rebar.
Have you tried earth bag? I’ve been curious and want to try it.
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So agree with comment, we got huge problems with not accepting better and affordable build types and dropping information on the issue here, because it will get worse. So a lot of people dont know in 2000 a failing UK company made deals with US Housing Authorities this is why we got huge ICC build code restrictions which really is just an old boys club that fills up friends of friends wink, wink pockets and they used a CA law firm to network throughout the country to use legal contraints on the public as a private legal advisory board to congressional members ONLY and their plan is by 2030 to have secured worldwide ICC codes by this once FAILING UK company as they boast publically their profit potential. US is based on the rights and freedoms of common man to own land, to build a homestead of choice. How we let a FAILING UK company come in here to restrict affordable modes of building on faked out "its for your safety" bull is an insult to Americans who are suppose to have freedom but someone has learned how to push profit agendas and override American Constitutional Rights and we truly need to wake up here as we have forfeited common sense, ease of build types for homeowners that make sense to be sold out on wasteful, expensive no longer affordable of main stream Americans, it has to stop! Ive seen absolute genius ways to build and the people behind it are who we should support as they evolved from human needs not how much can I make.
In your other video that shows your shredder machine, I noticed your foam gets everywhere and clings to everything. The best way to help eliminate the static when grinding the foam is to just mist it with water occasionally. This makes clean up so much easier and quicker. I regularly cut 2 lb density EPS on my CNC router table and I keep a spray bottle of water near by when I clean up the shavings and dust after cutting. You may be able to hook up a ring of fine atomizers around the inside housing of your blade and wet the foam slightly while cutting. You're going to be adding water anyways, so having wet styrofoam shouldn't be a problem in your mix.
DesignCutters I have been thinking about doing this and glad to hear you confirm it is a good idea. I am thinking of ways to shred and fully contain the shredded styrofoam so it does not go everywhere.
I grew up in Germany and we used a similar material to coat houses on the outside in the 80's and 90's. The material was delivered by a bulk tanker and blown in our silo on site. We used Putzmeister's Gipsomat to mix it and spray it against the wall. It was another option to insulate. Most of the times we installed several inches of Styrofoam panels to the outside and than used the fibermesh with a skim coat and than the stucco finish. I think Knauf and Sto were some of the companies that provided that material.
In the 60's and 70's they used the air crete panels for walls in commercial buildings and schools too. I remember seeing some remnants of those in my dad's storage yard in the 70's and 80's from old projects.
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Are you talking AAC?
👍🙂👍
That was a solid set of shout outs.
I’ve actually heard of the majority of the people you gave a shout out to.👍
Attribution is always good. It's how you make better wheels.
I've been following the same guys.
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Breathtaking! Awesome, inspiring, and easy! I'm rewatching this a few times to let some of the details soak in. I have a foam gen. but was stuck on how to do walls and floors. And you showed the way to do that and attic/truss insulation with structural rigidity.
I have been worried about chaos Specifically, after severe weather events. The debris all flocked in pink insulation (hazardous), as well as any surviving living trees, etc. Often spelling destruction of them when clean up commences. Now, with Aircrete and your instruction, you've eased my conscious about events yet unseen.
Thank you! New builds incoming!
In Florida, we pour the walls in a frame that is laird out on the floor. Once dry, it is tipped up set in place. This would make it much easier!
I was about to ask about tilt up construction. I may still.
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I like folks that focus on reclamation & end up turning ecologically terrible materials into entombed solutions. Good work
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There are wattle and daub houses in England over 700 years old. When I saw you using this material to fill a void it reminded me of wattle and daub construction. Great video. I subscribed.
Straw bales (the older one man size) make excellent walls. Pinned together with willow canes and daubed over with lime mortar, it lasts and lasts.
@@davidelliott5843 Will rot with moisture
@@DarkLinkAD that's why architects say that you've got to make the roof and the base.... Head and feet.... Dry....... well and the rest takes care of itself.
@@DarkLinkAD no not if you dont put it directly on the ground! build a stem wall first then stack your bales!
@@StonemanRocks I dont buy it..
I love your creativity! In coming up with the whole styrofoam idea in the first place, then imagining different ways to use it, and finally I think my favorite idea was the lawnmower shredder! 😄
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Absolutely fantastic. I'm in South Africa and here we have massive problems with lack of housing. I'm sure this is going to be such an awesome help. Thank you so much for sharing your experience
Stephen is from South Africa originally! We all would love to see some relief there. Thanks for watching!
Aircrete will contract. Easily 1" each direction. Both aircrete and styrofoam have bad hygroscopic qualities. In Finland we had bricks that sandwiched styrofoam block between concrete slabs. Nowadays styrofoam has been replaced with XPS. This material WILL collect water from air. And without rebar that would be absolutely not by code in EU. Hygroscopic point of view painted stucco is also one of worst choices for outside surfaces. In Finland that shed would not survive many seasonal cycles as moisture from inside would be driven by vapor pressure to the walls, retained by XPS balls and stucco-paint combo and then ice would make micro cracks to/near outer surface of the block.
