Tuesday, August 4, 2015

We've built a Rocket... Mass Stove?..Heater?...Furnace?


Image result for stelle permaculture rocket mass heater
Midwest Permaculture


I've hinted about it and now it's time to get down to the brass tacks or fire brick as it may be; we have a furnace embedded in our floor. I was the one four years ago who said "sell it all, we need a different life!" which lead us to the Poor Farm 3 months ago. Keith was the one who uttered the crazy words of "Earthship Home." I was the one who countered with "Grain Bin House Baby!" While he completed the psychotic circle when he told me "Gonna build you a Rocket Mass Heater." Seriously, why can't we just give each other striped ties and crockpots like normal couples do? I heard that.


Image result for rocket mass stove
cassiopaea.org


Don't worry. We haven't given up on the Earthship home aka The Tire House, it's just we can only build one home at a time. Go ahead and call us limited, you won't be the first. Our long range goal is to use the GBH, which we are building right now, for interns who want to spend time with us learning how to be more self sufficient. When it is completed as as finances allow we will start on the Earthship home.

When we planned (and I use that PLAN word quite loosely) to build the GBH we knew we wanted to keep the square footage small and the total build cost low. When both floors are completed we'll have about 700 total SF to ramble around in. At first we considered the basic floor mounted wood stove for heat but after finding out that a large amount of the heat generated pretty much goes right out the top of your home, that one must be prepared to feed in a lot of wood several times a day in very cold weather, and that chimney fires are a real threat, we settled on the Rocket Mass Heater or RMH.

Wickipedia does a good enough job of describing the general idea and a detailed explanation with lots of cool photos exists on Paul Wheaton's web page richsoil.com. but the resource we relied on most was the book written by Ianto Evans and Leslie Jackson called Rocket Mass Heaters Third Edition. We also consulted with our good friend Jay Molter of Molter Corporation who advised us on fire brick types, sizes and morter, insulating materials for the steel barrel and the basics of how not to burn down our new house.


Most examples we saw on the internet as well as one in person, the one at the top of this post built by friends of ours, consist of the rocket mass stove hooked into a large sofa or bench made of cob, concrete or other masonry type materials. As the stove burns its wood the masonry mass absorbs the heat and releases it over many many hours and depending on the size of your home, the efficiency of your stove, this release of heat may go on for two or three days. As much as Keith and I liked how this heater worked we were concerned about giving up so much floor space for the bench part. What if we didn't like where we put it? So because it was my turn for the next nutty idea, I suggested we make our "mass" the concrete floor of our bin. Hmmmmm.

We liked the idea but could not find too many other examples on the internet, lots and lots of benchs, beds and tables made into "mass" heaters but not so many floors, as in none. All the more reason for us to take on the task, we really like going where no man...or homesteader, has gone before. Now, if any of you know of someone who has done a RMH in the floor of their home (and they are still alive to tell about it) be sure to tell us.

Thus, after the gravel part of our GBH floor was tamped down firm, Keith began piecing together our stove. First we went to Menards where we were able to purchase all the stove pipe parts. After that a visit to Molter Corporation where we got our firebrick, Kaowool and morter. Our steel barrel was found locally. We then played with the firebrick configuration following the information given in the book by Evans and Jackson.

The base looks like this: (Don't you LOVE the floor underneath? Yeah, that's the 150 year old house on the property that is serving as our storage shed/barn/workshop/freezer hold etc...)


The next two photos are a couple of more prototypes.



 
Finally, the partially completed version being set up on the gravel base of our GBH floor



To the left (in the photo above) is the feed chamber where we feed in small 2-3 inch thick sticks rather than large logs. The room air rushes to the right (sounds like a rocket thus the name rocket mass heater) and will go up the middle section which will soon be covered with a burn chamber and steel barrel. Refer to the second photo in this post. This hot air comes back down within the burn chamber and feeds into the black pipe on the right. The hole in the black pipe will be level with the floor and serve as one of the cleanup holes; a place to vacuum out ash. Most of what you see in the above photo will be in our cement floor.

