• Use of recycled, environmentally-sensitive materials to create healthy, non-toxic housing;

• Transfer of straw bale construction techniques and practices to area developers, low-income persons, owner/builders and contractors; and

• Creation of affordable housing which sustains the existing community and promotes greater self-sufficiency among area residents.

In 1997, a Christmas present was opened in Spokane, Washington that grew within the hearts, and constructed with the hands, of people interested in community built, sustainably designed, low cost urban housing. A 970 sq. ft (interior), 3-bedroom, urban-infill, single family house, named the SPREAD House - Spokane Resource-Efficient, Affordable Demonstration House - was built on a 6000 sq. ft abandoned corner lot within a 1930’s inter-city residential neighborhood. The primary goal of SPREAD was the development of an affordable home for a low-income family, which utilized resource-efficient building materials and practices. SPREAD also desired to provide training and educational opportunities for building officials, owner/builders, and local apprenticeship programs. Straw bale, an agricultural by-product of grain that surrounds Spokane, was chosen as the main focus of the construction materials.

The ensuing final report includes key information on the various stages of this unique project, initial goals and actual results, related costs, and potential resources for others to take a look at. --- The intent of the report is to help provide a foundation of experiences from which others can work, limit possible duplication of unnecessary steps, share with others items that really worked, and offer some advice on ideas and/or methods that probably should be discarded. --- We hope you will find the report both interesting and helpful, especially if you are about to undertake a similar community-based project of your own.

In the fall of 1996, a group of Inland Northwest community agencies, organizations, businesses, and private citizens initiated the SPREAD House partnership. The lead organization of the project was the Spokane Neighborhood Action Programs (SNAP), a community action agency, whose mission is "to provide opportunities, resources, & services to low-income & other highly vulnerable populations in a manner which enhances dignity & promotes self-sufficiency." SNAP is the owner and manager of the house which will be part of the organization’s rental inventory for the next 30 years. Other key entities involved in the initial stages of the project include: the City of Spokane; area building and construction trades apprenticeship programs; Resource Efficient Building & Remodeling Council (REBAR); the Washington Environmental Council (WEC); the Washington Rural Communities Network (WRCN); the Spokane Community Gardens; area architects; designers and engineers; area construction businesses and suppliers; and interested community members.

The primary goal of the project was to use alternative building materials and construction practices that address, and help solve, existing social, economic and environmental problems that confront both urban and rural communities in the region --- in this case, affordable housing.

SPREAD also had several key secondary goals that it hoped to achieve:

1. Training and educational opportunities for community building officials, owner/builders, and local apprenticeship programs in the areas of alternative building practices and materials;
2. Use of recycled, environmentally-sensitive materials to create healthy, non-toxic housing;
3. Transfer of straw bale construction techniques and practices to area developers, low-income persons, owner/builders and contractors; and
4. Creation of affordable housing which sustains the existing community and promotes greater self-sufficiency among area residents.

Locally, the people who came together to plan the project, as well as those who endorsed such efforts, wanted to demonstrate that positive, affordable, resource-efficient/ waste reducing, healthy, durable solutions exist for current Inland Northwest problems. Was the SPREAD Project able to achieve its goals? --- The report will address this question and others.

Briefly, it is important to state why this project, an "urban" project, is relevant to rural communities in the region. In short, rural and urban communities in the Inland NW often confront similar problems. Hence, by working together and sharing information, where possible, lessons can be learned by all, and hopefully at least some of the costs will be born over a larger group of people who have an interest in seeking out possible sustainable/ holistic solutions.

The SPREAD Project addressed several key on-going issues that rural and urban communities hold in common. They are as follows:

• First, affordable housing issues don’t stop at the city limits. There is a need for such housing in rural areas, especially affordable housing that is environmentally friendly and resource efficient.

• Second, there is the need to develop agri-by-product markets that provide alternatives to area field burning. In this case, the SPREAD Project utilized a product that depends on a smaller-scale, more localized solution that was not heavily capitalized and currently available. Other people in the region are also looking at alternatives which are more highly capitalized. Initial production of one alternative, strawboard, is expected soon.

