3D Home Printing Landmark: 10 Houses in a Day

The global South is experiencing urban growth on a scale unprecedented in human history, far outstripping the great urbanization wave that swept across Europe and North America during the 19th and 20th centuries.

Faced with growth at this pace, governments – both national and local – often become overwhelmed by the rate of change and find it difficult to cope. One of the most common complaints urban-dwellers around the world have is about their living conditions. Even in developed countries, creating enough housing to match demand can be a struggle.

Quality housing is crucial to human development and quality of life. Adequate living space and access to running water make a significant contribution to people’s health and well-being. Despite this obvious conclusion, millions of urban dwellers live in squalid conditions with poor sanitation, overcrowding, crime, pollution, noise and a general feeling of insecurity. Insecure people find it difficult to access stable jobs and suffer stigma for living in poor-quality neighbourhoods.

But many initiatives are seeking to speed up the pace of home construction.

These include the Moladi construction system from South Africa (moladi.net). Moladi uses moulds to assemble houses, so that the building skills required are minimal and easily learned. Built to a template that has been tested for structural soundness and using a design that produces a high-quality home both in structure and appearance, the Moladi system seeks to provide an alternative to makeshift homes that are structurally unsound and vulnerable to fires, earthquakes and other natural disasters.

Another clever approach is a home and dwelling assembly system developed by architect Teddy Cruz (http://estudioteddycruz.com) (http://visarts.ucsd.edu/faculty/teddy-cruz) that allows slum dwellers to gradually construct a building in stages as they can afford it. It is earthquake-safe and fire resistant.

Another approach turns to the fast-growing technology of 3D printing (http://en.wikipedia.org/wiki/3D_printing). This technology has gone mainstream in the past five years in the form of desktop-sized 3D printers, or fabricators as they are sometimes called. The machines assemble objects in an additive fashion – layer-by-layer – using digital designs from a computer.

3D printers can make a complex object without having to resort to mass manufacturing. An accurate, one-off object can be created with the same precision as a machined object. Architects, for example, use the technology to make 3D models of their designs. And now a company in China is hoping to use 3D printers to make houses.

The WinSun Decoration Design Engineering Co. (http://www.yhbm.com/index.aspx) 3D printed 10 houses in 24 hours in Shanghai’s Qinpu district, reported Business Insider.

This landmark achievement was accomplished with a giant printer – 152 meters long, 10 meters wide, and 6 meters high – which manufactured walls for the house from a mix of construction waste and cement.

As a sign of the confidence the company has in the innovative construction technique, it built its own 10,000 square meter headquarters in one month using the same materials. The company’s chief executive officer, Ma Yihe, is also the inventor of the technique. It is a very flexible technology and the material can be tinted different colors according to the customer’s wishes. It is cheap to work with and is also less draining on environmental resources than traditional building materials.

The 10 houses consist of two concrete side supporting walls with glass panels at the front and back and with a triangle roof. They will be used as offices at a high-tech industrial park in Shanghai. The company has big plans, hoping to use the technology to build more homes – and even skyscrapers.

Competition is heating up as people around the world seek to perfect 3D technology to print houses to meet the growing demand for dwellings.

In The Netherlands, Dutch architectural firm Dus Architects (dusarchitects.com)  commissioned the development of a leviathan 3D printer so it could print entire rooms. Modeled on a much smaller home desktop version, the Ultimaker (ultimaker.com), this printer creates whole rooms that are then assembled into custom-built houses.

The 6-meter high KamerMaker (kamermaker.com), or “room builder”, is being used in Amsterdam to build a full-size house.

The project is called “3D Print Canal House” (http://3dprintcanalhouse.com/). The printer assembles the rooms individually, and then they are snapped together to make a house. The internal structure of the building blocks are in a honey-comb pattern, which is then filled with a foam that becomes as hard as concrete.

“For the first time in history, over half of the world’s population is living in cities,” Dus Architects founder Hans Vermeulen told cnet.com. “We need a rapid building technique to keep up the pace with the growth of the megacities. And we think 3D printing can be that technique.

