Source: WATERSHED MATERIALS LLC submitted to NRP
COMMUNITY-BASED MOBILE MANUFACTURING OF STRUCTURAL MASONRY USING REGIONAL MATERIALS
Sponsoring Institution
National Institute of Food and Agriculture
Project Status
COMPLETE
Funding Source
Reporting Frequency
Annual
Accession No.
1012797
Grant No.
2017-33610-26753
Cumulative Award Amt.
$96,864.00
Proposal No.
2017-00750
Multistate No.
(N/A)
Project Start Date
Aug 1, 2017
Project End Date
Mar 31, 2018
Grant Year
2017
Program Code
[8.6]- Rural & Community Development
Recipient Organization
WATERSHED MATERIALS LLC
2303 NAPA VALLEJO HWY
NAPA,CA 94558
Performing Department
(N/A)
Non Technical Summary
Dramatic social, economic and technological changes have affected rural regions over the past 30 years as they transition from agrarian to post-agrarian economies. The waning of agricultural production has been accompanied by decreased access to desirable jobs and increased vulnerability to natural disasters brought on by climate change and exacerbated by low quality rural housing. This proposal will develop technology capable of converting natural mineral soils, a nearly ubiquitous resource in rural regions, into quality masonry construction materials with a reduced carbon footprint. This masonry can be used to provide affordable, resilient and sustainable housing with improved energy efficiency in rural regions. Additionally, the technology developed will provide valuable manufacturing jobs in post-agrarian regions while providing a basis for sustainable community development.
Animal Health Component
25%
Research Effort Categories
Basic
25%
Applied
25%
Developmental
50%
Classification

Knowledge Area (KA)Subject of Investigation (SOI)Field of Science (FOS)Percent
6086110202060%
6086110200040%
Goals / Objectives
The primary goal of this application is to develop technology that is capable of converting natural mineral soils into quality masonry products. The specific objectives of the research are stated below. Adapt the Watershed Materials' pilot production model to a mobile configuration readily deployable to diverse geographic locales. Develop a quantitative raw materials characterization and mix design optimization program and optimize systems for correlating laboratory and field characterization data, and for correlating characterization data with masonry unit performance.Validate the socio-economic feasibility of establishing regional masonry block plants in rural communities as a pathway to enhancing sustainable community development.
Project Methods
The research is divided into three areas in order to fulfill the specific objectives. The important milestones are listed for each of the proposed three areas. Mobile Masonry Manufacturing Plant Design. Draft and package all engineering plans and drawings on plant components that will be outsourced to custom fabricators and obtain pricing.Conduct production-scale testing to validate that the existing prototype block press is capable of long hours of operation under field conditions. The durability and minimum maintenance requirements of the prototype will be the main parameters evaluated.Lay out a mobilization strategy including costs for hauling, temporary facilities, and weather protection on site.Explore locations for the first project site and sample material feedstocks based on: ease of access, availability of suitable raw material feedstocks, availability of power and water, the needs of the community in terms of jobs and housing, and the interest in the community and its local government to participate in the program. Raw Materials Characterization and Mix Design OptimizationCharacterization of raw materials using a combination of three independent analytical methods: QXRD, image analysis using scanning electron microscopy (SEM) and energy-dispersive spectroscopy (EDS) to characterize raw materials.Develop a correlation between the QXRD/SEM/EDS/MSIA mineralogical characterization and analysis and mix design optimization. The dependent variable will be the clay to feldspar ratio. A total of 5 soil mixes will be prepared with the following ratios of kaolinite to feldspar of: 1:0, 3:1, 1:1, 1:3, 0:1. The unconfined compressive strength, total water absorption,drying shrinkage, capillary water absorption, desorption isotherms, and freeze-thaw durability will be measured in the resulting stabilized mixtures of each of the soil mixes. Ordinary portland cement will be used as the binder (6 wt.%).The results obtained by characterizing soils with QXRD/SEM/EDS analysis will be compared with a combination of standardized tests including: ASTM test methods (C117, D4318 and C1777), California Test 227, AASHTO TP57, and the modified methylene blue value index for implementation in the field. Socio-economic model for implementation The company will develop a mobilization strategy for the proposed mobile block plant at two potential pilot locations in Calaveras and Lake Counties, both located in California in relative proximity to Watershed Materials' headquarters..Community outreach will be undertaken to educate the citizenry and local political bodies on the proposed plan, evaluate the local response, and identify potential barriers to success. Calculations on the projections for energy and carbon savings in Watershed Materials' masonry as compared to incumbent stick-frame and manufactured housing, building on a life-cycle analysis (LCA).Develop architectural and engineering plans for affordable masonry housing emphasizing on energy efficiency and resilience in the face of natural disaster.The company will work with government agencies to obtain permits and verify building code compliance and approvals for pilot building projects in both counties.

