Man, goings-on is a weird word. It just never looks or sounds exactly right. Anyway, there have been a number of these so-called goings-on lately. Here’s the lowdown on what’s been keeping me busy…
By now you know that the cob bed has been completely removed, but the wall has been replastered, and the floor redone as well. Just yesterday, I finished oiling the finish layer of the floor, so now it is curing. I can’t remember how long I waited last year for the oil to cure, but it must have been at least a week. Most of the past month of work on the house has been waiting – waiting for both layers of the floor to dry, for plaster to dry, for oil to cure. The actual work has been quite quick and simple. But we should finally be able to move back into the house very shortly.
Wabi-sabi is moving slowly but surely towards completing our urbanite foundation for the kitchen. I’ve gotta say… stacking stone is one of the things I’d really love to learn well with an experienced builder. Granted, urbanite and stone are different animals (and stone comes in many shapes and forms itself), but I often stumble over what is “good enough” when it comes to stacking the material. I have a good handle on what is “acceptable” but still — there are so many cases when you sacrifice one thing for another if you just can’t make the perfect fit or find the exact right piece. How to balance that is something I’d love to learn more about…
Last week, we set out to make some progress on stacking the urbanite foundation for our kitchen. There were a few things I learned from my own foundation, and a few things we wanted to do differently for this building. At first, we thought we’d want to dry stack the entire thing, but realized we would definitely benefit from some mortar, especially around the area where our giant posts will be sitting on the foundation.
I have not been super pleased with the clay/sand mortar I made for my own home, so I haven’t been pushing for a mud mortar. It wicks moisture big time and was a pretty big issue over winter and into the early spring — in those early days of spring, earthworms had managed to tunnel through the mortar into the house! (The mortar has since dried out. I think it was mostly wet from snow contact against the foundation over winter.)
In April, I went to gather urbanite for the kitchen foundation (which has finally been started as of last week!). Urbanite is, of course, reclaimed concrete from old roads and sidewalks.
I’ve collected and used urbanite for my home, but this time, walking in a giant yard brimming with the stuff, I got a decidedly post-industrial feeling about the whole thing. There was something sorta post-modern about the whole affair: scrambling over giant piles of rubble from dozens of demolition jobs, looking for the right size pieces of concrete to reuse in a completely different sort of building. I imagined that if I didn’t pick through this stuff, it would likely still be there the next year, and the next, and probably until well beyond my life or that of even our current capitalist, globalized society.
The foundation is now mostly complete with the addition of a third course on the west side of the building. The past few days have been spent trying to piece together that topmost course with the remaining urbanite, and stuffing additional nooks with a clay/sand mortar. The construction of the foundation has gotten funkier over time since we used all the nice flat pieces at the start, and all that was left for the third course was the irregular stuff.
The mortar mix is kinda tricky to work with because of its high sand content (about 3:1); it’s very gritty and difficult to jam into tight spaces. I’m glad now that there are only a handful of cracks remaining. But it sure does feel great not using any nasty new cement mix!
On Monday, I hope to get a delivery of sand to begin cobbing the walls. Look out!
Progress on the cob house has been continuing at a good clip. The second course of the foundation has been laid out. We started to run out of larger pieces of urbanite, and fell back on medium and smaller pieces, which I thought to be less than ideal. Unfortunately, the majority of the urbanite I have collected is very irregularly shaped, so it’s trickier to work with than flat stuff. I think it will be fine, though.
We started to fill in the cracks between urbanite with more clay/sand mortar. Whenever there is rain in the forecast, I throw tarps over the entire foundation to prevent it from getting went. The mortar would probably just wash away if it got thoroughly soaked. But anyway, the purpose of the mortar is to prevent the passage of wind and rodents into the living space. Eventually, the interior face of the foundation will be cobbed over or plastered over to for extra protection.
Yesterday, my first work exchanger arrived. It will be fun to have new help around the work site.
On Friday, I hope to get sand delivered, because I expect cobbing will begin within another week… yeehaw!
The first course of the foundation is now pretty much complete.
Unfortunately, I had nowhere near enough urbanite that I thought I needed, and I made another trip to collect more over the weekend. This second time I played it safe and filled the trailer about twice as much as the first go-round, hopefully insuring that I would have more than plenty.
Yesterday, I ran into a little snag in the assembly of the foundation when I realized I needed a massive slab of urbanite for underneath the door frame. Either that or I could spend some time attempting to level a couple of smaller, very uneven pieces. Forget that, I thought.
I went into Rutledge with four others, thinking we could heft an appropriately massive, flat slab I spotted earlier that day. Apparently not. It was hugely heavy. Instead, Brandon, a (very proactive!) visitor got Zimmermans Excavating (which was just down the road) to bring their backhoe and lift the piece into the pickup truck. We drove back to DR and to my warren, backed up to the spot in the foundation where the piece needed to be, and tipped the slab off the truck bed onto the ground, and then wiggled and walked the piece into its final resting place and then leveled it. That single piece of urbanite was probably three to four times the size of any other piece we had collected.
Later that day, Jeff and I stomped the first batch of earthen mortar (clay sand mortar) at a ratio of three buckets of sand to one clay. This we used to fill in the gaps (think cement mortar) between urbanite, along with gravel and smaller chunks of concrete. Today, we pretty much completed the first course and began stacking pieces for the second, final course.
I suspect this second course will be much trickier…
Two days ago, I went on a trip to collect urbanite (think broken up concrete from sidewalks and roadbeds) in a small town about twenty miles away. Thankfully, four willing folks offered their help in picking up the material. Urbanite is extremely heavy and you don’t want to move it more than you have to.
After an hour of collecting the concrete, we were physically exhausted. Unfortunately, we could not back up the pickup truck with trailer directly next to the huge pile — instead, it was about a twenty yard walk to the trailer, which made it that much more difficult. After unloading the urbanite at my work site, I was quite wiped out.
The next day, Jeff (my work exchanger) and I started assembling the concrete into the shape of the foundation wall, which is to be about 18″ thick. Working with the urbanite is almost like playing Tetris — you need to carefully find the right pieces to match up and fit together. Before starting, I thought I might have enough to finish the whole thing — boy, I was off. I didn’t even have enough to finish a single course:
So, it looks like I will have to make yet another exhausting trip.
Once the first course is laid out, I will make a clay/sand mortar at a ratio of four buckets of sand to one bucket of clay. This will fill the cracks between stones, preventing the entry of rodents, and blocking the passage of wind. Normally, one might use a cement mortar mix, but I am pretty opposed to using concrete in this building (unless it is recycled). (Fun fact: concrete is the second most consumed substance on earth, right behind water.) I hope the clay/sand mix will be sufficient.
If all goes well, I might start cobbing within a couple of weeks.
About The Year of Mud
Hi there, I’m Ziggy. In 2008, I launched The Year of Mud while building my first natural home. This blog is a collection of personal stories and experiences building with clay, straw, and wood over the past 15+ years. A few of the things that get me fired up are natural plasters, timber framing, & Japanese architecture. Since 2012, we’ve been hosting Natural Building Workshops so you can learn essential skills to build your own natural home.
