(De) and (Re) Construction

As civilization (?) expanded westward, everything had to be built up from scratch. Developing new land, erecting new structures, creating new cities. But this era has long since passed. Even in China, where up to 20 new cities are being built every year, the bubble is about to burst. Construction is increasingly shifting from a practice of creating new built environments, to renovating , repairing, and sometimes just removing the existing structures. And what are we to do with all the existing materials?

Re-using of materials has long been the mantra of our schoolchildren, and many industries have also seen the wisdom of providing for the recycling of the product in its end use. For example, in the US, 95% of “junked” cars are processed for recycling, with about 75% of the car’s manufactured content mostly metals) eventually being recycled for raw material use. 

Concrete Excavator w/ Magnet

One of the main reasons automobiles could be recycled was due to the nature of metals, and the ability to purify and separate out elements for re-use in their raw state. Construction is not quite so straightforward, since it involves many more materials which are intermixed within the same assembly. Possibly the “cleanest” of materials for construction reuse is concrete. The only problem has always been the removal of rebar, but one solution has been invented by a company in Ohio , who attached a magnet to the excavator bucket, which can be activated as it runs over a pile of crushed concrete to pull out the rebar. The cleaned, crushed concrete can be re-used for roadbed and rebar is fully recyclable. In some areas, this has grown to be a sizeable business, such as Recycled Materials Company, which was launched by the need to demolish and recycle the concrete at the old Stapleton Airport in Denver.

More difficult is the repurposing of all the miscellaneous materials from deconstruction. Here again, there is a business opportunity. Instead of paying to have a building demolished, an owner can hire a deconstruction arm of a non-profit company (such as Habitat Re-Store) to remove the property as a donation to a material re-use store. The owner gets a tax deduction, and the store gets paid for receiving merchandise. They get paid again for selling it. Of course, the cost of removal may exceeds the removal revenue, but even then – Habitat uses volunteers!

Renovation companies are growing. From my experience, the difference between a successful operation and a big junkyard is in the systematic documenting of materials, making this available on the web, and keeping good business practices. Overstuffed, cat-infested warehouses just get more material, tend to hike up their prices to overcome the low sales, and eventually go out of business. It is a business.

Repurposed Snow Fencing

One person who has done this well, in the re-use of industrial byproducts and waste for the use in construction and other industries is Damon Carson, of Repurposed Materials. Because the company is selective in the materials they gathers, and can provide a fairly steady supply, it is possible for entrepreneurial ventures like Luxwood to manufacture furniture with the use of reclaimed wood.

The problem in developing a business model in construction which could accommodate the use of repurposed materials is the extra cost of sourcing this material and adjusting the construction process to accommodate for special installation. Such a scenario could be addressed through a “joint venture,” so to speak, with the owner as the scouting party. A scope would need to be developed for acceptable type of materials, and specifications developed to help guide owners choices. The material types might start with reliable local supplies of recycled materials. While this requires a higher degree of organization on the contractor’s part, in order to be more flexible without upsetting the core building process, I see evidence of this trend growing. Not only for homeowners, but also commercial properties – where owners are looking for more unique architecture.

It is time for a mind shift, beyond the extraction of raw materials for the manufacturing of new goods, and beyond the sourcing of materials from chemistry labs. There is an abundant source of innovative materials awaiting us in the form of existing materials ready to be repurposed for another life-cycle. Time to think of de-construction as intrinsically linked with re-construction.

"Better Road Building Paves Way for Energy Savings"

Warm-mix asphalt is not the usual topic which I would expect in the National Geographic Daily News , but it certainly is a sign of the commitment of the magazine to energy ssues. It piqued my interest about the true potential of this new roadmix to save energy and provide a more durable surface. I remember well the bathtub sized potholes in the streets of Chicago, and wonder if this mix might prove to be more resilient.