“We bought a container from the Internet and we transformed it into one of the biggest printers on this planet.”

This technology can also easily use recycled waste materials and lower the pollution and cost of moving building materials around. The Dus Architects prototype house is expected to take three years to complete (so, still in its early development phase) and will look like a typical Dutch canal house with a pointy, gabled roof (http://www.build.com.au/gabled-roof).

One of the pioneering advocates for using 3D technology to address the global South’s urbanization and housing challenge has been Larry Sass, director of the Digital Design Fabrication Group (http://ddf.mit.edu/) at the Massachusetts Institute of Technology (MIT).

Three technologies have been developed at MIT since the 1950s that have made digital fabrication possible – computer numerical control (CNC), which enables computers to control machines; computer-aided design software in the 1960s; and 3D printing in the 1980s to make solid models using digital designs.

Sass told MIT’s Spectrum newsletter (spectrum.mit.edu) that large-scale 3D printing would mean “buildings will rise faster, use fewer resources, cost less, and be more delightful to the eye than ever before.”

He envisions a future in which architects will be able to send their designs by computer to a 3D printer and it will then be able to start “printing” the building or a house accurately according to the original designs.

The conventional way of making buildings has been stuck in the same approach since the 1800s, according to Sass. It uses highly skilled and extensive labour, it is slow and plagued by weather disruptions and urban congestion, and it is expensive, often using materials brought from far away.

Digitally fabricating buildings takes a radically different approach: the building is made in a series of precision-cut, interlocking parts and then assembled on site like a jigsaw puzzle.

“It’s the right delivery system for the developing world, because the developing world doesn’t have an infrastructure of tools, air guns, saws and power,” Sass said.

“Design and high-quality construction is mostly for the rich,” added Sass, who was raised in Harlem, a New York City neighbourhood with high poverty levels. “I’ve always wanted to figure out how to bring design choice and architectural delight to the poor.”

By David South, Development Challenges, South-South Solutions

Published: July 2014

Development Challenges, South-South Solutions was launched as an e-newsletter in 2006 by UNDP's South-South Cooperation Unit (now the United Nations Office for South-South Cooperation) based in New York, USA. It led on profiling the rise of the global South as an economic powerhouse and was one of the first regular publications to champion the global South's innovators, entrepreneurs, and pioneers. It tracked the key trends that are now so profoundly reshaping how development is seen and done. This includes the rapid take-up of mobile phones and information technology in the global South (as profiled in the first issue of magazine Southern Innovator), the move to becoming a majority urban world, a growing global innovator culture, and the plethora of solutions being developed in the global South to tackle its problems and improve living conditions and boost human development. The success of the e-newsletter led to the launch of the magazine Southern Innovator.  

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Debt-free Homes For the Poor

As the population around the world’s cities grows, and slums grow larger and more prevalent, the urgent need for affordable and decent housing becomes more pressing. The world’s megacities – like Buenos Aires, Argentina, where more than 13 million live in the metropolitan region – have to find a way to provide housing that is both cheap and does the minimum possible amount of harm to the environment.

About one-third of the world’s urban dwellers live in slums, and the United Nations estimates that the number of people living in such conditions will double by 2030 as a result of rapid urbanization in developing countries. Latin America is already the most urbanized region in the developing world.

“Throughout Latin America you have economies that are growing and doing well, but the way the economies are growing is actually generating more shanty towns,” said Erik Vittrup, senior adviser on Latin America and the Caribbean for the U.N. Human Settlements Program. “It’s a growth that is just generating wealth for those who (already) have it.”

How well people dwell is integral to their mental and physical health. Most squatters and slum dwellers live in makeshift homes made from whatever they can get their hands on. These dwellings are usually unsafe and vulnerable to fire, floods, and earthquakes.

But across the South, initiatives are proving it is possible to build good quality homes for the poor while avoiding burdening them with debt. Pioneering ways are being developed for the poor to build their own high-quality houses using recycled materials and environmentally friendly products.

