Growing Food Year-Round with a Faswall Greenhouse

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Greenhouse, Faswall, cold climate greenhouse, four-season greenhouse, Gunnison, ColoradoWhen Susan Wyman of Gunnison Gardens in Colorado contacted us last year about building a greenhouse with Faswall’s highly insulated block forms, we could immediately see the benefit of using our eco ICFs for the project. Greenhouses work by enhancing solar gain. Add the heat-retaining thermal mass and Faswall’s insulating blocks, and it seemed likely that this greenhouse would work better than most.

Susan lives in a part of the world where heat retention is particularly important. Gunnison, Colorado is one of the five coldest cities in the United States. “When we got frost on the 14th of July, I didn’t know if that was the first frost or last frost,” she says.

Because of that, Gunnison might seem like an unlikely place to garden year-round. But that’s what Gunnison Gardens is doing. The farm is in its third year of growing plants, vegetables and cold-hardy vegetables for local residents. (We’re also delighted that they’re a dealer for Durable GreenBed, our raised gardening bed kits.) They hope to eventually become a source of sustainably-grown food for the region.

“The U.S. is headed toward a low-energy future,” Susan says. “Since I think we’re going to be concerned about food security in the future as well, we have to look at how we’re going to feed our communities throughout the winter without having to rely on fossil fuel energy.”

That’s why a greenhouse was so important to Susan. But she didn’t want to build one that require fossil fuels to operate. “I was looking to build a cold climate greenhouse or four-season greenhouse,” she says. “A lot of folks have built these structures in Colorado and Minnesota and other places. They’re often done with poured concrete. I was looking for a more environmentally-friendly DIY project.”

Susan researched cold climate and four-season greenhouses online and by reading books such as The Forest Garden Greenhouse (which she highly recommends). Then she designed a structure that fit Gunnison Gardens’ needs.

Next she searched for the right materials to build the greenhouse with. When she found Faswall, an eco ICF wall form, she was impressed by the blocks’ very high thermal mass and recycled material content. The fact that the product was easy to use was also a plus; Gunnison Gardens employees were going to build the greenhouse, and most of them had little to no construction experience.Greenhouse, Faswall, cold climate greenhouse, four-season greenhouse, Gunnison, Colorado

One of the first and most important steps in creating the greenhouse was building a climate battery. Also known as a subterranean heating and cooling system, a climate battery is basically a net zero energy heating system. To build the climate battery, Susan and her staff dug five feet into the ground and laid tubes made from perforated and corrugated HDPE. A fan would force warm air from the greenhouse into the ground, where it would warm the soil and create a good growing environment for plants. At night, any warm air stored in the earth could be pushed back into the greenhouse to keep the structure warm.

“A lot of our plants are growing in the soil in the floor of the greenhouse,” Susan says. “So keeping that soil warm is critical for plant health.”

To capture the solar energy needed to provide that warmth, the team at Gunnison Gardens built a wall with three layers of polycarbonate plastic on the south-facing side. The remaining walls were constructed from Faswall. The greenhouse was finished with spray-in insulation on the north side of the metal roof.

“The block itself is very easy to understand,” Susan says of Faswall. After one day of coaching from Faswall construction expert Mark Maricle, her staff was able to put up the remaining walls with little assistance.

The finished structure is around 30 feet wide, 80 feet long and 19 feet tall. “So far it’s gotten to minus 15 degrees Fahrenheit outside and it’s never frozen inside the greenhouse,” Susan reports. “It stays above 40 degrees.

Greenhouse, Faswall, cold climate greenhouse, four-season greenhouse, Gunnison, Colorado“The structure works in part because Colorado is really sunny,” Susan continues. “The solar gain in phenomenal.” In addition, “the mass of that thermal wall is amazing in terms of maintaining heat storage and release during the night.”

