Hemcrete, BioBric & Poroton
Sustainable & SolidWall Systems with Ecological Materials
In the context of radical environmental requirements and dramatic energy savings the
future of human habitat will have to combine sustainable, dense mixed urban
neighbourhoods, Eco-Towns with solid, durable and healthy Eco-Homes.
Ecological systems depending on high technology and energy consumption cannot
anymore be relied upon as sustainable and viable options for future building types and
will remain complementary and experimental endeavours. We will more likely have
to generalize and optimize passive systems allying natural materials, renewable
resources, regional economies and local skills. We will more likely adopt smart and
timeless solutions adapting from past vernacular traditions and adapting to best new
scientific and technical knowledge.
A Typical Cavity Wall Construction
The cavity wall and other hybrid wall structures present shortcomings and liabilities
which will increase with new legal requirements regarding carbon emissions and
energy efficiency. They also present a growing degree of complicatedness and
dependence on fossil based resources and apear less and less convincing and losing
ecological, economical and technical credibility.
In order to comply with modern regulations and in the context of the “Eco-House”
the cavity wall has to increase its cavity almost to a breaking point of structural
consistence and stability. This creates additional complication, reassessment of skills,
longer building times and higher costs. Both cavity wall and sandwich wall need to
increase their wall thickness and reschedule their components to achieve both energy
savings and required carbon footprints. Eventually some wall systems are growing
quite thick with substantial layers of insulation without however being able to take
advantage of solar gains and benefit of thermal mass. Most conventional systems are
voracious of novelties, of specialisation and innovative materials and membranes,
either natural or chemical. The building process is turning into an absurdly
complicated technical assemblage. Not only is this frustrating, expensive and time
taking in the reality of the building process, but it is also highly antagonistic to the
original purpose of sustainability, ecological comfort and good practice.
The Cavity Wall, the Imperfect Remedy
The paradoxical purpose of the Cavity Wall is Separation and Isolation
The illogical and unhealthy Schizophrenia of the Cavity Wall
The Traditional Solid Wall, a Sustainable Alternative
The logical Beauty of the Sustainable Solid Wall: Articulating Exterior & Interior
42,5 cm aerated clay block Wall rendered with Lime Mortar (outside) and “Marmorino”
Plaster (inside). Base, sill and door frame in local limestone.
The simple and quick building process allows to dedicate more time to details and ornament!
(Wall Building Experiment during The Prince’s Foundation Summerschool in Lincoln, 2008)
The Ecological Complexity , Evidence & Simplicity of the Aerated Brick Wall
“The Better Way to Build”
Building single leaf, load bearing and rendered walls with fired, aerated clay blocks
allows for a quick, cost efficient and extremely simple building process. The clay
blocks of various producers have achieved a degree of complexity and of excellence
after at least 20 years of experience in Continental Europe.
The efficiency of the system is due both to 1) the nature of the clay blocks: extruded
with vertical perforations and aerated by a micro-porous structure, the clay blocks
maintain a good thermal mass with less density and higher insulation values. And, 2)
the building technique of accurate thin bed joints and interlocking vertical joints
(eliminating maximum of thermal bridges through mortar joints) . As the building
process is virtually dry the wall is immediately ready for finishing without the risk of
long-term drying out shrinkage.
The walls are weather and air tight, very vapour permeable (avoiding condensation),
excellent for thermal insulation. They offer an efficient protection against Summer
over-heating and temperature breaks in winter. They are fire resistant and have good
acoustic qualities.
They can carry loads from concrete floors and can also be used as infill panels in
framed buildings. They can also be used below dpc level with tanking to build cellars.
U _ Values*
The U_Values indicated for various types of aerated clay blocks are consistently
around 0,25/0,26 W/mK for a 365 mm wall and 0,22 W/mK for a 425mm wall.
*U_Value is the coefficient of heat transmission through the materials composing the
envelope of a building. The lower the U-Value the less heat is uselessly escaping, and
the less the building is affected by either cold or hot exterior temperatures.