 
Above is more of the black stove pipe which had gravel packed against it to hold in place while the concrete was poured over top, resulting in 6 inches of concrete ABOVE the top surface of the stove pipe. The exhaust pipe heading straight up will be extended all the way up the inside of the GBH and out the ceiling. If all goes well what comes out of that exhaust pipe at roof level will be pure steam, NOT smoke as this RMH burns very hot and very clean.
 
Down below you can now see the feed and burn chambers as they look buried in our concrete floor. Our next step will be the placement of the steel barrel over the heat riser. This area will be one of the hottest sections of the stove and the top of the barrel can be used to cook food, raise bread, heat tea water, who knows; maybe we'll put a hot tub on top of it to make those cold winter night even more pleasurable. From all we have read if the RMH is built well we may only have to fire it up every three days in winter as the concrete floor will be enough mass to absorb and then release the heat steadily for that time period. Even if only once a day it will be far more efficient than a traditional wood stove. Only time, cold weather  and a bunch of little wood sticks will tell.
 
Feed chamber for sticks on the right now, flush with our floor
and the fire brick in middle and opening on left
going into pipe in floor will be covered by the stainless steel barrel.

Exhaust stove pipe on left
cap over another clean out hole in stove pipe
in floor is on the right.
 
 
 



Friday, July 31, 2015

The Grain Bin House: The Foundation Part 4 and The Rising of The Bin



So, after a very pleasant sabbatical to Ireland for five weeks to attend an Irish Studies program at NUIG (National University Ireland, Galway) as part of my creative writing degree from UIUC (University of Illinois)...I am thrilled to be back on The Poor Farm. I was also thrilled to leave. Even more thrilled to have received the scholarships I did making the trip possible. What can I say? I'm easily thrilled.

Our Grain Bin House was put on hold in late June through mid July due to the unrelenting rains here in central Illinois. While I was gone I was disappointed that I was missing so much of the build and yet slightly happy it had been delayed. Keith kept me up to date via email and  finally Foster Mechanics were able to finish the foundation. Let me say it one more time...this crew was amazing in their work ethic. If you recall there was quite a deep "moat" left around the base of the foundation, it looked like this:

 
 
That moat was filled with concrete creating the thick outer foundation the grain bin would rest upon. After the concrete dried the gravel encircling the black metal form and holding it in place was dug out and put back inside the circle to build up the base for the floor. The black metal form was removed. Keith then wrapped 4 x 8 sheets, of pink Styrofoam board around the outside concrete ring, giving us a moisture barrier between the foundation and the soil. He held those Styrofoam boards in place with dirt and then backfilled completely. So now the foundation is complete and looks like this:
 
 
Eventually the dirt will come right up to the edge of the grain bin completely covering up the pink Styrofoam and it will slope away from the bin to ensure good drainage. The rising of the bin itself started from the top ring with the ceiling pieces attached and then was raised metal ring by metal ring. I have to digress here and give a special thanks to our son Colton who took these pictures in my absence.
 
 
 

 
 
 
 
 
 
 
Although it resembles the leaning tower of Pisa in the pic above it is now quite level. Prior to the rising of the 21 foot diameter bin, Keith built our Rocket Mass Stove, embedding it in the concrete floor. Yes, our future "furnace" and only source of heat for our new home is buried under concrete. Well, about 1/2 of it is. Confused? Join the masses,  but after you see those pics I think you'll be as sold as I am on the concept. I'll cover all the RMS stuff in my next post. I promise it won't be six weeks from now.

Thursday, June 18, 2015

Rain Rain Go Away You've Wrecked Our Pastures and Our Brains

 


 
 After 3 solid build days on the Grain Bin House we got slammed with rain, and more rain and even more rain. Construction came to a mud sliding halt. It has rained at night, in the morning and in the afternoons. It has rained while we were trying to fix electric fences, cook outside, set up a new milking system for our cow Polly, put together our rocket mass stove, manage baby ducklings, plumb the water lines, host a few guests, move livestock around, hang laundry (which has now been hanging for 3 days) ..you name it, it has been rained upon.



At times, the sun would peek through, tease us for a couple of hours and bake us with humidity, then the rain came back and our feet, legs, clothes just got muddier. Wet clothes would only stink up the caravan (remember we have no dryer) so they got hung outside, alongside the clean clothes which of course had returned to their former dirty state. But as my good buddy G. reminded me today, "You choose this life didn't you?" Why yes G. we did.