2016 was the first year Gunnison Gardens used the new greenhouse. Susan was able to grow warm weather crops like tomatoes, cucumbers and melons into the fall. The strawberries are still going. This year she’ll start seedlings in March and cultivate foods such as broccoli, cauliflower and sweet potatoes later in the year.

For farmers, garden center, homesteaders or homeowners thinking about building a greenhouse, Susan has this advice: “Do your homework up front, build it to last, and crunch your numbers. Make sure it makes financial sense.”

Following those steps created a positive result for Gunnison Gardens. “I’m really pleased with the outcome,” Susan says. “It was a big undertaking for us, but I’m convinced this is what we need for the long term.”

If you’d like more information about using Faswall for a greenhouse, storage building, home, office or a project of your own design, please contact us.

Buddhist Temple in Texas Showcases Faswall’s Versatility

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Buddhist organization in Dallas building a temple, cafeteria and dormitoryWhen a Buddhist community in Dallas started making plans for a new temple, cafeteria and dormitory, they wanted to create the healthiest and most ecological buildings possible. Inspired by the work of EcoNest® Company, they decided a mixture of straw and clay would be their primary building material.

While this combination is ideal for shaping and insulating walls, they also needed a product that would create a strong, durable and dry foundation (and, for the two-story dorms, strong bearing walls). They selected Faswall, a versatile ICF wall form that’s ideal for many types of projects. While Faswall’s easy-to-use blocks can be used to create DIY or contractor-built homes, office buildings, warehouses, outbuildings and other structures, they also make great foundations and basements for buildings crafted from other materials.

The leadership team in the Buddhist community liked Faswall because the concrete and wood blocks are made of 100 percent organic materials. Eighty-five percent of the wood in each Faswall block is clean, recycled pallet wood. It’s combined with virgin wood and Portland cement to create a product that will not off-gas chemicals into buildings.

“Many of our customers are interested in using the Faswall block to create healthy living environmeWorking on a Buddhist temple in Dallas, Texasnts,” says ShelterWorks co-owner Paul Wood. “They want indoor air quality that’s exceptional. Faswall creates an excellent vapor-permeable membrane that allows indoor air quality to be a natural part of the building and living experience.”

The vapor-permeable nature of the blocks is important when it comes to other factors that affect indoor air quality. Because of Faswall’s porous hygroscopic nature (i.e. the walls store and release water vapor through diffusion), the blocks keep relatively humidity levels low enough that mold spores don’t grow in the walls. That keeps potentially toxic mold out of your building.

Faswall’s ability to regulate relative humidity also keeps the structure more comfortable and livable. Most of the time, humidity is higher inside a home due to activities such as showering, cooking, even breathing. When a home has walls that don’t breathe, and therefore relies on mechanical ventilation to vacate moisture, the indoor air can become denser than the desired 30 to 40 percent humidity level. That leads to the heavy-feeling air we often experience in basements.

Faswall’s porosity allows excess indoor humidity to diffuse through the walls. With proper waterproofing, they don’t allow water to seep into structures. That’s why they’re great for foundations.Building a Buddhist community center in Dallas

The other reason is that their mineralized wood composition makes them strong and durable. Faswall gives people building with straw bale, timber frame or clay/straw slipform a good base wall system to support upper walls.

The Dallas project isn’t the only time Faswall has been used to build a Buddhist temple. Check out this story and video of the Sravasti Abbey in Washington to see their beautiful structure, which is built entirely with Faswall blocks. Other religious congregations have also selected Faswall as their building material of choice.

Perhaps that’s not surprising. Faith helps comfort us in times of despair, celebrate in times of joy, slow down and reflect on the things thaOne of the buildings at a Buddhist community in Dallas, Texast are important to us. Just as a belief system is a versatile tool for living, Faswall is a versatile tool for creating the places that nurture and protect us.

No matter what type of structure you’re thinking about building – and no matter what type of material you’re thinking about using – Faswall can play a role in your next project. Contact us today to learn more about using Faswall building blocks for churches, temples, foundations, homes, offices, commercial buildings, outbuildings and more.