New Opportunities for Crafts in Sustainable Construction & Ecological Materials
Crafting and Rendering the Cornice with Lime Mortar
(All photos taken during the Prince’s Foundation’s Summerschool in Lincoln, 2008)
The Prince of Wales’ Crafts Aprrentices’
Aerated Clay Block Wall built during the Summer School in Lincoln:
An Opportunity for Sustainable Crafts & Architecture
This wall was built and rendered in less than a week by some craftsmen and
apprentices of the Summer School. Rather than spending their time in complicated
and laborious building activities most of the available time could be used to design
and produce in refined detailing and some ornament. The almost dry and efficient
building system of aerated clay blocks not only creates a more comfortable working
context, but speeds up construction time to twice or three times (with crafts people
trained and familiar with the system) the time needed to build cavity walls!
The blocks are extruded with vertical perforations. Sawdust which is mixed in with the clay
matrix, burns away during firing to give a micro-porous structure.
There are various types of Aerated Clay Blocks available on the European building market,
and often produced locally in Germany, Austria, France, Italy, Spain, etc. During the Lincoln
Summerschool the Prince’s Foundation used BIOBRIC, a French block imported into the UK.
Presently the Aerated Clay Blocks are produced under licence in the UK. POROTON, (an
invention from 1958 by a Swedish engineer), is a popular and affordable building material
throughout Northern Europe.
Most of the aerated clay block producers offer a full range of standard blocks and specials,
corner blocks, reveal blocks, make up blocks, insulated clay lintels, blocks for ring beams,
etc.
Environmental & Ecological Considerations
Ecologically Friendly Construction
1. Relation with the surrounding environment
2. Low environmental impact in the manufacturing process
3. Low degree of “nuisance” during construction
Energy management
High level of continuous thermal insulation reduces energy demand in heating. Thermal bridges values are also
much lower than conventional construction.
Maintenance
No maintenance required.
Humidity and condensation
High protection against dampness penetration and the formation of condensation.
Acoustic Insulation
Good results are easily achieved.
Quality of living environment
Healthier living environment is assured by the lack of dampness, the good insulation values and the resistance
against biological growth.
Air quality
The clay blocks do not contain pollutants such as fibres, organic airborne materials (benzene, toluene, solvents,
ethers), formaldehyde and so on (there are about 100 possible pollutants in organic airborne materials such as
PFA). No fungicides or insecticides are present and no radioactive components.
Water purity
No adverse effect on the water table.
Water and Waste management
No effect on domestic water consumption and in waste management
Recyclability
The aerated clay blocks are totally recyclable.
In case of fire
Masonry clay blocks are totally fire proof (class A1). Furthermore no toxic gases will be released when exposed to
fire.
In case of flooding
Prolonged exposure to water will not alter the structure of the clay blocks and their mechanical and thermal
characteristics will be the same once dry.
In case of earth tremors
Excellent behaviour in seismic areas. The holding structure, with reinforcing rods contained in the column blocks
and continuous lintels at each floor level is very efficient. The only recommendation is seismic areas is to fill the
perp joints, an operation not necessary in other areas.
In case of pests and insects presence
The blocks cannot be attacked by pests and insects.
(quoted from the Bouyer Leroux BioBric website: [Link]/[Link]
Timber Frame Construction
Conventional timber frame systems which should be more sympathetic because of their
interesting carbon footprint fail however often to satisfy thermal mass and energy efficiency
issues. Their design is often dictated by the insulation industry or the component suppliers.
They suffer also from an excessive complicated layering of various components and
membranes, many of which are not renewable and fossil-fuel based.
The Unsustainable Complication of the Framed Sandwich Wall
The Better Alternative
Hemp Lime Technology
“Tradical Hemcrete is a unique, highly sustainable construction product for the
creation of insulating walls as well as insulation layers for floors and roofs. Hemcrete
is a blend of specially prepared hemp shiv (Tradical HF) and special lime based
binder (Tradical HB). Together these products form a bio-composite building material
that can be used both for the creation of buildings that have excellent thermal and
acoustic properties as well as creating a healthy living and working environment.“
Properties of Tradical Hemcrete
Low Density,-High Thermal Insulation, High Sound Insulation, High Thermal Inertia, Good
Vapour Permeability, Good Flexibility, Fire and Pest Resistant, Significant Reduction of CO2
Emission, Air tightness, Recyclable and Renewable, Non Toxic, etc.
