Construction Stage Part 1
Last update of this page : 30 May 2005
See web page http://home.iprimus.com.au/fredb19/solarhouse/house01.htm for additional photographic gallery items and technical detail.
PHOTO 1
Photo 1 shows the commencement (approximately May 2002) of the first rammed earth wall section. The 2 tall formwork pieces at each end of the wall section are placed to determine the length of the wall section, which are about 3 metres long. The first 600mm high horizontal formwork is in place and the rammers are ramming earth into this lower section of the wall. The person on the right is the "shoveller" who shovels the earth mix into the area enclosed by the formwork. The 2 workmen with the air-pneumatic hammers ram the earth until it starts to "ring", showing it is rammed to an extremely compacted level.
PHOTO 2
Photo 2 shows the workmen completing the ramming at the full height of the wall section. Notice the "shoveller" standing in a large, elevated tray which is periodically loaded with earth using a bob-cat. The bob-cat is used to mix the earth in the required ratio. In this case approximately 40% road base and 60% decomposed granite. The mix has 5% white cement, a small amount of liquid sealant and is very slightly dampened, then mixed thoroughly prior to immediately being rammed into the formwork.
PHOTO 3
Photo 3 shows the formwork being dismantled. This dismantling takes place immediately the ramming process at the full height of the wall is completed. The color of the wall is still dark due to the moisture content.
PHOTO 4
Photo 4 shows the workmen giving a quick "wire-brushing" over the surface to provide the final finish. The wall section is essentially complete at this stage and does not need protection from weather.
PHOTO 5
Photo 5 showing some of the external walls completed. Notice the formwork sections stacked in the foreground and the tall, narrow window slots built into the rammed earth walls.
PHOTO 6
Photo 6 shows a mix of soil in the foreground and many of the walls completed. There are a total of 27 wall sections in the house. The intersection between each wall section has a full length, vertical keyed section and on teh external surface, a vertical, 50mm wide, triangular groove (clearly showing between the two wall sections to the left of the bob-cat. The workmen are ramming on an internal wall.
PHOTO 7
Photo 7 shows some internal walls, The tall slots are narrow window openings which will have full-length, 300mm wide timber louvres to aid in summer cross-flow ventilation.
PHOTO 8
Approximately 2 weeks after commencing construction. Notice the internal walls to provide room separation and planned thermal mass to provide extra internal thermal inertia. The dark color on the most recent constructed wall in the centre is caused by it still being damp. It takes about 3 days to dry out. Documentary evidence supports the postulation that the rammed earth continues to remain chemically active for many years and grows harder with age, just as many of the earth's rocks have formed over many centuries.
PHOTO 9
Photo 9, taken 30 June 2002. Shows the steel construction underway. The engineers obviously do not want the place to blow away in a cyclone!
PHOTO 10
Photo 10, taken 17 July 2002. This image shows the trusses in place and the timber bearers for the high roof section. Within the next two weeks roofing will go on and the task of the complex wiring starts.
PHOTO 11
This image shows the louvre window frames in place in the sitting room. Most of the window frames are in place and the house is heading toward lock-up stage.
PHOTO 12
The roofing is almost complete. Notice the two clear-glazed skylights on the "guest-wing". These will form an important light and energy window for winter months. These skylights will be covered with adjustable, stainless steel reflective covers to provide summer shade with good light entry, and will be angled to reflect winter sunshine direct to the tiled floor and rammed earth wall below.
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This web page is maintained by Fred & Jeanette Birkbeck