Home Exemplifies High Performance Building With Faswall

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Jack Clark high performance home ColoradoOur last blog post discussed the theory behind designing and building high performance homes. For this post, we’d like to discuss the practice of building high performance homes with Faswall ICF wall forms.

Jack and Carolyn Clark’s 3,200 square foot home in Ft. Collins, Colorado exemplifies many components of high performance building. The home is very energy efficient, thanks in part to Faswall’s extremely high thermal mass. It’s built to last for at least 300 years, so it’s quite durable. High-quality materials such as 3-0 windows and a propane/heat pump HVAC system ensure excellent life-cycle performance. Since both Jack and Carolyn have allergies, they used building materials designed to ensure good indoor air quality and occupant productivity.

The Clark residence sits on an acre of land Jack’s parents bought in 1972. Their 750-square-foot house overlooked Horsetooth Reservoir and was intended to be a summer home. But his parents made it their permanent residence until they passed away.

Jack wanted to stay on the property, but he had a different vision for his forever home. He wanted more space and a house that could be passed down to future generations of his family. Jack had his parents’ old home deconstructed in 2012, then started looking into suitable building materials for a new structure.Jack Clark high performance home Colorado

“Carolyn and I wanted to incorporate as many progressive products and techniques as possible for the build,” Jack says. “I was looking for a unique, thermally-efficient, cost-effective approach. We met [ShelterWorks co-owner] Paul Wood at a home and garden show in Denver and became very interested in his building method right away because the Faswall system allowed for well-insulated, high internal thermal mass wall construction.” Local Faswall representative Mark Maricle was also a great resource throughout the building process.

Faswall was also a good fit with some of Jack and Carolyn’s architectural requirements. They both grew up in a section of New Jersey with many Dutch Colonial style homes. They liked the deep window wells found on those structures, which is an added bonus of using Faswall’s one foot by two foot blocks. They wanted to finish the interior walls with smooth plaster and the exterior with lap siding, which meant using a building material flexible enough to accept any type of finish.

Once he selected Faswall, Jack went in search of a builder. He wanted someone willing to work with a non-traditional material. He also needed someone with enough attention to detail to build a high-quality home capable of lasting for 300 years.

Jack Clark high performance home ColoradoHe found both in Matt Doner of Traditional Roots Joinery & Construction in Ft. Collins. Matt is primarily a timber frame builder, but he was excited to combine his carpentry skills with the easy-to-use Faswall blocks.

The home that evolved incorporated the best of both. Jack says one of his favorite features in his Faswall home is the beams crossing the vaulted ceilings. They’re made with Northwest fir and locally-sourced Ft. Collins walnut. Jack also likes the elevator, which makes moving people and furniture around the space much easier; the highly efficient windows and sliding glass doors, all of which were manufactured by a Colorado company; and those deep window wells. The home has the exact same orientation as his parent’s house, which gives the family views of the reservoir.

Function dictated design for the house, Jack says, and the layout is a great fit with the family’s needs. An open floor plan upstairs makes entertaining more enjoyable. A mud room/laundry room/bathroom accommodates muddy dogs and gardeners, as well as sopping boots on snowy days. The Clarks hope to eventually add a wrap-around porch, much like the ones on the Dutch Colonial homes they remember so fondly.

Jack has tracked the home’s performance since he moved in and is very pleased with what he’s found. Their electricity comes from the rural cooperative, and the home has a propane/heat pump furnace for heating and cooling. “The rural electric bill averages $100 per month, and we use no more than 21 gallons of propane per month,” he says. “Our utilities (other than water) average $125 per month for a 3,200 square foot home with three adults living here full time.”