Also not to code for any sort of structural application in the US under IBC or IRC without rebar
@@Dancorcoran68 the code doesn’t always exist. The county where I’m building now has no inspectors, you literally buy permit for footprint and they don’t care about anything else. Texas, Dacotas and some other states don’t have those neither I think.it all depends on the county you are building at I guess. Rebar is super cheap compared to the concrete. I always use plenty :) in this case though with aircreate, rebar wouldn’t help I think :)
Mika I read some Nordic country had a ton of pine tar they’d cover structures with. Sure stucco probably wouldn’t work in a country with a ton of snow, but look at the southwest In the US. The Pueblo Native American cities literally are something like Adobe that’s existed for a thousand years, well the one settlement. They also get little water.
Obviously someone shouldn’t build a house or structures with this styrofoam method, but it looks like it worked for him. Seems like he did mention someone could pour concrete and then just pour this styrofoam mix later for insulation. It’d probably work fine for a horse shed or chicken coop for what’s worth. If you can get styrofoam for free that’s a hell of a lot cheaper material wise then buying concrete especially if it’s just a garden shed or something.
how about wax as waterproofing.
@@rocketsmall4547 I’ve never seen it done this way. wax is def good to remove hairs from my chest :)
bitumen is often applied to concrete to waterproof it
You know while back I saw people building with papercreate. Take a bunch of paper, shrink it or get it wet, then mix with concrete and place in your forms. I even saw a guy using his old washer for that. Paper is free, all you need is to add Portland cement.
A friend is building a house with rammed earth. The technique is super old but the structure will be really strong too.
The traditional hollow cinder blocks are very strong too and depending of where you are in USA can find them 1$ a piece.
If you have heard of the ‘three little pigs’ fairy tale might consider something stronger than papercreate :)
This is great I would really like to see a demonstration of this creating a DIY SIPs panel. You could even insert pvc conduit as you pack for wire runs in the walls
Look above it by idea
Yes, Sip's to attach to a Timber Frame / Post and Beam would be amazing
SIP EPS foamcrete panels? That could be beneficial in areas with high fire risk
Would also love to see this!
Could even include some wire for added strength
Love this. You look like a dad, so I'm gonna say thanks dad!
You're welcome son? haha subscribe for new builds coming soon!
I have a few ideas for you. 1) Look at nylon Bird Netting. It comes in giant sizes to go over fruit trees to keep birds out. It is also used to keep Hawks away from chickens. You might be able to use it instead of the fiber meshing. 2) Look a heat shrinkable plastic that is used to cover boats for winter storage. Now if you utilize old fashioned chair webbing/bird net/ +heat shrinkable plastic, you can heat shrink the plastic down onto a complex form. I once made a tailbox for my recumbent bike for loaded touring using chloroplast strips (like a basket) and the heat shrinkable plastic. The tailbox turned out both lightweight and aerodynamic... Once the plastic shrinks, the structure becomes drum like. 3) For complex shapes, such as roof elements, with embedded beams that are at right angles to the shape, perhaps adding a small amount of concrete hardener might allow the mix to stiffen enough to continue pouring. 4) Bird netting could also be used like sidewalk screen within the mix. Bird Netting is cheap... 5) There is a fiberglass/epoxy product that you can coat both sides of a dry stacked cement block wall. It is probably expensive, but it waterproof when used for foundations. 6) For your Arched Cabin, what if you made your arched wooden beams in a "U" shape. Now, you could put plastic on the inside of the "U". You could then place webbing/netting/heat shrink to the arched areas. You could then slip form each side. Filling the top might be problematic. You might be able split the arch and pour one side and then the other, remove the forms, and slide the two halves together. I hope these ideas help!!! KEEP UP THE GREAT WORK!!!!! Bob Cromer email: roberthcromer@gmail.com
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Glad to see another, recent video shared with creative thoughts applied to aircrete!
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Back in the 70s we just added a gallon of dish soap into the mixer truck and pumped it into apartments to level floors.
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Thanks for all your good experimentation and innovation!
Also, for removing so much STYROFOAM from landfills & encouraging others to do likewise.. Great work!
How would one dispose of styrofoam aircrete once it reaches it's end of life? Would this type of aircrete be able to be recycled the same way concrete would be, or does the added strofoam mean it needs to be taken to the landfill? What are the consequences of leaving styrofoam aircrete to decay when abandoned onsite? I dont mean to be a negative nancy, just wondering what the net lifetime impact of this would be.
@@liquidfrice were do they recycle concrete?