Red Rock Aggregate in Asphalt

In my previous life, I was on the concrete side of the concrete vs. asphalt debate. The argument was for a longer service life (ie lower LCA), lower heat island effect, higher load bearing, and ability to recycle old roadbeds (Recycled Concrete Aggregate - RCA). I’ve championed pervious pavement for the ability to resupply the water table. On the other hand, I have to admit that concrete surfaces can be quite noisy, and require a higher level of installation skill – which was notoriously missing on one of my neighborhood streets which is now infamously known as the “roller coaster.” On the other side of the debate, asphalt makes a good overlay, and can also be recycled (Reclaimed Asphalt Pavement - RAP. And, the lower temperatures of the new warm-mix asphalt not only improves the conditions of the workers, but also reduces emissions and has about 30% fuel savings. So which is the better choice?

Both. Recycling concrete is a good idea in principle, but the use of the aggregate has been limited to low grade applications like base materials, haul roads and staging areas. It is difficult to use it for ready-mix concrete, because the random and uncontrollable composition of the aggregate (porosity, impurities, chemical composition) makes it difficult to guarantee the ability of the Portland cement to bind the rock. However, the characteristics of the rock are far less of an issue when the binder is asphalt, which allows it to be used in a high grade application – such as the actual roadbed.

There are several possible combinations available - such as using the RCA as the road base, or mixing the RCA and RAP for the road surface. Or one can mix in crumb rubber, using up some of the mountains of tires accumulated in America, and gaining a quieter road surface in the process.

Swiss Concrete Asphalt + Cobbletone 

The lesson learned is that industries which have traditionally been fierce competitors (concrete vs asphalt), or even totally unrelated (rubber tires) can come together to provide better product – in this case using more recycled material, providing a more durable surface, and a smoother roadbed for improved fuel efficiency of the vehicles.

This is an example of innovation on the edge of the industries, where a strategy which has allowed the IT world to keep nimble and make rapid improvement. Maybe this feature in the National Geographic will inspire yet another connectivity of ideas, and figure out a way to make roads last as long as the old Appian Way.

Freedom or Responsibility: Greening the Built Environment

“Freedom Day” as our state euphemistically calls the Martin Luther King Holiday, is an opportunity to reflect on the many types of freedom enjoyed by mankind. Democratic nations enjoy free will and liberty to make choices in life concerning education, speech, and self-determination.

These same freedoms apply to all of your neighbors. In principle, this would mean that your son’s rock band can practice whenever they want. But we all recognize the mayhem this would create, and recognize that freedom is not a wholesale lack of restrictions. It comes with a responsibility towards other humans. However, because we don’t all have the same understanding of noise, per the example, then an arrangement need to be made for a common solution, Hopefully, this can come about through some means of representation, but in general, we recognize the need for some common ground rules, for example a noise ordinance. All groupings of people create some sort of governing body, to watch out for the welfare of the greater good.

From an environmental perspective, we recognize the need to protect humanity. For example, laws are passed to prevent toxins from polluting waterways, or harming manufacturing workers. History has shown us that mankind, and it’s representation as “industry” has more often than not acted out of economic interest, without consideration to environmental harm. It often takes a third party to research and recognize the environmental considerations, which is then presented to a government to safeguard the public.

And so it is with energy and green building. Our guest blog on the GreenBuilding Advisor has generated considerable discussion regarding the possible paths towards a greener built environment. And while some express hope that human nature will rise to the occasion, Mike Collignan has so clearly pointed out that the voluntary market efforts have resulted in a mere 4.45% – 5.39% penetration over the last two decades. So the pseudo democratic, quasi capitalistic economy is clearly not the most effective in catalyzing the change which is needed.

In fact, industry and the building trades have a heavy hand of influence through their trade organizations in the commercializing and weakening of many of the voluntary green building rating systems and standards. (ENERGY Star excepted, Sam Rashkin & colleagues rely on solid building science in the development of their benchmark and trainings). It is about short term economics.

As part of my research, I have found two sets of Emotional Intelligence testing data which indicates that people in the construction industry has strong skills in independence and assertiveness, but much lower skills related to empathy and social responsibility. Perhaps this is a good place to start, with entering freshman, new hires, and whenever the discussion of a green building product arises. Are we seeing our businesses only within the narrow confines of our short-term results, and the freedoms to build as we please? Or do we understand the opportunity to contribute to the greater good? And yes, there are sufficient exemplary companies who have successfully combined the goals, so it can be done.

Today we think about freedom. The freedom to make the right choices for our fellow man, and for future generations.