In Colombia , Alejandro Salazar, a chemical engineer, professor at the Universidad del Valle (http://www.univalle.edu.co/english/) and innovator running several companies pioneering new building technologies using recycled waste, is building high-quality, inexpensive houses for the poor.  By combining free building materials recovered from waste, a government grant and the voluntary labour of the homeowners, Salazar’s company is able to build homes for the poor that don’t leave them with ongoing bank debt from mortgages.

Based in Cali, Colombia (http://gosouthamerica.about.com/od/cali/p/Cali.htm), his companies Ecoingenieria (product and material research and development), Ecomat SA (production of eco-materials using industrial waste and construction rubble), Constructora Paez, (social housing construction using eco-products) and Wassh SA (environmental management and transformation of dangerous solid waste into non-dangerous materials), are focused on pioneering new technologies for housing.

“Our company uses two basic technologies,” said Salazar. “The production of eco-materials from solid waste and demolition waste, and the implementation of an agile building system, which does not require skilled labour and is hand-transportable. All the pieces are produced in a prefabrication plant that uses the eco-materials.”

Salazar has found a way to provide homes quicker than existing NGOs – Popular Housing Organizations (OPV), as they are called – established to address homelessness in Colombia. The homeless poor are caught in a Catch-22: they need to have a formal job to receive homebuilding assistance from the government, and they usually can not save up enough money for a down payment on the home.

Salazar’s solution is to take the maximum grant given by the central government, which is US $4,730, and combine it with the recycled building materials and homeowners’ own labour. He says this allows a house to be built for roughly half the price of a similarly sized one that uses conventional materials: the eco-materials house costs around US $ 6,590, compared to US $12,000 using conventional materials. Land is often either donated by the municipality or the family already owns it. And in Salazar’s experience, the whole family chips in with the building: husbands, sons, brothers, fathers, wives.

The training takes just three days on eco-materials and a day in construction techniques for house building.

“To date, we have built with this method 306 houses,” said Salazar. “For the coming year, we expect to deliver around 500 houses or more. To build a house, after acquiring the land, we need three people working eight hours a day to build it in four weeks – all under the supervision of a workforce teacher and the supervision of an engineer or architect.

“The houses are designed by architects with the participation of the community or families. They do some workshops and the design conforms to their vision and expectation. In Colombia, there is an earthquake resistance code which is binding in law and provides detailed specifications of the materials, foundations, structure and roof.”

The pre-fabricated building materials are made from recovered waste from a wide variety of sources: ceramic red brick, coarse ash and fly ash, slag from steel, copper slag, porcelain insulators used for electrical power lines, nickel slag, sludge from sugar and alcohol plants and water treatment plants.

“The raw materials we use are industrial solid waste and demolition waste. It costs the industry a lot to throw away this waste,” Salazar said.

He said the biggest obstacle to the new homes is psychological: many people initially “tend to reject at first-hand the technology.”

“When visiting the factory and then visiting the homes – or model homes – they then compare it with a traditional house, and realize that the best eco-homes when finished meet the standards of Colombian earthquake resistance and are also cheaper,” he said.

Compared to using conventional building materials, the eco-materials reduce the cost of a new home. And the company still makes a profit from it!

In Paraguay, Elsa Zaldivar is using recycled plastic, cotton netting, corn husks, and loofah sponges (http://en.wikipedia.org/wiki/Luffa) to make cheap, lightweight construction panels for housing. This has a double benefit: it makes for cheap housing and it is good for the environment.

“That’s very important in Paraguay,” said Zaldivar, “because we’ve already reduced our original forest to less than 10 percent of the national territory.”

Zaldivar got her experience working with people in the impoverished area of Caaguazú, where in the past she helped with the building of toilets and making stoves. She found that involving local people in this work made a huge difference: “They told me: ‘Now we feel like we’re people with dignity.’”

She encourages local women to grow loofah – a plant that once flourished but was being ignored. While the fruit is edible she was more interested in the crusty sponge that is left over when the plant is dried. The women started a cooperative selling loofah sponges, mats and slippers. But there was a lot of waste in the process, with a third not suitable for export. She then came up with the idea to use the loofahs for wall and roof panels for cheap housing.