Clearly pushing that shit in to the concrete will make it a lot harder to clean after its life is over. Wtf are people even thinking. Make from a problem bigger problem. Same as plastic mixed with concrete and make patio slabs in Africa what a f achievement how will you ever get rid of the microplastic after that it just won't be possible ever. They film them because oil companies now jump on plastic because they know the game is over on oil.
Actually after tornado's here in TN it went all back into the landfills and proved a deadly structure
@@liquidfrice grind it up and make recycled styroaircrete.
Amazing. Clever, Creative, Cost Effective. Thank You for taking the time to make this video.
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I would suggest trying a mix with fiberglass fibers in the mix as well. It's used with concrete furniture and counter tops. It may add the reinforcement needed to stiffen up the vertical slabs.
What he's showcasing is low weight, low cost, high thermal resistance, high yield efficiency building material. Fiberglass fibers are expensive vs recycled Styrofoam and fiberglass fiber is not a low weight product if used in solid mass structural rigidity applications. The weight of the fiberglass webbing used on surface applications herein is justified because of the need for long term structural integrity and durability. You wouldn't want to leave this product as an exposed raw surface due to the high styro content. Glass fibers and even steel fibers are used in cementeous applications already, but they are not cheap, and the increase weight dramatically.
@@ThirdeyedeasInc I'm not so sure styrofoam is such a great thing from the perspective of fire. Styrene emits pretty noxious fumes when burning.
You could substitute hemp fibers as a low cost alternative.
Basalt fiber is best.
@@davidprins9401 except, hemp fibers are easy to come by.
This is amazing--mind blown--can't wait to get started, and perfect timing as I am planning a small build right now!!!! THANK YOU
Whats the build? I want to build rooftop desk since house is on hill with LA skyline/ Hollywood sign 20 mile in distance. Sunset!! Or 4foot wide 3deep length the side of house no one goes by.
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Breaking new ground is always expensive and time consuming. Thanks for your time and effort.
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Steve, you're a flippin' legend. Really inspiring! Love the recycled materials aspect -- trash is an underrated resource. God bless you and your family!
Too bad the end product cannot be recycled.
Styrofoam can be recycled, concrete aswell, the 2 shouldn't be mixed, because now it can only go to landfill.
I'll tell you for years I've always considered waste products as potential building products I mean look at what Mike pillow did to make a million dollar business he went to these memory foam companies and picked up their waste to which he uniformly shredded or tour to which he inserted into a pillow case which then would yield him a $40 profit and from what I understand he was able to get this product for free I mean how many products required zero dollars
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I thought this was the best way to go over foamcrete 3 years ago just for the simple reason of recycling styrofoam and the great economics but didn’t really see it happening so i decided it must have drawbacks like fire risk or something . So glad you did this video content. You have reignited my vision !
Thank you! We are in this together!
Very creative use of recycled materials. Thank you for sharing your knowledge and experience !
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I'm very inspired and excited about your research and results. Please continue with this work.
That's the plan!
Amazing, thanks for all the helpful tidbits very generous of you!
You're welcome!
Australia had a science diy programe on Ms tv in the 1980's on this very concept. So did the BBC.. They did build with this product, how ever they discovered that Styrofoam had the same electrical charge as Portland cement. I think it was a - charge. But the 2 products repelled each other, making the final structure strength compromised. They had to modify the Styrofoam to have a + charge for the 2 products to come together. Not as easy as it sounds. But from memory they achieved it. I like your way of thinking. Your sure considered all concepts here. Well done. Im subscribed
So the negative charge was stronger than the adhesive properties of the concrete? I guess if it weren't mixed well, like clumping of the Styrofoam, I could see that being an issue...
Hemp is supposed to carry an electric charge, but I have not been able to determine if it is +ve or -ve ... but hemp has been used in concrete mixes so I would tend to think it is +ve charged and might be useful for Stephen to experiment with. It is a great growing plant and thereby not only would he be styrofoam recycling, but also carbon sequestering at the same time. Perhaps a local college or university might have a engineering program that could help with formulations?
In some European countries styrocrete is written in construction code they graded it from structural light concrete to just fireproof insulation. The technology they developed is not a secret that's why so many companies make blocks out of this material Earth block, Perfect block ,Legacy block ...
I wonder if placing a couple long-haired CATS in large totes of the processed sytrofoam - to play and tumble around - might help in discharging or dissipating the electrical charge of the material. I have observed that very effect after having received merchandise in large boxes packed with styrofoam "peanuts".
Initially, the cats attract most all of the peanuts to their fur, and after a while of play, the peanuts stop sticking to them. If one is unfortunate enough to have only Union (or otherwise just plain LAZY) cats available to them, stirring them around inside the totes might be accomplished with a broom.
Utilizing a couple of cans of anti-static fabric spray on the cats fur might possibly also help.