• Third, with respect to other resource issues, it is critical to look at materials that might lessen the demand on forests, as well as complement other construction materials. In addition, given the current discussions regarding salmon, the future status of the BPA and regional electricity supplies, and other demands placed on the Columbia River system, it is important to look seriously at alternatives that will help the region achieve the greatest levels of energy efficiency in our personal and working worlds. --- In the case of straw bale construction, the insulative value of the walls helps to reduce the energy demanded to heat the structure.

A community straw bale construction project was a new idea for the Inland Northwest area, but not unknown in other areas of the country. Tucson, Arizona, to name one location, has recently organized and constructed two semi-load bearing, straw bale, affordable housing projects: one sponsored by the Tucson Habitat for Humanity, and the other by the Tucson Urban League. Surprisingly, maybe to some, Spokane, a smaller urban city that is perceived by many to be a relatively conservative community and region of the country, was willing to take a serious look at the alternative construction method. The City of Spokane’s Multifamily Housing Program provided major financing for the project, and the City’s Building Department worked with the SPREAD group from the beginning to address and solve key permitting issues. The SPREAD House was constructed with the help of community members who donated their time and/or resources, including four local apprenticeship programs. In fact, the level of interest shown by residents through out the Inland Northwest never seemed to wane --- the public Open House in December had approximately 350+ people attend, while another 50+ attended the Ribbon-Cutting Ceremony. There was, and still is, a real community interest in the project. --- Why?

The SPREAD Project sought ways to reduce the demand on forests and other natural resources in an effort to use those resources in a manner that will allow long-term benefits to future generations. Straw bale construction offers an alternative to local straw that is being burnt, enhancing revenue sources to some area farmers while reducing air, and potentially water, pollution. Both affect com- munities throughout the region.

When looking at long-term market development of straw bale constructed homes, it is critical to take into account the availability of straw in the area. Since the SPREAD House utilized wheat straw bales [approximately 250 bales (roughly 6 tons)], Table 1 provides information on the availability of both irrigated and dryland grown wheat straw in Washington State. Tonnage of straw available has been calculated from the number of bushels of winter and spring wheat produced. Though there appears to be ample straw available in the state for straw bale construction and other value-added opportunities such as strawboard manufacturing, it is important to keep in mind not only that there are different methods used in growing wheat, but also there are different methods of handling the straw by-product including harvesting the material from the field, tilling the by-product back into the soil or letting the straw lay fallow in order to rebuild the soil, as well as burning the straw after the wheat is harvested. Some of these methods and their impact on availability of straw are reflected in the numbers found in Table 1. Specifically, in dryland wheat production, a 50% availability factor is used versus the 75% availability factor associated with irrigated production. Not found in Table 1 though is the amount of "construction material" --- swath cut, 2 or 3-string bales --- available, or that could become available, throughout the region. --- This would need to be further researched. [Note: Rotary cut bales are not appropriate for construction.]