Along with industrial engineer Pedro Padros, she developed a way to combine loofah with plastic waste. Padros invented a machine to melt the recycled plastic and mix the molten plastic with loofah, vegetable fibres and chopped corn husks. It has produced a building panel that is lighter and easier to move around than lumber or brick. With a grant from the Inter-American Development Bank, design improvements have been made and the cost-per-panel brought down from US $6 per square meter. It is now competitive with the cost of wood panels. The great thing about the panels is that they can be recycled again when they wear out, completing the cycle.

“To have a decent home liberates people,” said Zaldivar.

By David South, Development Challenges, South-South Solutions

Published: January 2009

Development Challenges, South-South Solutions was launched as an e-newsletter in 2006 by UNDP's South-South Cooperation Unit (now the United Nations Office for South-South Cooperation) based in New York, USA. It led on profiling the rise of the global South as an economic powerhouse and was one of the first regular publications to champion the global South's innovators, entrepreneurs, and pioneers. It tracked the key trends that are now so profoundly reshaping how development is seen and done. This includes the rapid take-up of mobile phones and information technology in the global South (as profiled in the first issue of magazine Southern Innovator), the move to becoming a majority urban world, a growing global innovator culture, and the plethora of solutions being developed in the global South to tackle its problems and improve living conditions and boost human development. The success of the e-newsletter led to the launch of the magazine Southern Innovator.  

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Making Bamboo Houses Easier to Build

More than 1 billion people around the world lack decent shelter. Of these, the majority live in urban areas, usually in slums and informal settlements (UN-HABITAT). Latin America has a serious shortage of adequate housing: in Colombia, 43 percent of the population needs decent housing; in Brazil, 45 percent; Peru, 53 percent.

The challenge is to provide good quality homes without significantly harming the environment – and with constrained budgets. Bamboo – cheap, strong, quickly renewable and beautiful to look at (http://en.wikipedia.org/wiki/Bamboo) – is an ideal solution to replace traditional wood lumber. In Bolivia, pioneering work is underway to improve the quality of homes and buildings made with bamboo.

Bamboo is the fastest growing woody plant in the world, sometimes growing over 1 metre a day. Bolivia (http://en.wikipedia.org/wiki/Bolivia) has about 17 identified bamboo species, of which five have a significant economic value. Around the world, there are 1,000 species of bamboo. They grow in a wide variety of climates, from cold mountains to hot tropical regions.

Once called the “poor man’s timber” – a temporary building material to replace once there is more money – bamboo is now getting the respect it deserves. Bamboo for housing has a long history in Latin America, stretching back 4,500 years to ancient civilizations. In Asia, it has long been a traditional construction material. But most of the existing bamboo dwellings in Latin America are 50 to 100 years old.

The most popular species of bamboo used in South America is Guadua, which is known for being large, straight and attractive.

“In Bolivia, there is no other building material more competitive in costs,” said Jose Luis Reque Campero, coordinator of the Bolbambu Programme of the Architectural Research Institute, Universidad Mayor de San Simon, Bolivia (http://www.umss.edu.bo/).

“Bamboo is the material that requires less energy, followed by wood and concrete, with steel in last place, needing energy necessary for its production 50 times greater than that required by bamboo.”

Campero also says bamboo is much less expensive than traditional building materials.

“But the biggest advantage is certainly the possibility of planting bamboo, and then reaping houses,” he said.

Campero has focused his efforts on a key component of bamboo housing: the joints that bind the bamboo poles together. Driven by the desire to find ways to improve the ease of building bamboo homes and their strength, Campero came up with the Bamboo Bolivia Space Structures, Structural System: EVO (BBSS-EVO) (named after Bolivia’s president, Evo Morales – http://en.wikipedia.org/wiki/Evo_Morales).

Traditional joints took a long time to make and required power tools and complex instruction manuals. Simplifying the building techniques necessary for bamboo construction was important because, while bamboo was cheap, the labour costs were high.