@@brucelarsen6650 omg🤣🤣🤣🤣🤣🤣🤣🤣🤣🤣
AMAZING! Pure info' syrup!
Thank you very much, you've saved me hundreds of hours of research! 🙏❤️
Thats why we do it!
Man, I'm amazed that you had the money, the time, the resources, the basic knowledge, the tools, the curiosity, and more importantly the will to share all that.
I'm the same kind of guy buy I would definitely try this out.
I can thank you enough
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Inventive, creative and generous! Thanks so much for doing what you do and above all for SHARING your information. 👍💪
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Very cool!! I’ve been interested in aircrete for a long time I just have too many projects to complete yet and a warm shop before I can start experimenting. Subscribed and looking forward to future videos.
We’re did you find that elevator?
@@Top12Boardsport On CZcams. Search for Winch elevator. You will see several of them. Really cool.
@@AbundanceBuild Have ever consider using "glass foam" aggravate in concrete pour for a slab?
BTW there are few companies that make blocks of of this material that is used as an ICF. And I have seen a structural engineer test wrapping fiberglass mats, a inside failing CMU wall to reinforce it. But there is the 1st time I have seen these build ideas combined in there manner.
One last question was there any issue with you local code enforcement signing off on it? That seemed like the major road block in it being used more.
@@AbundanceBuild czcams.com/video/r-pI724I_tE/video.html . Really easy and cheap. I do ecological housing in Uruguay. Hot outside, and inside cool with no AC.
@@AbundanceBuild . Sandwich panel. Cheap. Very strong. No fire. czcams.com/video/s_dRkIpgxCs/video.html . 2 months, four people, done ✅.
I've used pumice-crete, which is a lot like this material, just crushed pumice instead of styrofoam, and same procedure for building walls. To keep from getting the voids under the windows, leave out the bottoms of the window frames and put a 2x4 turned on edge about 12" up from the bottom of the sides. This will support the sides while you pour and leave space to reach in thru the window opening with a trowel to pull the mix in from under the sides of the window frame. Level it off, then remove the 2x4 and add the bottom of the window frame after the mix has set up. No void to fill later.
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Awesome, great ,impressive job done, sir !
👏👏👏
Thank you
Guys... there is a whole GREEN BUSINESS with this idea of making custom panels for folks or building blocks and get a ton of free press by repurposing styrofoam... great stuff!!!
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Awesome stuff! Subbed and would love to see more content on this topic!
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There has been a couple of products using this type of material that was manufactured into blocks and or panels that you glued together and placed rebar in then poured concret into the center. Very fast, easy and efficient. There are many houses up to hotels made in this manner throughout the world. It works very well in regions where the temperatures are extreme, such as deserts and polar regions.
My friends used blocks with that material and poured like cinder blocks to build the foundation of their home and garage. They used rebar and poured concrete. It was a couple in their 60’s and they were doing all of the build themselves. They were VERY happy with the results.
@@catherinegrace2366 logic brand blocks we use in Mn all the time great product.
"Perfect block" has a few videos that show its installation.
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This is awesome! Thank you for your video and wonderful explanation of how it all works. I look forward to watching your future projects. There is truly unlimited uses for this stuff. Wow, I am amazed!
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This is amazing. Great work. Have been very loosely following the aircrete pioneers. And you sir, are among them. What a fantastic leap. Nice job. Subbed 👍
Thank you!
This is a very ingenious way to build economically while reducing energy needs and also helping the environment by recycling. It’s amazing how Steven is thinking outside the “box” and providing so much benefit.
it is but seriously people there way much more environmentally friendly ways of building. Aircrete is a great product nonetheless !
@@ottodidakt3069
Like what?
I dont like it, its weak and is very labour intensive.I dont think it will perform well in a fire, or earthquakes/flooding and natural disasters.
@@tubester4567 I said the same thing. I've been building for 31 years and seismic, high wind, and flood plane codes have changed several times since I started. Depending on where you live snow load might also be an issue
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I added styrofoam to my concrete mix when I was making large flower pots. The reg concrete pots I made was just so heavy and this was my solution, although I found working with styrofoam a bit messy, the static stick is no joke.
Could you tell me what the mix/ratio of your styrofoam mix please Brandy; I’ve saw so many different ones ; I’d like the easiest way to do it thanks
@@jillsmith5687 It has been years and I didnt have an exact ratio but it was a fair amount, I could easily see styrofoam throughout the mix. I would try making small batches to get the consistancy you like. FYI too much strofoam will impact the intergrity of the peice so if you need it to be strong add less. Also its best to seal or paint the final product bc you will see the styrofoam. I gave mine a good sanding and stained it to look like tree bark.
See my comment above about an old science and technology show here in Australia that showed a product that solved the static problem.
If you can work with a misting fan you will be fine. My garden hose sprayer has a misting option that does great.
