Workshop Retrospective - July 2022
So this year I got to do something I’ve been wanting to do for a decade - attend a weeklong straw bale construction workshop. The workshop I attended was taught by Andrew Morrison (of Strawbale.com) and hosted by a very nice family in northern Kentucky.
The first thing I have to say is that it was an amazing experience. The workshop structure with a lot of groupwork, communal meals, late night music performances and camping on site really gave you a chance to get close to people and feel connected to a community.
(If any of my fellow Kentucky attendees are reading this, I was the person who went to the hospital for an infected spider bite. That was, obviously, not a highlight of the week but I only missed a little bit of the workshop over my 4 hour hospital waiting room adventure. My foot is once again the correct size & no longer cartoonishly swollen.)
We were lucky enough to attend a workshop attended by not only Andrew (who is an extremely gifted communicator and educator) but also Dee and Timbo, who will be taking over the workshop business after Andrew retires. They use a different style of building with straw, so there several opportunities to compare multiple methods.
The house we were working on was strawbale infill over an ICF walk-out basement. The method Andrew uses in all his workshops is as follows:
Preparing the toe-ups with their fill material and nails to secure the bottom course of bales
Placing the bales; notches are cut where necessary with a chainsaw. The last course of bales is oversized for the space and is used to compress the wall
Trueing the wall with a tamper
Using a weed whacker to smooth the walls
Stuffing any gaps left by the bale stacking
Cutting channels for & having electrical work installed in the outer walls
Attaching 2x2 steel wire mesh from toe-up to top beam (using pneumatic nail guns) in order to support the wall , then quilting the layers together through the bales
Shaping window/door reveals by stuffing with loose straw before attaching mesh in those locations
Plastering with a three layer lime plaster made of hydraulic lime
Because of the size of the house and the fact that you needed to use a ladder to get to most of the site, we didn’t get as far as most workshops do. We finished shaping about half of the windows and only got to work a little bit on plastering. However, I still learned a lot and it has given me renewed confidence in pursuing my own house project. Personally, I felt like I got more out of the workshop having already done a significant amount of reading, including reading Andrew’s book.
Here were some of my takeaways for any projects I build:
I can physically carry a bale, but I’d want to do more weight training before trying to carry many bales by myself or lift them into higher courses.
I am not tall enough to easily compress bales for retying in the way Andrew teaches. Either I need to build a setup to raise me up/lower the bales, or find a different method.
Sections between windows require no notching and are awesome
Notching bales with a chainsaw is doable, but I definitely want to try using a manual saw & see how much longer it’d take. especially on multi-notch bales, it was very difficult to get precise enough on a chainsaw.
Your notches will always need to be deeper than you think, so just add half an inch from the beginning.
The stage where you tension the wall by jamming a 14 inch bale into a 10 inch tall hole is not something I could do on my own. It really requires a person who’s six foot and has a lot of upper body strength to wield either a steel tamper or a large mallet above their head. I need to look into alternate methods of tensioning the wall (possibly using ratchet straps to pull the wall down beneath the last course so it would take less force to push in the last bale?)
I do not like the weed-whacker step. I could use a weed-whacker but I don’t want to - I’ll definitely look into quieter and more ergonomic options to smooth out the bale surface.
Without a wide enough top plate, it is very difficult to get the mesh stapled at a welded joint like you need for a secure hold.
Stuffing the rounded reveals with loose straw sucks and takes forever. Timbo mentioned that he does the window reveals with a cob mixture that’s covered by wire mesh and that sounds so much easier.
Andrew uses hydraulic lime, which can set regardless of the thickness of the plaster coat (if, say, there are large depressions that are filled in with the base coat). He does not use any straw in his lime plasters anymore, though it’s still in the video instructions he has on his website.
Timbo said he prefers hydrated lime, which is cheaper, easier to source, dries slower and excess can be saved by covering the plaster with water. A fiber for strength is required for hydrated lime. Timbo said that he avoids the issues of deep plaster layers by filling any divots/gaps with straw/clay before plastering.
I really loved plastering for the 30 minutes we did it, which tells me nothing about how I’d feel about plastering four hours into my third coat 😅