Thanks to the insulative value of the Faswall blocks, as well as strategically placed insulation, the home stays comfortable no matter how warm or cool it gets outside. “The thermal mass maintains the inside temperature better than convention builds,” he says. “Therefore the HVAC does not have to ‘catch up’ as much to maintain temperature. When we have 50 degree days and 20 degree nights, the house will lose no more than one to two degrees overnight.”Jack Clark high performance home Colorado

Jack has several pieces of advice for anyone building with Faswall. It’s important to look at the whole home when planning for energy efficiency. “Besides picking very efficient heating/cooling equipment, insulate the ground floor slab from the ground below it and the footers,” he says. “Consider using varied insulation types according to where the insulation is installed and the clearances required.

“Do not be stingy with glazing,” Jack continues. “Look closely at what the window and door frames are made of. Fiberglass is non-conductive and will not warp.  Consider how much sun and what type of sun should pass through the glazing. All heat and light can be controlled to the owner’s benefit. Choose a window and door supplier that understands this and can customize products to control the heat loss and gain.”

Jack Clark high performance home ColoradoAlthough Jack didn’t build his own home, he has this advice for do it yourself home builders: “It pays to get tricks from Paul or one of his representatives. It will make the job go smoothly.”

Would you like to learn more about how Faswall can help you build a high performance home? Whether you’re a builder or contractor, architect or engineer, or DIY home builder, we can help. We can also offer advice on using Faswall for high-efficient, high performance, eco-friendly office buildings, outbuildings, warehouses and much more. Please contact us today for more information. If you want more information about Faswall right away, check out our free technical manuals.

High Performance Homes Will Define The Future of Building

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High performance, green builidng, ICF wall form, FaswallFor years homeowners, contractors, architects and material manufacturers have focused on “green building,” or constructing homes and businesses that have less of an impact on the planet. But more and more, they’re moving away from the term green building in favor of “high performance building.” Industry experts believe this phrase does a better job of explaining the myriad goals they hope to meet, including lowering a home’s carbon footprint, saving the owner money on energy bills, and creating a structure that will last for a long time.

Since the term high performance building is so new, there’s still a lot of confusion about it. What does high performance building mean? Why is high performance building better than green building? How do you build a high performance home, office, warehouse or other structure? We’ll explore these questions in more depth.

The National Institute of Building Science defines high performance building as creating structures that “integrate and optimize all major high-performance building attributes, including energy efficiency, durability, life-cycle performance and occupant productivity.”

That’s a bit of a mouthful. Let’s break it down.

Energy efficiency is one of the most important parts of high performance building. Decreasing your home’s energy usage is important for many reasons. In the United States, electricity production is the largest contributor to climate change, creating 31% of our total greenhouse gas emissions. Forty-one percent of all the energy Americans produce is consumed by residential and commercial buildings. If people can significantly lower the amount of energy needed to power their homes, they can make a big difference in the fight against climate change.

high performance, green building, ICF wall form, FaswallIncreasing your home’s energy efficiency can help you save money on your utility bills, and get you closer to the goal of living partially or completely off the grid. For people interested in homes that utilize net zero, Passive House or passive solar principles, building an energy efficient structure is a must.

Durability is another important component to a high performance home. When you construct a building that will  last for a long time, all the energy and materials that went into making it remain there. From an environmental perspective, saving the embodied energy of the home is vital because it keeps materials out of landfills and decreases the amount of new materials that have to be harvested, mined and processed. The longer a home stands, the longer you can retain that embodied energy.

The average high performance home is designed to last for up to 200 years. Because it’s built to such high standards and with such quality materials, it’s better able to withstand natural and man-made hazards such as severe weather (hurricanes, tornadoes, tsunamis, etc.) and wildfires. If you’ve ever dreamed of having a house you can pass down to your children and grandchildren, building a high performance home will help you fulfill that dream.

high performance, green builidng, ICF wall form, FaswallLife-cycle performance is similar to durability. It takes into account how well the building performs over its long life.

Having good life-cycle performance means the home meets all the owner’s goals (no or low utility bills, lower maintenance costs, good indoor air quality, etc.). It does that now and into the future. A high performance building should be built well enough and smart enough that it doesn’t require a lot of time or money to maintain. Not only is it made with high quality materials, it utilizes the best in building science to reduce mold, rot and other problems. Some examples of smart building science include looking at a building’s envelope, thermal mass, materials, heating and ventilation systems, and defense against rain and the natural elements.