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Great job. I have been searching building materials for years and this is the best so far that I've seen or heard of.
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Love your passion for these projects.
I can imagine you really enjoy "thinking" and planning! Good job!
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I think you've been inhabiting my head!
I've been looking at aircrete, hempcrete, and gothic arch building for the past few years and slowly formulating a plan to do a tiny house.
Very interested to see the final product
Great minds! New builds incoming!
This was one of the most amazing videos I've watched this entire year. Not only do I like to learn new ways of building so this had me interested but this is making a whole new ball game for construction I can't wait to try some ideas I've had just watching your video just now I've never even heard of air Crete until now
Aircrete is in experimental stages still. It is so new it is not recognized by building codes. Many versions of aircrete out there on you tube are too weak to be load bearing structure. But in this video he told you how he laminated it with wire and plaster or something, makes it much stronger.
Just saying, because it is so new, many versions of it are no good, some are ok, and in the future there will be even better. But that part is up to you then since you are who might desire to work in the field. I suggest adding hemp to the aircrete and foam mix and you might have a superior product. You will still need to laminate it, but laminate it with hemp also.
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Fantastic video, looking at a barn addition, I cant wait to try some of this, thank you so very much!!!!! Really awesome!!!!!
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Your enthusiasm is amazing. Thanks for one of the best information packed videos on this subject.
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You have my complete attention. My mind is racing, thinking of the possibilities. Subscribed and eagerly awaiting some of your follow-up videos.
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What an awesome build! Great ideas for repurposing styrofoam and keeping one less thing out of the landfill. Please do videos on your tools you have created. Super job and I can't wait to see what's next.
keeping 1 more thing out of.
.
If people were really interested in keeping things out of the landfill, they would ban plastic made products and go back to metal and glass like they used to.
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Awesome 👍😎, thanks for the info and ideas
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My favorite aircrete channel. Dude drops nuggets every sentence.
Haha thanks!
Seems like you could pour a floor and then tip up wall panels, complete with rebar and pre-installed wood nailing ribs. Medium sized tractor for the lift. Really nice video, thanks for sharing.
That's what I was thinking. I didn't see in the video but is he using any vibration to settle or remove air?
@@jakeledg looks like all he's using is the packer thing he made
That’s a good idea. Domegaia has been experimenting with building a wall like that they call it the flip up method or something?
Call a tilt-up wall system.
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And Bravo to your extensive thermal-resistance testing program! A lot of effort went into that. Thank you for sharing the results. I have found rigid insulation, aircrete and epscrete to all absorb and hold significant moisture, and want to prevent that to maintain insulation - for walls that can generate condensation or for underground applications. One aircrete contractor told me that crystalline-generating waterproofers such as Xypex etc do work in Portland-cement Aircrete, but you have to wait 28+ days to see a result. I have tried including Waste Latex Paint in epscrete, which is very tough to formulate because WLP really retards the cement (interferes with hydration), but you can get it to work well and make a less-brittle more-waterproof material. And WLP is free! Many Counties give away blended pails to get rid of it.
try adding calcium chloride for faster setting
Waste latex paint is great because it's free or cheap, but the best paint formula for mixing with concrete would likely be elastomeric, especially in climates that experience both high and low temperature extremes. I've been wanting to experiment with this.
Space crete...!! Awesome reply , informative..thankers
@@JesusSaves86AB My memory is that elastomeric has more interference with cement hydration. They both do this and at high dose will cause aircrete deflation before setting, without the right accelerator. The EPS-crete is much more forgiving. I keep encouraging WLP to DIY cheapskates because it is an enormous waste product that waterproofs and extends the durability of concrete, and many Counties just give it away in pails. A lot of testing is needed to get formulations right, esp aircrete. With concrete, most work has been in New Zealand, and also Quebec, and Florida.
@SpaceCrete - Thank you, very helpful comments regarding water absorption issues of aircrete and a mention that the concrete additive Xypex, a crystal generating waterproofing product I am interested in, can work if given enough set time. Wondering if you have any thoughts regarding low-density Timbercrete, similara to "Woodcrete" developed in the 1940's by an inventor in Idaho, which I would like to use as a lightweight waterproof cement fill layer over corrugated steel structural roofing panels: Nucor type 3C-36 or 2C-36, in place of regular density concrete ? Trying to develop actually affordable SF residential housing ... at scale, using parabolic barrel vaults with a corrugated steel panel skin, following in the shadow of my hero Pier Nervi, an engineer's engineer and concrete master. SkyCiv online FEA has been very useful to pre-test a design before submitting it to our professional engineer here in Seattle.