The joint looks like a giant two-headed Q-Tip. Each end is made of four pieces of bamboo, connected by a long screw with bolts on each end taken from old cars. The joint is inserted inside the bamboo poles and snaps shut, joining poles tightly together and, as each piece is assembled, looking like a child’s building toy as the structure of the bamboo home takes shape.

The new joint was easier to assemble and was quickly adopted by local builders. It also allows for a vast range of structures and shapes to be built, limited only by imagination and physics.

Devising joints made from bamboo has the advantage of avoiding the weight and cost of bringing in concrete, especially to remote areas.

“The manufacturing process is fully in the workshop and indoors,” said Campero, “which in addition to allowing a degree of quality control in production, improves working conditions for staff and protects the material.”

The whole building process adheres to “the principles of the famous phrase: ‘do-it-yourself’.”

The Evo joint allows for flexibility and easy assembly and disassembly, enabling the builder to move around parts of the structure and not be wedded to the original structural plan. This has the advantage of customizing the building to its physical location.

Working in the tropical forests of Cochabamba (http://en.wikipedia.org/wiki/Cochabamba), Campero has been testing his designs with the local people, who were looking to improve the tourist infrastructure in the resort town of Cristal Mayu.

Costa Rica in Central America – ironically a country without indigenous bamboo plants – has used its National Bamboo Project of Costa Rica (http://www.unesco.org/most/centram1.htm) to prove it is possible to both cultivate bamboo and use it to provide housing for the poor, confirming the wisdom of millions of people: bamboo is economical, convenient, safe and looks great.

Campero has received a great deal of interest in his innovations and is looking for funding partners in 2009 to take his work further.

He has this advice for other builders and designers: “Stick to developing local technologies, use what you have and innovate, use native materials and the local environment for the development of elements, components and construction systems. Don’t rely on advanced technology tools for manufacture, and stay in harmony with the human need for creativity.”

By David South, Development Challenges, South-South Solutions

Published: December 2008

Development Challenges, South-South Solutions was launched as an e-newsletter in 2006 by UNDP's South-South Cooperation Unit (now the United Nations Office for South-South Cooperation) based in New York, USA. It led on profiling the rise of the global South as an economic powerhouse and was one of the first regular publications to champion the global South's innovators, entrepreneurs, and pioneers. It tracked the key trends that are now so profoundly reshaping how development is seen and done. This includes the rapid take-up of mobile phones and information technology in the global South (as profiled in the first issue of magazine Southern Innovator), the move to becoming a majority urban world, a growing global innovator culture, and the plethora of solutions being developed in the global South to tackle its problems and improve living conditions and boost human development. The success of the e-newsletter led to the launch of the magazine Southern Innovator.  

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Rammed-Earth Houses: China Shows how to Improve and Respect Traditional Homes

The pace of change across the South has been blistering. Over the past decade, the overall population has moved from being primarily rural to majority urban. In the process, rural communities have suffered, as they have seen their young and ambitious leave in droves seeking a better life in cities.

More than 200 million Chinese farmers have moved to cities in recent years. It’s easy to see why. Chinese farms are tiny, with the average rural household farming just 0.6 hectares. And incomes are low compared to the cost of living: average annual income was just US$606 in 2007, a third of city salaries.

But it is possible to improve the quality of life in rural areas and in turn boost economic fortunes.

In China, projects that upgrade homes to modern standards while respecting traditional designs and architecture are breathing new life into rural communities. A return to the age-old technique of using earth as the principal building material is saving energy and keeping house costs low.

The tradition of packing earth to build a wall dates back to some of the earliest stretches of the Great Wall of China in 220 BC.

Currently it is estimated that half the world’s population-approximately 3 billion people on six continents – lives or works in buildings constructed of earth.

This traditional building technique is being used in the reconstruction effort to build new homes after the May 12, 2008 earthquake in Sichuan Province. The earthquake left millions of people homeless in the country’s worst natural disaster in 30 years, and has made low-cost but efficient house building critical.