 
 
 
 


And on the evenings when we felt truly beat up by the hassles of tiny living in a swampy acreage with very few of the modern conveniences we used to have, we were graced with the most amazing silver linings in the clouds that besieged us.

Tomorrow...only hot sun is forecast. Bring it!

Friday, June 12, 2015

The Grain Bin House: The Foundation, Part 3 (and a contest!)

 
 Ah weather, thou has vexed us this week. We had nearly two inches of rain Sunday night and scattered storms all though the week. The "moat" around the GBH filled partially with water but more frustrating was the softness of our drive making it impossible for a concrete truck to deliver precious cargo. But, finally on Thursday in between rain fits our guys returned, sucked out most of the moat water and attached the outside metal forms to the foundations rebar ring...

            

In the afternoon when the humidity and heat soared  the concrete company was summoned. Hearing them rumble down our road was an exciting as...well...hearing the concrete truck responsible for  pouring your first foundation to your first GBH rumble down the road! Even better was the moment all that wet, grey, rocky, slop came pouring down it's rickety metal sluice.



I believe I wept a little.


 



Filling in the gap between the two metal circles with 9 yards of concrete ($1400 worth) the crew worked in near tropical conditions while Keith and I applauded from the comfort of our white plastic chairs in the shade.

We're just supportive that way.

But after a couple of minutes of rest we did return to our own outdoor work; a new milking set up for Bessie, (I mean Polly) among other tasks. It did not take long though for the guys to get the one and 1/2 truckloads of concrete settled into it's trough.  Soon enough the foundation was complete.  Almost.


Next, the metal forms on the outside of the foundation will be removed, hard foam insulation will be cut and curved around the concrete and then dirt will be backfilled against that making it virtually impossible for little pests like ants and mice to get into our mini fortress. Big pests, aka family, will be allowed to enter through our single doorway.

The rebar pointing up through the fresh concrete will eventually be bent towards the inner circle and buried within the concrete floor which will be poured over and around the rocket mass stove heater built on top of the inner gravel. Keith and I will build the rocket thingy this next week. Foster Mechanics will then come back, pour the floor and start raising the walls of the GBH.

It's beginning to look a lot like Christmas...

At the end of the day, there was a fair amount of concrete still left in the truck and since we had already paid for it Keith quickly put together some wooden forms to contain the surplus and put it to good use.  Can you guess what he is making?


Leave a comment with your guess and the first one to answer correctly will get a free bar of homemade soap.  I make a mean bar of soap which will treat your skin very nicely. Yes, you can play if you live in another country. I believe in global blog pandering.

Monday, June 8, 2015

The Grain Bin House: The Foundation, Part 2

On day two of the GBH build, (Saturday) after laying out the basic diameter and digging the footing the day before; our bin guys got busy with additional support for the concrete foundation to be poured. First they secured older pieces of galvanized bin metal against the circular base of what will be our GBH floor, with rebar bent in place as they went.  Then more gravel was added and pounded down in the GBH floor area.




 
Cutting the rebar took time as they were meticulous about spacing and attaching. The white PVC pipes in the photo below will drain water softener fluid directly into our leach field bypassing the septic tank while the other larger pipe will drain our shower, dishwasher and sink water. We will not be putting a regular flush toilet in the GBH, only our compost toilet, nor will there be a tub or dishwasher.


After the first go round they decided a second row of rebar would be even better. That's my husband Keith in the trenches to give you an idea of how deep the foundation will be. Foam insulation panels will be placed outside the rebar all the way around, backfilled with dirt and then concrete will be poured between the insulation and this older, uglier piece of galvanized metal circling our GBH floor, hiding it and all the rebar completely.

 
The grain bin body will then go on top of the concrete foundation but I am getting way ahead of myself. Last night we had nearly two inches of rain and so no GBH work was done today but hopefully they will be able to resume tomorrow. This gave us time to make our final plans for the Rocket Mass Stove Heater we will be installing ourselves in the GBH floor, before they pour the final floor, as our only source of heat.
 