Have admired your own work with super-low-slump(?) concrete additive: Spacecrete, and hope your development work on that product is going well. Perhaps when you are at a point of dealing with VC investors (or there now) may I suggest a very good book: "Venture Deals - Be Smarter than your Lawyer and Venture Capitalist" by Brad Feld and Jason Mendelson. Can not recommend it highly enough. I gave the book to my brother the doctor who has formed a health services startup in Boston and is negotiating term sheets with VC's and their lawyers in a series-A round. He has found the book an invaluable guide during this critical phase of his young company. Full disclosure: we are a few of the SEC "fully qualified" angel investors who believe in the mission of my brother's new firm which is working to greatly improve health outcomes for patients via more focused primary care while dramatically reducing costs.
-- many regards
This is one the best things I have seen this is perfect for building a enclosed hunting stand for us in the north great video thx
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When I was 15 years old, I worked for Sauzer’s Kiddieland, (in Schererville, Indiana), … & we built a fiberglass dome over the top of a 120+ year old merry go round, … partly to protect the ride from the elements of the weather, but also as a facade, to hide the garish machinery that made it work, … the key to building the dome, was done with triangles, & steel shims, building three, 1/2 geodesic circles, with per cut lumber, filling the voids with sections of precut clear plexiglass, that allowed the sun to shine through, & yet, not get sunburned, … every piece of the wooden framing, was stained, a polyurethaned, by hand, to further protect the structure, from the elements, … this was during the spring, & summer of 1968, when I worked for Frank Sauzer, …
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Nicely done. This is exactly what I am also looking into since 2016. I have tested EPS infil with great success and about to mix with aircrete. Thanks to Harry, the Honeys, Don & many others. MGO will be a major part, also PU foam can be chopped down too to recycle, as with glass powdered etc. Great job.
Thanks Don. Is MGO magnesium Oxide? if so I am interested in where you are getting it, how much it is and how hard is it to work with?
I'd be interested in that experiment!
Very good idea, thanks for your time and researching! I was thinking from the outside we need facade, of course there is lot of ways to do it but..., If we vibrate the concrete then we get nice surface. Now there is lot of products on the market, there are some fluids which you can spray on the concrete and it is water-resistant later and you can be sure that your concrete wall doesn't take moisture in winter days. After that you can choose some paints do decorate it.
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I love your shredder solution. I would not have thought of that in, well in like 20 years i tried to. So elegant.
Thank you!
Very interesting aircrete strategy. LOVE IT!
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Flyash is builders sand in powder form. Can be had for free from coal fired power plants.
Good advice.
Thanks for the tip!
Great video and I stopped it half way. A suggestion to use plastic forming for a mold instead of plywood for your dome. There are some really good plastics you can use that can be made very tight and strong after you fasten it by using a heat gun. There are also some plastics that are a mat make in texture that shrink very well with a heat controlled iron. Many are used in small aircrafts. Experiment with the fabric that you are now using to coat your precast panels and be sure to check that it will not crack after exposing to heat. I experimented years ago with some woven almost screen type of fabric that came from a carpet factory that was used for the carpet backing. It shrunk so good it started to distort the wooden frame I made. If you can select a good plastic fabric that will shrink and reinforce your Aircrete mixture please let me know what it is because I am in the Philippines and it is difficult to source out for products. Keep up the good work and videos.... Now back to your video.
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Very cool. Thank you for sharing!
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Terrific video, can't wait to see your next project!
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Love the research
A couple thoughts for your next project .
In flood areas you might want to blend shredded styro into concrete .so your building doesnt float away . Bags of fiberglass or nylon fibres mixed in give amazing strength drill holes then use cement board screws if you are adding drywall . Make thicker walls so theres no need to insert lumber into it for structure .
Use plastic vapour barrier on your forms and they come off the wall easily and give a smooth finish .
Im looking forward to uour next video
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That's a great idea you have. I'd like to build a shed with this, possibly adding metal studs inside for added strength. Thanks for posting.
It's been done already on CZcams.
Wooden studs are ok if one wraps them in plastic first so the water doesn’t sucks out from the mix into the wood. That is how we make some bathroomfloors in Sweden if the floor beams are way too chopped up by plumbing and electrical drill holes. We buy a ready product like this czcams.com/video/GGRMXYPlwps/video.html
@@mackemacchiato3238 The wood would be slow to dry if it did absorb water from the drying cement, but that seems like it would be an issue of shrinkage and warpage from the water, rather than concerns for rot.
A lot of people think rot is caused by it getting wet. But rot occurs only by repeated wet then dry cycles MANY times.
Even a handful of cycles won't cause rot to cause any structural issue. The fungus that makes wood rot only thrives at a specific moisture content, which is why the wood "swinging" through that % repeatedly enables rot.
It's why a wood fence post will rot off right at the ground before anywhere else: that is the most frequent spot on the post where it cycles from wet to dry over and over.
"Dry rot" is not a thing, despite old timers referring to it.