Table 1						Wheat Straw Availability in Washington State in Tons/Yr.
County & District										Irrigated (a)							Dryland (b)						Total
Central
	Benton									27,169							35,138						62,306
	Chelan									0							645						645
	Kittitas									7,706							278						7,984
	Klickitat									3,938							17,820						21,758
	Okanogan									990							3,420						4,410
	Yakima									32,693							3,405						36,098
								Total		72,495							60,705						133,200
East Central
	Adams									195,000							90,000						285,000
	Douglas									4,000							83,000						87,000
	Franklin									100,000							28,000						128,000
	Grant									228,000							49,000						277,000
	Lincoln									70,000							228,000						298,000
								Total		597,000							478,000						1,075,000
Northeast
	Spokane									5,153							75,930						81,083
	Stevens									1,193							8,910						10,103
		Other Counties											360						420							780
								Total		6,705							85,260						91,965
Southeast
	Asotin									0							7,695						7,695
	Columbia									585							72,675						73,260
	Garfield									675							49,530						50,205
	Walla Walla									32,805							133,725						166,530
	Whitman									1,260							426,720						427,980
								Total		35,325							690,345						725,670
West
	Clark									0							405						405
	Cowlitz									0							315						315
	Island									0							450						450
	King									0							75						75
	Lewis									0							705						705
	Skagit									0							1,575						1,575
	Snohomish									0							510						510
	Whatcom									0							420						420
								Total		0							4,455						4,455
Washington State Total											711,525							1,318,765						2,030,290
					(a) Basis: 0.75 tons straw removable/ton of wheat produced.
			(b) Basis: 0.5 tons straw removable/ton wheat produced.
Conversion from bushels of wheat to tons of straw available based on 60lbs. of wheat/bushel.
				Formula: (Bushels of wheat * 60/2000)=Tons of straw produced
Initial data found in the Washington Agricultural Statistics Service's Washington Agricultural Statistics: 1991-1992.
Agri-Business Commercialization & Development Center in Richland, WA determined that the 1992 data is typical for the 10-year average, plus provided the formulas for estimating irrigated and dryland straw availability.

III. Collaborative Nature of Project.

The SPREAD Project has been a collaborative effort, even down to writing the final report....

The project started in monthly roundtable meetings in November 1996, with all aspects of the community invited. At the first official group meeting in November, the head of the Building Department attended. Hence, the group immediately delved into addressing the Building Department’s concerns, especially the utilization of straw bales. By the next month’s meeting, the City’s Lead Plans Examiner attended meetings as the Building Department’s representative. Difficult decisions from design and construction issues to funding required for a small but complex project evolved fast, due to the excitement and commitment of the core members. In order to facilitate information sharing and the decision making process, meetings were held throughout the winter and spring and into the summer. Also to keep key people and other interested individuals informed who were unable to attend the monthly meetings, a one-page newsletter was sent out.

In addition, the core Spread group did organize itself into working groups, or teams, focused on the areas indicated in Figure 1. Two of the peripheral working groups, Trade Expo and Videotaping, did not materialize to the extent initially anticipated for lack of time and available people to follow through on these aspects of the project.

During the process, members of the Working Groups identified key organizations and individuals who were not involved in the project already, but who might want to be. In essence, the working groups’ "arms" extended out to the community to educate people about SPREAD, while offering the opportunity to become involved. The Building and Construction Trade Apprenticeship programs, the Spokane Community Gardens, the Spokane Master Composters, and several groups from Habitat for Humanity are representative of the wonderful organizations, businesses and individuals who helped out on the project. The SPREAD House and landscaping were completed with the help of over 1500 volunteer hours. --- For a list of volunteers and other participants, please see the end of the report.

Although key members of the SPREAD group were experienced in different aspects of construction and housing development, the project was at many times an owner built house. This is one of the elements that made the process challenging and rewarding for all, but even more challenging for SNAP --- primarily an agency that contracts out its construction projects.

The SPREAD collaborative effort, like most other collaborative efforts, has had its ups and downs --- but overall it did succeed. Balancing the needs and interests of different organizations, agencies, businesses and individuals has been a major challenge. Working on a publicly funded housing project presented different opportunities and obstacles for entities and individuals used to working with the private sector, and vice versa. Timelines and constraints, as well as the range of flexibility and resource availability, are several areas that are not always the same in both the private and public worlds. --- What has kept the project on track though is the need and desire to see the project completed, not only for reasons of accountability, but also to demonstrate that viable alternatives do exist.

The City of Spokane possesses one of the oldest and most established Building Departments in the Inland Empire region. Its origins trace from the Great Spokane Fire of 1889 that nearly devastated the entire city. As a result of this occurrence, building regulations (primarily requiring masonry construction for new construction in the urban core) were established very early on. The depart-ment is a very stable one. The departmental heads are all long-term employees and the turn-over rate in the department has been historically low.

