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                      Structures, LCA


A business where the business derives its power from the people who work there and money is used as a tool to serve the people.

What is needed first is energy and resource conservation
- NOT more energy production

The Evolution Of Concrete In Modern Construction

I am finding more materials, products, technologies and techniques that make concrete a very versatile and extremely green technology. It is amazing what is out there.

Most of this technology goes back nearly one hundred years!

I am working on ideas using a combination of standard and lightweight concrete and steel to supply affordable, sustainable housing in poor places or anywhere you wanted low cost, low maintainence, energy efficient, sustainable, green buildings.

My varied background gives me a unique perspective on construction.

I am finding great promise in combining a form of lightweight concrete that is composed of almost 100% waste materials.
We are calling it EPSCrete or StyroCrete.
Polystyrene waste is currently clogging our landfills and polluting the environment world wide. At least 85% of the ingredients in EPSCrete is scrap polystyrene.

If GreenCuncreteUSA's Green Cement (which is also made from almost 100% waste materials) is used to make the EPSCrete and you use a steel frame made from mostly recycled steel
you have a building made with almost 100% recycled sources.

Click Here For More On Lightweight Concrete Technology

Here are some rough sketches of how these unique buildings could be put together.

Here is a page that will give some idea of details:

Ingredients Of My Evolving Dream Building System - The Potential Here Excites Me

Ingredient #1 Polystyrene Cement / EPSCrete / StyroCrete -

Lightweight Concrete From Waste

Wayne's World was built with RASTRA

The Noble Oklahoma House used the same technology.

The problem I have with this kind of products is you have to ship the forms from where they are manufactured to where you are going to build, stack them, pour them, etc. - Too Expensive

I think poured in place EPSCrete is the answer to this problem. It is being done - see below
Both RASTRA uses about eighty five percent recycled polystyrene and a little portland cement to produce very unique forms that (as far as I can see) are some of the best products on the market for building any kind of structure.

he ground scrap polystyrene provides lightweight insulative aggregate to produce cellular concrete blocks while taking a lot of scrap polystyrene out of the waste stream.
How cool is that?

Rastra has been around since 1972.
Definitely Not Pie In The Sky Technology.
Constructing Super Sustainable Buildings All Around The World
(Except the Good Ole' USA?)

All around the world there are a number of companies producing EPSCrete and foamed concrete and using it for - Cast in place (CIP), block, panels, roofs, floors, production plants, mobile units, residential, commercial, sprayed, troweled. These guys are doing it all!

Check out:

Tech Service Polska - Poland
Roofs, floors, terraces, swimming pools, walls, insulating plasters and block.

Siberian Constructing Technologies Russia
Making a variety of products from EPSCrete and foamed lightweight concrete.

Simprolit - Russia

Plates, blocks, panels and more.

Coisoimper Advanced Technology - Italy

Take some time and look through this website. Coisoimper is doing it all with EPSCrete and foamed mud. They are even mixing EPSCrete and foamed mud?!!
It blows my mind!

Why are there no companies doing this here in the USA?
I guess we still have too many trees and energy is still too cheap.

A voice in the wilderness.

Richard Basaraba is way interested in ESPCrete. Mixing his green cement with EPSCrete is a sweet spot in building super sustainable, energy efficient buildings in my opinion.

Using EPSCrete and green cement it is possible to build with about 99% recycled product.

I have been opening up the subject of EPSCrete at the:
Ferrocement Educational Network:

Seems there are some innovative people already making EPSCrete using local scrap!
If you think you might want to play with making your own EPSCrete this is the place to start.

Ingredient #2 Another Piece Of The Puzzle Falls Into Place -

How do you efficiently grind up all this scrap polystyrene to a size suited for making EPSCrete?
Enter into the EPSCrete mix:

EnStyro 563-542-7255

I see great potential in EnStyro's business pla
n. They are making equipment to harvest the vast amount of scrap polystyrene (EPS) currently being thrown away and putting it to a variety of really good uses.

Uses for EnStyro's foam shredding equipment:

You can produce aggregate from local EPS waste suitable for making EPSCrete to form and pour walls on site. All from locally acquired materials that would otherwise wind up in the dump. Another great plus is that this would save on shipping any kind of block around the country.

Use the
Green Cement (see below) to make the StyroCrete and you are using almost 100% local recycled material to pour bomb proof walls, floors, roofs, you name it.

See this new You Tube video of their foam whacker in action:

We Got One Comin' - Stay Tuned!

One of Enstyro's products is EnStyrock
Poured in place cellular concrete using EnStyrock provides a light weight aggregate that has the strength of standard rock aggregate and is also a good insulator. Very cool (or warm).

  Ingredient #3 Green Cement - Concrete Using No Portland Cement? WOW!

One of the big drawbacks to using concrete to build anything green is the fact that it takes a lot of energy to produce the portland cement used in making most cement.

I would argue concrete is far superior to using the last remaining trees on the planet to put up flimsy structures for bugs to eat and storms to blow away.
However enormous amounts of energy are consumed in the making of portland cement.

This has been a very valid point as to why concrete is not a very green construction material.
What if there was an alternative way to make cement using vast amounts of waste materials and no portland cement?

What if this process would also reduce the cost of producing concrete by half or more?

I have been talking with Richard Basaraba who is introducing just such a product through his new company Green Concrete

Richard has worked in the cement industry for many years and has a process that turns flyash into a superior substitute for standard portland cement.

You can talk with Richard at 404.309.0851 or email him at
If Richard has his way we will be building with materials made from scrap polystyrene and waste flyash for an almost 100% recycled content building.

The big hurdle I see, regarding Green Cement, will be overcoming the current legitimate hysteria about all the flyash blowing and flowing into the environment from piles all over the world where power companies have been dumping the stuff for decades.

My research has found that once you encase the flyash in a concrete structure the danger is nil.
Flyash has been used to produce concrete for decades and has proven a valuable and cost saving ingredient in standard portland based mixes.

Richard has taken the technology to a whole new level with his no portland cement using only flyash. I say lets scoop up all those piles and build sustainable buildings!

I am also exploring an alternative to EPSCrete - Cast In Place Cellular Concrete (CIPCC) structures.

EPSCrete might be a problem where stringent building codes are in place.
Foamed lightweight concrete is a very interesting material and has a long track record.
Here is information on other lightweight concrete products.

I encourage anyone to present evidence or ideas pro or con on the issue of flyash.
If it will work - flyash will go from a toxic waste to a very valuable building material.

Paul Wellman, GES - COO  /  USGBC  LEED Certified AP

Green Construction In The 3rd World
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