Cast Pulp House
Biodegradable, non-toxic, cast pulp shell with inner, outer, and floor.

Solution

The biodegradable house is made from two-inch thick cast pulp. The outer shell is a simple basic molded stackable waterproof, fireproof enclosure. The inner shell is also cast but is an articulated mold which includes kitchen, bedroom, and bathroom features. The floor is the third component. The three interconnected rooms are the kitchen, living room, and bathroom with a central open area. There are numerous storage compartments. The house sleeps four to six persons. The house is 250 square feet. The roof collects water.

The shell material is a combination of recycled pulp, soy flour resin, and long recycled cardboard fibers which are cast into a six-part fiberglass mold. The surface is treated with impregnated wax.


The mold is the key to the idea. Once the mold is completed, the shell could actually be casted in a variety of materials including fiberglass, plasticized concrete, mud, or ceramic. Molding is a fast efficient process for making a durable, highly detailed structural shell. Essential features like the shower enclosure, kitchen countertop, seating, bed support structure are all cast into the inner molded surface. 

The air space between the inner and outer shell can promote ventilation and also can be insulated if necessary. To reduce the shell thicknesses, the space between the shells can be filled with foam as the primary structure to support the shells.

The concept is to stack and ship inners, outers, and floors. Stacking allows more to be shipped efficiently of each component. The only assembly required is to next the inner and outer shells on top of a floor. The floor would potentially contain electrical and plumbing.

The geometry allows six units to be "clustered" together to form a circle. The doorways can link as a passage between units.

Natural light enters thru a 3 foot opening in the center of the roof. There is a living roof with garden space. Water is collected through the roof into four cylinders above the bath area.

Pulp is the ideal material choice since it is frequently a left-over by-product of the paper industry. The investment would go into the system of fabrication and the mold. The pulp material would need to be scientifically developed for strength and integrity, but would utilize existing green materials  technology (plant based) Cast pulp packaging materials are very similar to the desired shell material but the casting would be much larger in scale.









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