I have recently been reading up about earthbag/superadobe construction.
One of the new techniques that some earthbaggers are very excited about utilizes a type open mesh bag material called "knit raschel." It was started in Brazil by a guy named Fernando Pacheco. They have named their new system Hiperadobe.
The knit raschel is the same type of netting material that is often used to bag produce like onions or oranges in the supermarket.
Here is a photo of what this type of knit raschel produce bag looks like.
http://www.marketeo.com/photoArticle/big/1940_big.jpg
The bag material has many advantages for construction. Very low cost, fast drying for the contents, no need to run barbed wire between bag layers during construction like typical woven polypropylene earthbags bags require, and when compacted, the earth adobe mixture they use in the knit raschel bags seeps out of the netting openings slightly to mix with the adjacent bags and layers to become one big solid block very much like rammed earth, but without all the extensive formwork or the hassles of ramming tires.
All this is fascinating, but what does it have to do with papercrete you ask?
Good question.
What about filling knit raschel bags or tubes with papercrete? (Manufacurers of the knit raschel material make big long tubes that are rolled up so that the company purchasing the tube can cut it to whatever length of bag they want and sew the ends shut.)
This concept has the potential to speed up papercrete construction rather dramatically while drastically reducing the man hours of labor required. No more need for fiddling around with papercrete blocks. No need to pour them into forms, individually turn and dry them. No need to then stack and store until ready to build walls. No need to morter them into place. No need to build slipforms, wait for a layer to dry, tear off and reattach the forms, and then repour the next layer. One can simply keep working as fast as your mixer can make papercrete and you can dump it into the bag. With a small crew of unskilled people, and splitting up the various tasks assembly line style, work should proceed rapidly. You only handle the papercrete one time. You mix it, and if you fill the bag while the bag is sitting on the wall, you never have to move the papercrete again.
The netting bags would be the formwork. The netting would remain in place and become part of the structure permanently. Think of it as a very light weight reinforcing mesh, ready for interior and exterior plaster, stucco, shingles, clapboards, or whatever you choose.
The netting would allow the papercrete to drain out the excess water easily and quickly. The netting would allow the papercrete to dry in place in the wall after it has been built. The drained but damp papercrete could easily be tamped into place as the wall is built providing for some compression of the damp slurry which greatly enhances papercrete's strength as well as insulation qualities. It would also help the layers of bags glue themselves together to become one big block of papercrete.
While earthbag is a great technology, one of the biggest drawbacks is that it can become difficult to insulate an earthbag structure if you do not have access to porous volcanic rock to fill the bags, like scoria or pumice. Where insulation is needed the most, like very cold northern regions, volcanic rock is often very expensive to have trucked in from long distances. Papercrete could be the perfect alternative that recycles material that is nearly universially available and being thrown away.
Interesting architectural shapes can be easily accomplished, like very graceful curving walls, the standard straight box type construction, or a blend of both working together.
I don't know of anyone that has attempted Hiperpapercrete. Heck I think I may have just invented the term, but I am confident that it could work well. It would be great if someone adventurous and sharp is willing to figure out the tricks and kinks being the trailblazer. No doubt there are some details that I have not considered, but I am confident they could be addressed.
Clearly a small test structure should be the first place to start to figure out the details of how to handle the process.
The idea of building an entire highly insulated papercrete structure in a few weekends using the help of a few unskilled laborers like family or friends seems very possible. Even reasonably sized children could help.
Anyone intrigued by the idea and want to be the first to give it a shot?
Here is a video of a Hiperadobe structure getting started using the knit raschel tube material filled with adobe soil. Instead of adobe soil, imagine filling the netting tube with wet papercrete, allowing it to drain while on the wall, and tamping that into place.
http://www.youtube.com/watch?v=LqqN9oumCHs
There are other videos of the Hiperadobe process on YouTube. Most of the videos come from Brazil, so don't be shocked if most are speaking Portuguese.
Thoughts anyone?
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