For the SPREAD Project, several factors existed within the local building official world that helped see the plans through the permitting stages. First, the Review Examiner assigned to the Project had previously specialized in out-of-the-box type projects. Second, innovate building activity, for the most part, had also been received favorably by local Building Officials, the heads of both the City and the County Building Departments. And finally, both City and County departments have had a history of cooperative efforts.

The City and the County had recently co-adopted a recent shallow frost protected foundation system (developed by the Lead Plans Examiner of the City) and the County had recently adopted a straw bale construction policy. Since the City Building Official had assigned the straw bale project under the direction of the Lead Plans Examiner, the stage was set quite favorably for the eventual approval of the straw bale project within the boundaries of the City of Spokane.

The basic premise allowing the project to proceed under the governing building codes is found in the Uniform Building Code. Section 104.2.8 allows "alternate" methods or materials to be used provided that they meet code standards for "suitability, strength, effectiveness, fire resistance, durability, safety and sanitation."

This catch-all legalism may be interpreted to allow reasonable alternatives, or simultaneously, may be used to disallow any alternatives. It all depends on the Building Official. While this situation may remind one of draconian regulatory powers ("why not just beg on one knee to the ‘minister of buildings?’") often Building Officials are open to new ideas and are willing to consider any information provided. The "key" word is information.

Once data is provided to justify a methodology, most Building Officials automatically go into "review mode."

This is good. Now one can find out what substantive objections there may be to a proposal. These now can be addressed. It becomes a process of elimination. If good solid data are presented and backed up with examples, a building permit may be forthcoming.

The SPREAD Project was submitted with an architect’s seal impressed on the drawings. This was a major factor in the success of this project. Typically, engineered building designs affixed with the seal of an architect or engineer are usually considered acceptable to most Building Departments in lieu of strict component based code compliance. This was the case here. The professional seal on the drawings "took the pressure off" of the code officials to require a detailed design review and to accept the liability for same. This was a key component in securing a permit.

To an owner-builder, however, such a process can prove to be daunting and many a disillusioned applicant may soon give up. For this reason, a change in the codes to allow some owner-builder flexibility may be the best solution to this problem. Several jurisdictions allow these "alternative minimum codes".

Beware, however, that most regulatory agencies view such a process as a possible "crack" in their armor of control. Such legislative action is possible (although not common) and used with success in other states.

The straw bale home in Spokane was approved and authorized somewhat outside of normal channels. This was in a sense, unfortunate, for it makes the approval process difficult to replicate. It was necessary perhaps, for the project to succeed. The Lead Plans Examiner attempted to "put it through normal channels" as much as possible, but the bottom line reveals that it was very much a "custom" project, and the bureaucratic pathways were made smooth beforehand.

Since the straw bale components were merely infill wall components in an otherwise timber-frame structure, structural concerns were mitigated early on. The engineered drawings submitted with an architect’s seal helped to assuage departmental concerns about the design of the project.

Potential problems were addressed at various "pre-development" meetings where project compon-ents and time-frames were developed.

The architects involved in the project would also submit ideas and materials information to the Lead Plans Examiner for approval. This "one on one" approach worked well but was not typical for most residential projects handled by the City.

The approach used for the straw bale project was more akin to that used for commercial projects.

Closer coordination between the building inspection staff and the plan review staff would have proved helpful. There was coordination. However, as the project progressed, communication between the different inspectors involved and the plan reviewer began to wane and was utilized only after potential problems became extant. The use of an FPSF (frost-protected shallow foundation) in conjunction with the straw bale walls created drainage issues heretofore not recognized. Luckily, these were solved with the cooperation of all involved, but a closer coordination up front would have saved effort and expense.

It would perhaps be a bit naïve to expect every project to run as smoothly – or even to be approved or allowed to the extent that this one was. What is really needed is an overhaul of the Building Codes to allow low income and/or alternative materials projects to succeed and flourish within a less restrictive code framework.

Overall, the project went about as well, or perhaps even better, than normally could be expected. With the personal oversight and cooperation of key players in the Building Department, the project reached fruition without much difficulty. Perhaps this reveals the biggest potential flaw -- that this straw bale project would be difficult to replicate en masse in the foreseeable time horizon.