Walling with permanent internal Formwork for Spray Application
The Carbon Balance
“The combination of patented, UK produced air-lime based binders and the woody
core of the UK grown industrial hemp plant results in construction products that
achieve the capture of significant amounts of carbon from the atmosphere.
Calculations show that approximately 110 kg of CO2 per m3 of Hemcrete walling
material is sequestrated more for roof insulation.”
The construction of buildings are responsible for approximately 50% or more for the
Carbon Dioxide Emission in the UK. The impact of reduced carbon footprints in the
building industry would be immediate and sensational. Current Government
regulations ask a 1 Ton CO2 reduction by year and Zero Carbon by 2016! Tradical
Hemcrete built houses can do much better: they have a negative Carbon footprint.
With 5000 Hemcrete houses among the 250.000 to be built annually, the Government
CO2 reduction targets would be met!
A typical house built in Tradical Hemcrete = minus 40 Tons to 50 Tons of CO2
The approximate U_value for a 400 mm Hemcrete wall is 0,20 W/m2K
Various Wall Systems & Finishes
There are various possibilities to build Hemcrete walls with rendering, boarding or
brick cladding finishes. The walls can be sprayed or cast depending on the wall type
and building site logistics, but can also be done with prefabricated blocks or panels.
Tradical Hemcrete can be used to build various types of framed wall systems. In
timber frame buildings it provides the wall form, the racking strength and the
insulation and forms a integrated solid system. In steel and concrete framed buildings
it provides the wall form and insulation in one monolithic product.
The excellent vapour permeability protects the timber from deterioration mechanisms
and extends its longevity.
The high thermal performance and air tightness allow for efficient single skin
structures without additional insulation.
Hemcrete offers a substantial thermal mass despite the lower density and weight
Hemcrete is a quite flexible material with relatively constant qualities in a variety of
geographical and climatic situations. Its compact porosity offers both a breathable,
airtight and vapour permeable structure and reacts well in humid and damp situations.
Hemcrete has however to be absolutely protected against durable water exposure
either up from the ground or from the top. It needs a carefully executed lime render,
sufficient overhangs and correct gutter detailing, and cannot of course be built in
flooding areas.
Building of the 2x4 Timber Frame, Brick Base and Shuttering Board for a 400 mm Hemcrete
Wall at the Summer School in Lincoln
An Opportunity for an affordable, healthy and sustainable Architecture
The finished Hemcrete Wall Structure at the Lincoln Summer School
Tradical® Hemcrete® for better than zero carbon buildings
Lhoist UK has developed a lime based binder that works with industrial hemp to form a
building material called Tradical® Hemcrete®. The carbon footprint of Tradical® Hemcrete®
is actually negative. The plant material (Tradical® HF) absorbs carbon through
photosynthesis as the plant grows and the carbon emission of the lime based binder
(Tradical® HB) is low enough that the net carbon footprint is still negative in the combined
product. The carbon remains in the Tradical® Hemcrete® bound by the lime based binder.
Tradical® Hemcrete® therefore has the ability to lock sequestered carbon into the fabric of
buildings whilst delivering highly insulated, quick to construct, comfortable, healthy,
sustainable and durable buildings.
The product has excellent insulation and acoustic properties and has been in use in France
for over 10 years in niche market new build and renovation on a small scale and has been
selected in the UK in the last two years for major new build projects including the Adnams
Distribution Centre in Suffolk and the CAT WISE project in Wales, as well as a number of
housing and extension projects around the UK.
Tradical® Hemcrete® is used as a solid wall form in combination with a structural building
frame, commonly timber, to build all types of building. It can also be used with other frame
materials and can be used in roof and floor insulation. Insulating plasters have also been
developed in France and retrofit insulation to existing buildings has also been carried out.
The net carbon saving effect, taking account also of the avoidance of using high embodied
energy materials, can be as much as 50 Tonnes of CO2 equivalent for a typical new build
house at construction stage. The excellent insulation performance of Tradical® Hemcrete®
alone would also deliver the opportunity to achieve very low or zero carbon emissions from
the buildings in use and, combined with the inherent carbon capture at the construction stage,
can provide the key to achieving better than zero carbon buildings. Certainly, Code for
Sustainable Homes Level 3 is readily achievable and designers are currently working on
Level 5 and 6 designs incorporating Tradical® Hemcrete®.