Making Progress in Construction

I’m an Explorer. My world is all about taking risks, trying out new concepts, being inspired by challenges. Nothing could be more interesting than a passionate discussion, a rapid-fire exchange of questions, values, vision, and ever-evolving ideas. And when this “ideation” moves toward the development of an elegant solution, my own role shifts more to helping develop strategies and selection criterion to realize the highest project value. At these moments, I look to my counterpart “refiners” to apply the robust measurements and tools to hone the final outcome. That is my idea of a perfect evening (add wine and a fireplace).

Explorers and Refiners, a bit like yin/yang, expansive/contracting, breathing in/ breathing out. These are the persona explored in “Progressmakers,” a term coined by Clampitt and DeKoch in a thought provoking book by the same name. Personas which describe not just individuals, but also phases of progress within a project or company, as it moves from one platform toward the next. An exploration phase involves risk-taking, sometimes voluntarily, but also under duress. Consider the Pilgrims, who chose the risk of crossed the ocean to unknown territories was preferable to sticking to their status quo. So it was in the 70’s, as gas prices pushed us to explore new insulation materials, radical alternatives in energy efficient construction, experimentation with capturing solar energy. And even after the economic impetus was removed, some “refiners” continued to test the materials, the systems, and develop the new field of building science. This in turn provides the basis for the next wave of experimentation, triggered by the escalating climate & environmental issues.

On a project level, one might recognize the traditional roles of designers (explorers) and engineers (refiners). But I would propose that we take off our blinders and separate the roles from the job titles. There is much to be gained when engineers bring the technical expertise to the creative process, or designers leverage their analytical skills to keep the review process relevant to the client’s needs. In an integrated delivery process, there are typically several iterations of expansive, exploratory ideation, followed by some fact-finding and concept testing. Participants involvement also ebbs and flows, but there is always room at the table for input.

This cycle concept also provides a perspective of the “continuous improvement” as described in lean processes, and the nuanced difference of lean as employed by Toyota, and as interpreted in the US. Peter Drucker once noted that the Japanese seek buy-in prior to the development of an idea, whereas the Americans look for buy-in after the fact. This was in response to the frustration of American manufacturers, who were flabbergasted at the amount of time their Japanese counterparts spent in cycles of exploration and refining, often seemingly starting from scratch with new groups of employees and stakeholders, all prior to product prototyping and release. By the same token, the Americans then felt rushed when the product decision was made, since the US culture was more accustomed to seeking input and product refinement after the proto-typing. From the perspective of construction, clearly it is less costly and more efficient to spend the time in design and make changes on paper than it is to change the product in the construction phase.

My initial research in exemplary case studies of “deep lean and deep green” projects has identified the same “Toyota-like” dedication to discovery and comprehensive project checking at the design phase. There is an amazing amount of ideation and critical analysis in these great rooms, with participation not only from the traditional core design team, but also from the trades, the public, the client and the regulatory agencies. These dynamic discussions bring progress not only to the specific project, but also carry forward the great “aha” moments to the next project. There is a perceptible shift in culture, a passion for perfection, a positive outlook and willingness to seek solutions.

Listening to my interviewees describe the very deeply integrated and lean processes is almost like my imagined discussions by the fireplace with a glass of wine. They seem somewhat unreal, impossible in today’s litigious society. Yet these teams are delivering amazing building projects, and those who “get it,” are able to repeat the process for continuously improving success. There are indeed progressmakers among us. Maybe it is time for us all to cross that ocean, to make the leap, and help move our industry to the next level of performance.

Environmental Engineering: a Paradigm Shift

There is no doubt that the global environmental predicament we are in calls for a paradigm shift in our stewardship of this planet. All too often, I lament the lack of collaboration, vision, and caring in the workforce, which are roadblocks to meaningful solutions. But it could well be that I am stuck in my own myth, and the world is changing around me. This week, I was inspired by two wonderful students, part of my own extended family, who fit a very different profile of 21st century workers.