The City Building Official in particular has shown a commendable willingness to allow new construction techniques to be developed. This had a tremendous impact in allowing the success of the project. Unfortunately, it would be naïve to suggest that similar circumstances would present themselves elsewhere.

Nonetheless, as a result of this project in Spokane, numerous outreach potentials have been developed which should help "pave the way" for future similar projects in the region. Examples of this can be seen in the Straw Bale Workshop conducted on-site. This workshop was geared specifically for Building Officials and Inspectors. It was instrumental in changing attitudes towards straw bale construction amongst Building Department personnel throughout the region. In addition, the mere fact that the City of Spokane (the largest city in the Inland Empire) has allowed the construction of a straw bale project is bound to have favorable impact.

As a result of this project in Spokane, numerous outreach potentials have been developed which should help "pave the way" for future similar projects in the region. The use of straw bale construction within the City of Spokane provides a powerful initiative and ground-breaking mechanism for other jurisdictions. It opens the door to allow other jurisdictions to accept alternatives to the status quo.

The majority of funding for construction came from City of Spokane’s Multifamily Housing Program. Other sources of funding included several smaller (up to $2,000) grants for specific items such as workshop coordination and attendance, as well as donations for construction and landscaping materials and labor.

Key to receiving the financing from the City was the ability to present the information on straw bale construction in a professional matter. Accompanying the grant proposal to the City was an information packet organized in a notebook under the headings below. (See Appendix A for specific resources listed.)

Basic Background Information

Journal Articles on Straw Bale Construction

Newspaper & Newsletter Articles on Straw Bale Construction Projects in the West

Reference Material

Web Sites of Interest

For individual homeowner financing, some banks and mortgage companies such as the Green Loan Program (Hallmark Mortgage) will consider financing such construction projects. --- Again, as was the case with the publicly financed project, an information packet on key alternative construction methods and materials is not a bad idea to have ready to present to lending institutions, building officials, insurance agents, and other interested parties.

Since S.N.A.P., the lead organization, owns and manages other housing throughout Spokane, getting insurance was actually fairly straightforward. The SPREAD house was just incorporated into SNAP’s existing policy. The local broker did have to call though its carrier, St. Paul Fire & Marine Insurance Co. (700 5th Ave., #4200/ Seattle, WA 98104-5025), for an okay. The insurance company sent out an underwriter for a tour to do a risk analysis. The upshot of the tour was that before insurance could be okayed, a fire extinguisher, garden hoses and security fence needed to be made accessible and/or installed, plus "No Smoking" signs had to be posted in clearly visible locations. --- For any construction project, especially one using straw bales, it is critical to have fire abatement equipment and "No Smoking" signs readily available. The greatest fire danger with straw bale is during the construction process when there tends to be loose straw around.

For the individual builder, or owner-builder, obtaining home insurance may be a bit more difficult. The best approach would be to shop around with your local agents. For example, Safeco Insurance - Select Markets Division, the homeowner’s policy underwriter, has recently okayed non-load bearing straw bale construction. Insurance companies and their underwriters are becoming more informed about the construction method, but expect questions related to fire and wind resistance, plus replacement costs. Straw bale construction is still new enough in the area that finding comparable structures for assessment purposes presents a problem. --- Again, as in the case of financing institutions, having an information packet ready to present to people would help smooth the way.

Finally, in terms of workers on site, SNAP paid additional Labor & Industry Insurance to make sure that volunteer workers were covered. Plus, participants in the straw bale workshop series were asked to sign a liability release form.

The project’s overall design criteria incorporate features that contribute to long-term maintenance of family and community well-being such as operating affordability, neighborhood sensitivity, environmentally sensitive use of materials, and landscaping that is both food producing and indigenous.