Rocket mass stove heater...sounds so scientific does it not? Lets' just hope Ralph doesn't send Alice to the moon accidently. It will be our first rocket mass stove heater you know.
photo www.eathineer.com

Sunday, June 7, 2015

The Grain Bin House: The Foundation, Part 1.


 

 
Two days ago Foster Mechanics of Paxton, Illinois started on our new home. Although they have installed many grain bins for their intended purpose of grain storage; this is their first grain bin home or GBH as I shall hence refer to it.

Arriving early Friday morning they worked hard all day. I was impressed with owner Phil Fosters way of operating his small backhoe while giving directions to his two man crew simultaneously. A true multi-tasker. No matter how many times we walked up the hill from our work site to their work site there was never once, one of them just standing about; always each man was working on a task. They also did a fantastic job of asking us lots of questions, clarifying how and why we wanted specific things done and double checking if unclear.

Watching these guys out dig out the diameter of our new home was thrilling. I had no idea a large circle of dirt could make me so giddy.





From there a trench was dug,  around the GBH footprint, 3 feet deep and 30 inches wide. This "moat" was filled with 18 inches of road rock gravel, sprayed with water and pounded down hard. This gravel footing will serve as the bottom of the concrete GBH foundation to be poured in the next few days. We are expecting rain today (Sunday) so pour date will be based on how much precipitation we get.






 
 
 
 
They also measured out the lines for our new septic system and dug the pit for our 750 gallon concrete septic tank which was delivered and put in place the afternoon of the first day. We had not planned or budgeted for this septic system, hoping to do a grey water system for our GBH water since we were going to use the compost toilet for solid waste but of course we ran into issues with Illinois Public Health ( a trend for us)  Seems there are no grey water codes in Illinois, and if there are no codes IDPH considers any actions outside of those codes to be illegal.  I'll discuss that in detail with our septic system costs, in a future post.





The septic tank had to be filled with water at the end of the day to avoid possible shifting and re-digging in the event of large amounts of rain prior to final hookup to the leach field. So after the first 10 hour work day we can see our new home taking shape quickly. Tomorrow I'll show you what they did on day 2, another highly productive day.

Wednesday, June 3, 2015

Chickenship

For those of you who wondered if we had poultry on our new place; this post is for you or them.
In my previous blog I talked about the Earthships being built in the southern states, very popular in New Mexico, and Arizona for their ability to conserve energy, and grow food with greywater systems.  Keith and I love the idea and will start experimenting with the technique this week as we design an Earthship or Chickenship as we have christened it,  for our poultry.

Earthships for people are made from recycled tires filled with pounded dirt and covered with homemade cob. The end results are beautiful, cost effective, sustainable. comfortable and a great way to use up the garbage in our lives.  Michael Reynolds is the guru behind their design.

Image result for michael reynolds earthship           Image result for michael reynolds earthship

When they come to put up the Grain Bin House (any day, any day) we will have them also dig out a spot in a sloped area to build the chickenship.

The birds are very excited about this new plan as it will be the first chickenship in Livingston County and perhaps in all of Illinois. We expect tons of media coverage, or at least one or two shares on Facebook.



The most important material needed for our chickenship is of course tires; fortunately there are a few here on The Poor Farm. Oh the treasures we have inherited with this place. Sorting them into similar sizes, widths and condition is one of my tasks this week.



 
Some tires are too worn or torn to be used and will have to be hauled away to be recycled again in playground mulch. After sorting and digging out the area, the chickenship will be partially built into a hillside for warmth in winter and coolness in summer.  Tires will laid in a straight line and pounded full with dirt. Another layer of rubber circles is thenplaced on top and more soil pounded in and eventually you have a wall of tires.
 
 
Image result for michael reynolds earthshipImage result for michael reynolds earthship
 
 
The wall can then be finished with a plaster of homemade cob made of dirt, sand and clay. When dry it becomes mortar like in strength. The front will be glass or plexiglass and the entire structure is for winter or nighttime only; the rest of the time our birds will continue to run free-range. They are our primary source not only of eggs but of tick, fly and mosquito control. They deserve the best in housing we can afford.
 
Which is basically a pile of old tires.