We believe occupant productivity comes down to the health and comfort of the people who live and work in the building. One of the biggest considerations for a healthy home is good indoor air quality. In older homes, air and moisture have many places to enter the house, but few places to escape. As a result, the air is full of dust mites, mold, bacteria, pollen and other allergens. It’s estimated that the air quality inside a typical home is two to five times worse than the air quality outside. That’s concerning because Americans spend 90% of their time indoors.

In high performance homes, the interior air is continually exchanged with outside air that has been filtered and tempered. That means mold is less likely to form inside the walls, allergens and pollutants don’t enter the home, and you and your family have a healthy, pleasant living environment. High performance homes are also built with non-toxic materials that will not off-gas formaldehyde, phthalates, VOCs, flame retardants and other harmful substances into the house.

high performance, green builidng, ICF wall form, FaswallAnother way high performance homes increase occupant productivity is by providing a high level of comfort. All the building science involved in creating high performance homes means structures have a consistent interior temperature, no drafts and very little noise. They are clean, full of light and smell good.

In addition to the four attributes described above, we would like to add that high performance homes are built with what we’ve come to know as green building materials. Green building materials contain recycled materials, are easy to recycle at the end of their lifecycle, have a minimal negative impact on the planet when they’re harvested and manufactured, and/or don’t contribute to bad indoor air quality.

High performance buildings should also be aesthetically pleasing and functional for the homeowner. If a building meets all its goals in terms of energy efficiency and occupant productivity, but it’s ugly or has a bad floor plan, no one will want to live there. It increases the likelihood that the building will be torn down at some point.

If you’re looking for the perfect building material for your high performance home or office, Faswall is an excellent choice. Faswall ICF wall forms create structures that are extremely energy efficient thanks to their high thermal mass.

high performance, green builidng, ICF wall form, FaswallFaswall is made with a blend of recycled wood and concrete, which makes the blocks extremely durable. Homes can last for well over 200 years. The mineralized wood composition ensures Faswall resists pests and will not mold or rot. Wood and concrete are completely organic materials that will not off-gas into the house.

The interior and exterior of a Faswall home, office, church, outbuilding or other structure can be finished any way you want. As you can see from the photographs, the structures look beautiful when they’re done. Faswall blocks are easy to work with, whether you’re an experienced contractor or a DIY home builder.

If you’d like to learn more about building a high performance home with Faswall, please contact us today. If you’d like to learn more about high performance homes in general, here are some resources:

High Performance Building Council

Whole Building Design Guide

High Performing Buildings magazine

American High-Performance Buildings Coalition

Faswall Home Featured on Oregon Home Magazine Blog

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Green building and net zero Hood River home featured in Oregon Home magazineOregon Home magazine featured a Faswall-built home in a recent blog post.

This Hood River home demonstrates many of the best things about Faswall. The blocks’ thermal mass keeps the structure warm in the winter and cool in the summer. The owner’s opted to use a green roof, which also helps with internal temperature control. Contractor Tom Reid with Green Home Design + Build in Hood River says it was easy to apply stucco inside and out. And the resulting home looks wonderful – something many people believe isn’t possible when you’re building a “green” building.

The article also mentions the fact that Faswall blocks are made with recycled wood and non-toxic cement. The recycled content of our blocks, coupled with the fact that they’re made of organic materials that will not off-gas into the home, makes them an even more eco-friendly building product.

The theme of Oregon Home’s most recent print magazine was “The Future of Housing.” It focused on new building technologies that are changing the way houses are built and maintained. We think Faswall is a great fit with this theme.

Thanks Oregon Home for thinking of us. If you’re interested in building a green, net zero or eco-friendly home, please contact us to learn why Faswall is right for you.

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