The house design was based on a simple low cost rectangular plan with the living area facing south and east, and the bedrooms to the north. An eastern entry porch, that looked out over the neighbor- hood (defendable space design concept), became the visual entry element. The narrow 50 foot wide corner lot that faced south, influenced the site massing. The building was sited to the middle of the

site, with open space for southern gardens to the front, and parking, compost, and recycling bins off the alley to the north. This sustainable urban siting of porches, gardens and alleys, was discussed during the building workshops, as being just as important as the building materials used in the design. A low slope, hip-roof shape was picked to not only protect the four walls of the straw bales from moisture, but to blend into and reinforce the 1930’s bungalow style of the neighborhood. In a time when many architects design urban housing that overwhelm the existing neighborhood, the design team felt it was necessary to reinforce the important elements of the urban environment, and even more so when constructing a demonstration house. --- One of the architect’s most rewarding moments during the project was when a person searched out the architect to thank him for designing a house that fit into the person’s neighborhood.

The house design emphasized construction utilizing recycled, environmentally sensitive materials. --- Many sustainable resource efficient materials were reviewed in the design process of the SPREAD post and beam straw bale infill house. Besides the use of straw, other materials considered included: shallow frost protected foundation, recycled glass cullet as foundation and slab base, handmade cement stabilized soil bricks, manufactured lumber, use of recycled lumber and kitchen cabinets, reused hardware and interior doors, recycled foam/cement insulation panels, and concrete waste as patio paving. All materials needed to meet not only the requirements of the urban building department, but the minimum construction budget, and the low skill labor of workshop participants and volunteers. The recycled glass cullet was the only element not used, due to its availability, but it was building department and engineer approved. The previous elements were blended with more conventional 2x4 pre-engineered roof trusses, cement stucco, gypsum plaster, recycled cellulose attic insulation, metal roofing, interior gypsum wall board partitions, and a radiant-heated, colored concrete slab floor.

For a checklist of design considerations that the project attempted to follow, as much as possible and where appropriate, see Appendix C. - Sustainable Construction Outline for Natural - Healthy - Energy Efficient-Homes.

Developing the landscape design for the site took a different approach to that of developing the house plans. Prior to breaking ground, a landscape design charette was held in April 1997 that was run by Steve Drown, University of Idaho Landscape Architecture Dept. professor. Participants in the Saturday workshop included

• Spokane Neighborhood Action Programs
• Spokane Community Gardens
• University of Idaho Landscape Architecture students
• Architects Studio PA (Sandpoint, ID)
• Washington Rural Communities Network, and
• Other members of the SPREAD Project.

The workshop was open to the general public, but word of the charette was specifically passed on to landscape and gardening educational programs and organizations, plus landscape and gardening professionals.

To facilitate the design process, four different scenarios were developed by Tom Runa of Architects Studio PA prior to the workshop and then handed out at the workshop. These scenarios included a renter profile, basic amenities which held true in all four cases, and then optional amenities that reflected the family profile.

Originally, there was planned a 2 x 8' garden tool storage shed attached to and centered on the north building wall with two sets of 2' x 8' lockable access doors. This was changed to a 5’x8’ individually standing tool shed located in the northwest corner of the property.)

Also, handed out at the workshop by Don Stephens, a member of SPREAD’s design team, was the following list of issues and options that landscape design should consider:

• Natural beauty, curb appeal/property value enhancement, neighborhood compatibility, life-cycle planning;

By the end of the workshop, four alternate plans were drafted that provided the basis for the final landscape plan.

The construction process did not always follow the standard general contractor’s Critical Path Method. The process was mostly based on available volunteer labor, workshop schedules, and apprenticeship fall training programs. This process required that the roof and straw bale walls were constructed before the underground utilities, thus delaying the slab construction. Although the SPREAD committee wished the schedule was less conflicting, the educational process of introducing alternative construction to the electrical and plumbing trades, and over 130 straw bale workshop participants was worth the construction delays.