Either constantly dry, or constantly wet, you'll get no rot. The wet version has been in evidence for 100 years at, for example, the St. Marks church in Venice supported by wood pilings driven into the mud that have never rotted.
@@brianmi40 Well Done ! (Sailing off the keel).
I like that idea of using metal studs as a skeleton inside the Crete.
Amazing this is perfect for kids play houses I’m interested in the making and mixing process love to see more
Great idea!
Great work! Thank you so much for experimenting, testing, building, then going more, 2nd story! Exciting option for many good purposes. Thanks for crediting other videos on CZcams from around world, too.
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Hey Takes a lot of and years experimentation before Building codes would let usage. We sure need to find a place to repurpose styrofoam in any form. Excellent video
Fortunately many jurisdictions allow 200 sf detached structures.
But, lots of testing and documentation can be done in the mean time
Styrofoam is one of the few things I CANT recycle in my area 😭 A great idea for reusing it!
@@foyjamez Yes outbuildings will be the way to experiment. Or in the middle of Arizona 😂
@@davidprins9401 True. I know that Mohave County allowed 300 squarefoot non-powered buildings as long as they were off the property line by 5' for years without any permitting. I'm sure they don't respond to much unless without a lot of prompting once you're out of sight from the main roads.
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Genius always flows from the practical. Love this. I would want to see compression and tensile failure testing before I would build too much.
Ben, the tensile test is fairly easy to do and I plan to do one soon. The compression test I am still trying to figure how to do that on a budget.
All the tensile strength is in the fiber embedded in the coating. It is your choice.
@@AbundanceBuild I hope you are able to add some rebar to a slab for a comparison on the tensile strength tests. Also was there a reason you did not use perlite and went to the eps? Thanks for doing the videos!
A harbor freight press with an air attachment and a gauge? Wouldn't that give you the compression test?
@@AbundanceBuild Hydraulic jack or porta power unit with a pressure gauge is a simple compression tester.
Wow, I think you nailed it!
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Two minutes into your video I knew I would subscribe to your channel. Great video well explained. Now I'm headed to see what other videos of yours I can find. Thanks
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I would be interested in seeing how other lightweight fillers in a mix like this would perform. One that comes to mind that is super cheap and similar to Styrofoam is rice hulls. They are basically waste and are very insulative while having a high resistance to rot and fire because of their high silica content. I know that rice hulls can be used as blown insulation that does not pack down due to weight if treated with chemicals or diatomaceous earth to prevent insects from nesting in it. It has slightly less insulative value than cellulose or fiberglass blown insulation, but is is just as light and far cheaper.
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@Knightswithoutatable I like your Rice Hull idea. This could be a possibility in our area in the Philippines as well.
Styrofoam is more challenging to get access to here in the Philippines.
Good Luck!
Greg
Nice nod to the guys I've followed for a few years. Nice seeing your innovation! I think you found the perfect material (in conjunction with rebar and stucco) to build a dome with. Now I'm stoked!
maybe use that basalt webbing instead of fiberglass or rebar, that would be cool
Thank you!
Good job. Finding new ways to build with new material. Keep it up.
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There is a concrete product called "vinyl patch/crete," and this has strips of vinyl fibers mixed into the concrete to increase the tensile strength... So, if you could find a free source of fibers and mix them in before your pour, you could probably get rid of the need for stucco.
Fiberglass or rock wool insulation could work.
@@slaplapdog Fiberbond fiberglass concrete is what i was thinking too.
Blow insulation
Chopped fiberglass is pretty cheap
Doesn't concrete break down fibreglass?
You should add chopped glass fiber from the stucco store to your concrete it will add a ton of tensile strength. By adding these fibers to 3k psi concrete it will be well over 10k psi search this 1/2" Chopped Fiberglass Fibers
That's what I was thinking, I want to try that mix, I also want to make the bent dome mild he did not make.
Thanks for the suggestion. I noticed that EZ block, which is an aircrete ICF block is very hairy which means they are using fibers in the mix.
@@AbundanceBuild get a chop gun and spray it :) I bet you will be casting structural member's. That's what I want to do next. Great vids on your castings.
Runs about $10/lb. is that average
Why would tensile strength be needed for his wall panels?
@iammimic79
Thanks for sharing your knowledge and expertise! I subscribed. Great job!
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I have been looking at aircrete to build a house with an arched roof. I am thankful that I saw your video today as you had the same idea and sounds like your mixture will be lots easier and better. Thank you.
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looking forward to the recipe video!
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Hey Stephen. Great content. Looking forward to the A frame shed. I make concrete planters using Portland, Sand, and Perlite. The perlite is a great light weight alternative.
What’s your ratio for the planters?
Perlite is expensive.
Perlite much heavier
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Looks like a real breakthrough and super smart, congratulations!
Thanks!