In western China, villages have been entirely rebuilt from scratch. The application of research and science to the traditional designs – roofs in the pagoda style, with buildings arranged around courtyards – enabled the development of homes that are energy efficient to run, and are more hygienic and earthquake safe. In Yongren County of Yunnan Province, over 7,000 mountain dwellers were moved to better farming land and over 2,000 homes were built in the new village of BaLaWu. Over 30 of the homes were built using rammed earth by the Xi-an team.

“The original homes had very low living quality,” said team member Hu Rong Rong of the Green Building Research Centre of Xi’an University of Architecture and Technology (http://www.xauat.edu.cn/jdeg/about.html), which oversees building of the new homes. “The architecture layout of the indoor space and courtyard was not reasonable. In the courtyard the areas for living, raising livestock, storing and processing crops were mixed up. The indoor environment was not comfortable. It was cold in the houses during winter and hot during summer. Most of the rooms lacked natural lighting and were dark in the daytime.

“In the poor areas, many people still live in earth houses because of the low cost. However, most of the earth houses have low living quality.

“After we finished the project, through our design, the living quality was improved very much. The dwellers were satisfied with their new houses.”

Land reform in China has brought more hope to the country’s 750 million rural poor, many of whom live on less than US$1 a day. It is hoped that giving the rural poor more control over their lives will bring an improvement in agricultural production, food security and economic prosperity. Reforms also mean the poor have more secure land rights.

Hu said gaining the trust and buy-in of the villagers was critical to the success of the project.

“We built the first home as a demonstration. After we finished, the villagers could experience the advantages of the new home. Most of them decided to use our design and they could choose the one they liked from several proposals.”

Poverty is a big problem in the villages. Incomes are very low, at 2000 RMB per year (US $290). Hu said “families were given a house-building allowance of 8000 RMB (US $1,160) to meet the cost of building materials – and the land was free for them to use.”

“The villagers built the houses by self-help. We helped them to design and build the houses for free,” Hu said.

The houses are pioneering in using natural sources to provide light, heat, waste disposal and gas for cooking and heating.

“We used natural material like earth as a main building material to get good thermal mass and also to reduce CO2 emission,” Hu said.

“We designed a simple family sewage-purge-pool and marsh-gas-well system to reduce pollution and get energy from wastes.”

Using rammed earth has a long history in China. Across Western China, there are many buildings constructed with rammed earth. And using earth has many advantages when resources are scarce or expensive: “Earth buildings avoid deforestation and pollution, and can achieve low energy costs throughout their lifetime,” said Hu.

“With living standards increasing, more and more people would like to use burned bricks and concrete to build new houses, which will consume more energy and bring pollution,” said Hu.

But like any technology, the application of modern science and environmental knowledge to the traditional designs, can reap huge improvements in the quality of the homes and comfort levels. And win people back to the benefits of rammed earth dwellings.

“Building with earth materials can be a way of helping with sustainable management of the earth’s resources,” said Hu.

And Hu is adamant the new, environmentally designed homes respect the wisdom of traditional design.

“The new earth house design should consider the local culture. It should be proved that both the house style and the construction technique can be accepted by the users.”

By David South, Development Challenges, South-South Solutions

Published: December 2008

Development Challenges, South-South Solutions was launched as an e-newsletter in 2006 by UNDP's South-South Cooperation Unit (now the United Nations Office for South-South Cooperation) based in New York, USA. It led on profiling the rise of the global South as an economic powerhouse and was one of the first regular publications to champion the global South's innovators, entrepreneurs, and pioneers. It tracked the key trends that are now so profoundly reshaping how development is seen and done. This includes the rapid take-up of mobile phones and information technology in the global South (as profiled in the first issue of magazine Southern Innovator), the move to becoming a majority urban world, a growing global innovator culture, and the plethora of solutions being developed in the global South to tackle its problems and improve living conditions and boost human development. The success of the e-newsletter led to the launch of the magazine Southern Innovator.  

Follow @SouthSouth1

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