In addition the vapour permeability of Tradical® Hemcrete® provides a healthy environment
that building occupants and users should benefit from in the long term and Tradical®
Hemcrete® delivers very comfortable, warm in winter, cool in summer buildings assisted by
the buffering effect on temperature changes that the product exhibits through its
hydrothermal characteristics.
Lhoist UK has responded to the increasing demand for sustainable and low carbon
construction products by bringing together a team of partners to deliver Tradical® Hemcrete®
as a building product available to mainstream construction. Lhoist has teamed up with Lime
Technology Ltd. to blend and package the products; with Hemcore Ltd. the principal
industrial hemp processing business in the UK to supply construction grade hemp; and with
Castle Cement Ltd. to provide access to a nationwide distribution network of over 1000
builders merchants.
(Press Release provided by Tradical)
CONCLUSIVE NOTES
Hemcrete and Aerated Clay Blocks (Biobric, Thermoplan, Poroton, etc.) can be used
to reasonably build buildings up to 4 floors, though Hemcrete has eventually been
used in buildings up to 6 floors in France.
The Aerated Clay Block can be used as a frame infill, both in new and old buildings,
and both materials have good credentials in both new buildings and conservation
projects.
Both systems can be combined in various manners, either by adding a Hemcrete
Panel or Render to the Aerated Clay Block Wall or by building a Clay Block Cellar or
Ground Floor with a Hemcrete Upper Floor, etc.
A very promising system is a combined aerated clay block and Hemcrete wall system
where U-values of 0,15 could be achieved in less than 500 mm walls. The Hemcrete
is directly sprayed on to the Aerated clay blocks. The maximum depth of the
Hemcrete is 500mm and there is no need for framing or ties! Hemcrete can then
additionally be used also to have thermally efficient floors and roofs.
One can also imagine a scenario with a more formal Clay Block Building facing the
street and a more vernacular Hemcrete structure as a Back Building or a Mews
Building, etc.
1) Both Aerated Clay Blocks and Hemcrete perform exceptionally in terms of
energy efficiency, insulation, thermal mass, vapour permeability, acoustic
comfort, etc. The required wall thickness for both has to be a minimum of
400mm.
2) Hemcrete achieves a quite good 0,20 W/m2K U_value for a 400 mm wall and
even 0,15 W/m2K for a 500 mm wall.
3) The Aerated Clay Blocks achieve approximately between 0,22 and 0,26
W/m2K for a 400 mm wall depending on the various block types and qualities.
4) Hemcrete performs spectacularly in terms of Greenhouse impact by locking
up 40T/50T CO2 house, whereas the Aerated Clay Blocks perform relatively
well by having a 30% lower CO2 footprint than comparable cavity walls.
5) Both Aerated Clay Blocks and Hemcrete need to be rendered. Hemcrete needs
a special attention regarding water exposure whereas Aerated Clay Blocks do
not suffer from water exposure.
6) Hemcrete is a wet building process and the wall take some time to dry out
sufficiently, whereas Aerated Clay Blocks is a dry building system allowing
for a more discontinuous building process.
7) Hemcrete is a relatively soft material unlike Aerated Clay Blocks and need
either to reinforce edges, projections and corners or soften them into
chamfered or rounded ones. This softness is also an issue regarding the
hanging and application of fixtures and needs to be addressed as an important
issue. One has to evaluate also the capacity of the Hemcrete wall to cope with
later alterations, perforations and refurbishments and additional service
conduits. Quite positively though any wall damage or conduit can be repaired
or respectively filled in or insulated by either Hemcrete or special light lime
mortar.
Hemcrete Project for a Development in Stamford (UK) (The Prince’s Foundation 2008)
Two Sustainable Wall Structures at the Summer School in Lincoln
This paper has been produced by Lucien Steil at the Prince’s Foundation for the Built
Environment following up on the Residential School of the Prince of Wales’
Building Crafts Apprentices in Lincoln in 2008 (The Summer School was planned,
coordinated and directed by Ben Bolgar and Lynette Green).
The findings of the paper were used to prepare the brief of “The Natural House”
project to be built at the Innovation Park at BRE (Building Research establishment)
by the Prince’s Foundation for the Built Environment.
[Link]