Progress 08/01/17 to 03/31/18

Outputs
Target Audience:The project has continued with its original focus which was to establish a teaching program to assist in rebuilding efforts in the communities of Lake and Calaveras counties that were devastated by the 2016 wildfires. Sadly, in 2017 horrible wildfires again struck Northern California, this time destroying more than 5000 homes in Napa and Sonoma counties. "This is truly one of the greatest if not the greatest tragedy that California has ever faced," said California Gov. Jerry Brown earlier this month (https://www.facebook.com/ABC10tv/videos/10155263485255000/)."The devastation is just unbelievable, it's a horror that no one could have imagined." Building departments in all of the affected counties have responded by initiating expedited plan checking procedures. Volunteer organizations such as Rebuild Our Community, Inc which was organized by builder David Lawson, (insert photo of Picard Residence) have begun to assemble the teams required to get displaced homeowners back into permanent housing. These teams comprised of architects, engineers, geologists, builders, bankers, and volunteers work together to find the most efficient and resilient building systems. In order to prepare for the "boots on the ground" component of Phase II, Watershed Materials recently opened an internship program to finalize the design and fabrication of the transportable plant. Our first intern, Brian Poirtier, a recent mechanical engineering graduate from Princeton, began work on June 1, 2018. Changes/Problems: Nothing Reported What opportunities for training and professional development has the project provided? Nothing Reported How have the results been disseminated to communities of interest?Numerous contacts and local advocates have been established in Lake County, CA including Congressman Mike Thompson. On October 24th and 25th of 2017, Watershed Materials hosted three community focus group meetings attended by a total of 21 Lake County residents, government officials, business owners, fire victims and other local stakeholders to discuss and answer questions about the proposed project, collect community feedback and conduct a socio-economic study following a "Livelihood Strategies" approach under the guidance of UC Davis collaborator Anne Visser, a PhD in the Sociology department whose work is focused on economic revitalization of economically depressed rural areas. The meetings also included a survey of conditions in the county and general responses to the proposed project. What do you plan to do during the next reporting period to accomplish the goals? Nothing Reported

Impacts
What was accomplished under these goals? Success of the project depends on the ability to develop a block manufacturing facility that is capable of producing high performance masonry building units from available feedstocks while at the same time being economical and rapidly deployable. Major strides have been made in Phase I toward this goal, as described in Section 1 below. HIghlights of the findings in this area are (1) a mixing machine which combines the tasks of proportion, blending, watering, and high-shear mixing, and (2) a block press capable of generating ultra high compressive force in order to produce masonry units of maximum dry density. Engineering drawings, test results, and financial models included in the Appendices confirm that the work undertaken in Phase I has met the original milestones laid out in the Phase I application and are track to support a successful Phase II application. A new analytical protocol based on Rietveld refinements was successfully applied to characterize raw materials. The mineralogy and gradation of the soil were optimized to produce blocks exceeding ASTM C90 requirements and freeze-thaw durability recommendations of the National Concrete and Masonry Association for blocks to be placed in service in the northern regions of USA. Community meetings were held, initial contacts made with local officials and stakeholders and a thorough socioeconomic impact assessment was prepared by Sociology professor Anne Visser analyzing relevant characteristics of the pilot project county and potential effects of and barriers to the project. The report summary states, "the project is positioned to address social challenges facing Lake County by providing jobs and promoting economic opportunity in the region. By revitalizing and improving the housing stock of the county over the long-term, the project can also help attract and retain young people and families to Lake County which can increase demand for new businesses and industries in the local economy (thereby creating more jobs)." Work has been done on the life-cycle assessment, architectural and engineering drawings have been prepared and initial contacts have been made with relevant officials.

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