While my generation had to learn and adopt an awareness of the environment and cause/ consequences of human actions within greater ecosystems, this generation of students grew up with this knowledge as fact. Both of these students are pursuing degree of environmental engineering, a growing fields, which was very much a non-sequitur in my day. Engineers were the numbers people, who built things, fixed things, or computed things. They dealt in specifics. Environmental studies were the domain of biologists, the earthy people, who looked at the big picture. There was no common language, and overlap was fraught with contention, since engineering activities were often disruptive to the environment. Even computers were problematic, given the vast amounts of resources used in the making of microchips.

Fortunately, there has been a paradigm shift to the recognition that engineering knowledge is a tool which can be harnessed to contribute to the solutions in the environment. So my niece will be leveraging her ability to create order and understand patterns through computing skills to help address issues of climate change, and energy modeling. The young man is honing his already keen sense of observation and analytical thinking to provide an insight into the problems and solutions of the human interface with the natural environment. Both seem to have a greater mental flexibility which allows them to see the big picture, as well as the ability to stay focused on specific tasks. They have the capability to become solution seeking engineers, breaking away from old formulaic approaches. These were the very characteristics which Engineer Ono sought for Toyota, to help with the process of continuous improvement.

But beyond the skills, this generation seems to have a much greater awareness of the limitations of resources, a heightened recognition of the impact of our consumer society, and a social awareness of responsibility to others. These young adults are the ones who are driving the launch of co-ops, who are downsizing to smaller houses, and who are calculating their carbon footprints. Since they grew up with technology, they are more realistic about the role it plays in finding solutions. They are just as likely to be the ones raising chickens, getting back to basic thermodynamics in designing energy efficiency, and tinkering with electric car motors.

Perhaps I am just fortunate to be surrounded by so many wonderful young adults, but it makes me want to stick around for the next 50 years to see what these kids come up with.

Innovations for the New Year

Tradition has it that the activities of the first days of the year set the tone for the remainder of the year. As a result of much basking in sunshine, good mountain air, and indulging in culinary creations, my creative little gray cells have gone into high gear and catalyzed quite a stream of creative thought. So I thought I would share some inventions, both recently implemented and cued up for future construction projects…

1) Three way door. This was a solution created for a tight hallway space to replace two door functions with one single door. There are two closed door positions, at 45⁰ and 90⁰ to the open position. The door swings on pin hinges at the floor and ceiling. The striker plate and door jamb was modified to allow the door to swing through the 45⁰ stop. This was an elegant solution to be able to close off the master bedroom while allowing public access to the “powder room” (WC ), or to enclose the full master suite. There are many creative door options which can help save space and increase functionality.

2) Dining Room to Office Conversion. I once read a clever idea by Sarah Suzanka to make use of a formal dining room as a library. This inspired me to design dining room cabinets to double as filing cabinets, installing DSL, undercounter lights and…. a desktop extension which could slide into place between two flanking cabinets when the french door to the kitchen was closed, thus creating a computer table top for office use. Designing multi-function rooms increases the adaptive re-use of spaces. This dining room can now become a home office.

3) Media wall - A wall which is really two bookshelves back to back, with the exception of a few of the “cells” which are full depth and house the stereo system. Cabinet doors on both sides allow for access to both components and all that messy wiring. I’m also thinking one could mount a large screen LED monitor within one of these spaces, which could then swivel to face either room, perhaps providing an extra screen for an office, as well as a TV monitor for a living room. It rationalizes the investment in a higher quality of equipment, as it will see a higher use. This also makes good use of space.

4) Transparent “art” walls flanking a staircase - Stairwells are often flanked by regular sheetrock walls, making them dark and very plebian. My solution was to flank the wall with sheets of acrylic, which had been carved out with a mountain scenery motive. This was the cheap and cheerful solution which I ordered from a sign shop, vs the far pricier option of transparent wall panels. Either way, it provides the functions of safety, structure and daylighting – as well as providing a focal point of design.

5) Drying Room – Mentioned in a previous blog posting (solar air heating), this would be a room which is heated by preheated, dry, air. It would be situated next to the laundry room, to provide a space to hang clothes (or herbs, crafts) to dry. Of course the air intake is also matched with an exhaust fan. I’m also thinking of reviving the fine old tradition of a root cellar, to store the fall crop, and to brew apple cider.
This seems to be an auspicious start to the New Year. So here’s to innovation, to tinkering, to crafting, and creativity. Cheers.