Awesome video bud😊👍👍👍
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Stephen a couple of suggestions:
1 - Compare the Expensive roofing mesh you have been using with the economical woven polyester landscape fabric -- I believe they are extremely similar.
2- Burlapcrete uses non-shrink grout and a bonding agent to make an extremely durable exterior surface. That would save you the cost of the plastic or the OSB.
great idea
Rodney which landscape fabric did you have in mind? I am finding several fabrics. The fiber mesh I am using is woven with good size holes in it to allow the mortar to penetrate throughout. I am using Boen 4.5 ounce 36 inch x 150ft from Home Depot. Buying 6 rolls at a time costs $36 per roll. $0.08/sq ft. Burlap is coming in higher than that from I am seeing.
@@stephenw1892 I compared the weave of the polyester roofing fabric recommended by Domegaia to woven landscape fabric. ...not the spun.
Sounds like your $36 is an option I need to investigate.
What did you mean by roofing mesh? The metal mesh? I'm looking into burlapcrete now. What if Stephen would have put sand in his styrocrete to make it strong like his stucco layer?
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I would like to see the detailed build for use as a planter raised bed system, thanks
Brilliant idea! Potentially bug, rodent, and rot proof. Could be made modular so it could be relocated.
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That’s is pretty interesting! Thank you for this information
Youre welcome!
Thanks alot Stephen, surely this is helpful. Greetings from Kenya
Greetings! You're welcome!
Interesting! Is there any reason to add soap bubbles to the mix if you are going to pop them by packing it in the forms? Thanks for sharing. 😊🏠
Part of them get popped by compacting but you need the aircrete as the filler glue for the styrofoam. It is still WAY lighter than concrete styrofoam.
Really beautiful piece, and I love the way you explained everything in detail. Can you please do us a video of how to make the styrofoam shredder? I'll love to see that.
Thanks
Yep.. that's what I want to see as well
Me, too
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Great video. Very thorough, visual, and inspiring.
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Finally something useful I can do with my foam generator.
haha new bubble free recipe video coming soon! subscribe to be notified!
This is outstanding.
I was wondering, to make a curved form, make the jig as you did, but instead of plastic use housewrap and then spray expanding foam over it to give it a coating that sets rigid. this would be your interior, then you could just pack your styrofoam aircrete onto the outside, bottom up like you are building with cob, and trowel it smooth as you go.
The inside could be plastered.
Do you think that would work out?
Thanks for the tip!
I would love a video on your recipe for aircrete with styrofoam
Prepper the next video will cover this. Thanks.
@@AbundanceBuild this was exactly the question I had. Thanks Stephen.
@@AbundanceBuild please
Great information.. thanks for sharing your work with the rest of us!
youre welcome!
Your innovations are awesome. Thanks for sharing👌👍😉
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Great job and explanation looking forward to seeing a panel completed with the fiber mesh. Honeydew carpenter built a great tool to get the stucco on your walls fast! I'd like to make panels for some raised garden beds.
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One method that would be good for someone trying to build like this alone, is instead of doing whole walls, make interlocking blocks. Kind of like those you see on some road construction projects. The size of which would be 3'-4' long by 1.5' wide and high. The size could be adjusted for whatever weight you have the capability to handle.
I am curious to know what your mix weighs when cured per cubic foot.
fwiw there are a couple companies that have and still make ICF blocks out of it....
Hi Rollin. The mix I am using weighs around 10 lbs /cu ft.
@@AbundanceBuild do you happen to know the compressive strength?
@@RollinShultz Almost nothing. Don't build walls with this and put a roof on it. Long-term the expanded polystyrene is no better than air and without any other proper binding/strength substrate, walls built with this, if they're under constant pressure, will fail. Stucco is absolutely not a way to strengthen anything, it's just a finish. Make decoration with this kind of aircrete, by all means, but please, never ever, ever use this to build anything that puts lives in danger if/when it fails.
@@tomteatom You are right that stucco is not the way to strengthen but latex cement on fiberglass mesh that is a 1 centimeter thick shell is the way to strengthen it and it is incredibly strong.
One of my favorite videos :)
Thanks!
Awesome video thanks can't wait to see more.
thanks!
Wonderful!
It’s so generous of you to share this with us! I hope we can make it a win for you as well. This idea has so much potential to change the world for good!
Does anybody know what happened to Darwin - the honeydew carpenter? He was so prolific with his contact and had so many good ideas and had such a good heart! I miss him and Mrs. honeydew Carpenter!
I was just thinking I haven’t heard from them in a long time. Wondering the same.
Thanks Shannon. They have moved and bought a bunch of raw land and are going to homestead on it. He has put out 2 videos about it. Search for them and you will find them. gorgeous land, daunting task ahead of them.
@@AbundanceBuild I just looked them up again too after seeing this 👍