Biocomposite Block Panels for Wall Construction

Ā The Army builds its installations across the globe through a mix of energy-intensive building materials and technologies. The current approach to Army building materials and technologies are high in carbon footprint, energy inefficient and unsustainable. The high carbon footprint contributes to greenhouse gas emissions that trap the heat in the atmosphere, which result in climate change. Unsustainable materials produce waste and pollution on Army installations, which leads to pollution of surrounding air, water and soil. Further, Army structural materials are prone to mold and pests that present hazards to Soldiers and occupants. This has resulted in increased Congressional and public attention to improving barracks health and safety, and additional Army investment in improving living conditions through alternative construction materials. To address these challenges, Sativa Building Systems conducted a Small Business Innovation Research (SBIR) Phase I research / research & development (R/R&D) feasibility study to determine how to modify and adapt its patented Z Panels for wall construction. The Z Panel is a pre-dried hempcrete block panel with unique design and functionality for complete wall envelope construction, which offers faster drying, mold, pest, fire, and rot resistance, when compared to traditional building materials. The current Z Panel solves many issues within conventional construction. In an effort to continuously innovate and deliver the most optimal structural insulation product to supply for US Army use, the core focus of this project was assessing feasibility of replacing the lime and pumice-based binder in the Z Panel, which are mined components, with a mushroom mycelium binder, which is bio-based.Ā The enhanced variation of the Z Panel is called the M Panel. Both hemp and mycelium can be grown and processed domestically in all 50 states, mitigating the security risk that accompanies international supply chain disruptions. This bio-based M Panel has potential to take the place of insulation, gypsum board, OSB/plywood sheathing, and vapor barrier, a 4 in 1 material. We have determined that commercialized production of the M Panel is in fact feasible. The U.S. Army Engineer Research and Development Center (ERDC) Construction Engineering Research Laboratory (CERL), with TPOC Talbot Rueppel, was identified as a potential transition partner for biocomposite insulation. The development and implementation of the M Panels for wall construction will provide the Army with sustainable building material. These panels will reduce the Army's reliance on traditional materials, lower costs, and contribute to energy efficiency and sustainability goals.