The house foundation is a Frost-Protected Shallow Foundation (FPSF) that allows a shallower foundation depth by utilizing special drainage and insulation methods. The City and County of Spokane have developed an "FPSF Inspection Guide" which spell out specifics. In the SPREAD House, foundation construction utilized a concrete grade beam (18"x20") on a compacted gravel base. According to the City Guide, a "# 4" washed round aggregate is ideal. The aggregate is wrapped in a filter fabric. Foam boards are placed vertically and then horizontally away from the foundation to minimize the loss of heat radiating from the foundation. Energrid panels (a product made from recycled styrofoam and concrete) help insulate the outside of the foundation wall, as well as provided a stuccoing surface at the foundation level. (Note: Since the end of the project, Energrid is no longer available because of a lawsuit settlement over patent rights. The same basic material available is called Rastra. Rastra’s website is www.baubuilder.com .)

As mentioned above, key to a FPSF is the drainage issue. Addressing this issue actually became more critical in the midst of the project when there was a realization that the codes for the FPSP and those for the chosen heating system conflicted with one another. The FPSF system requires foam board to be used on the outside walls and not under the slab. In the radiant heating system, foam board is required under the slab. The conflict was resolved by insuring that water flows away from the foundation by not only providing long overhangs which work well with straw bale walls, but also enhancing drainage away from the house by drain pipes and swales. The sandy make-up of the soil also allows for good drainage to take place. --- The concern for drainage did prohibit including a second gutter chain which would have gone from the roof gutter to a barrel on the ground.

On account of time constraints and lack of readily available framing skills, the load bearing walls and roof framing were contracted out. The load bearing walls are a modified post and beam design utilizing three 2"x 6" studs to create the posts with a laminated beam rested on top to support the 2"x 4" pre-engineered roof trusses. The location of the windows and doors were framed in using conventional style framing methods.

The modified post and beam method chosen created challenges when raising the bale walls. Each 3-studded post had to be notched around, as well as did the laminated beam. (By the end of the first weekend, everyone was an excellent notcher.) An alternate framing method which would involve less notching of bales, as well as provide interior nailing surfaces, is the use of two 2"x 4" studs sandwiched between two pieces of plywood.

In addition, an alternate framing method for the windows which would have saved wood, but would have been difficult under the given circumstances, is to frame a structure without the window locations in place. Then, before the bale wall raising, four-sided window frames are constructed and set aside, ready to be put in place during the wall raising.

Metal roofing was used on the house because of its durability factor and feasibility of being recycled. OSB, rather than plywood, was used for sheathing. (Note: Use of OSB may provide some complication with metal roofing. In some cases, use of OSB can invalidate the roofing warranty.)

Finally, recycled wood was used to construct the soffets.

Exterior Walls & Straw Bale Construction

The most unique feature of the project is the insulative material utilized in the exterior walls --- straw bales. Approximately 250 bales (roughly 6 tons) of straw with an average R-value of R40 (over twice a normal 2x6" wall) were used.

• Super-insulative technique that incorporates long-term energy savings;
• Enhanced soundproofing;
• Low maintenance;
• Utilization of a renewable resource; and
• Fire rating (2-hour commercial rating).

• Density
• Moisture
• Nutritional level

In terms of availability of straw, Table 1 provides some basic data regarding overall quantity in Washington. The SPREAD House was built with bales that came from a farm located in Nine Mile Falls, not far from Spokane. The bales were gotten directly off the fields the morning after they were baled with the help of several trucks, a trailer and a handful of able bodied people. --- As mentioned earlier, a decision was made to use wheat straw, the more acceptable agri-by-product for the first public project in the area, though timothy afterstraw and bluegrass are also being used in the region including B.C.. Finally, the bales were swath cut (not rotary cut), 2-string bales.

Described below are key building materials and tools used in the bale construction phase of the SPREAD House. Possible suppliers are also identified.

• Re-bar - Used to anchor the first row of bales to the foundation. (See Foundation photos). Plus, re-bar staples, a bent bar about 16" long (

• Metal Straps - Approximately 10’ long, placed on diagonals from sill plate to modified post and/or top beam, and vice versa. Straps are used as lateral bracing in the building. Potential Suppliers - Local building material suppliers.

• Bamboo Sticks - Approximately 3-4’ long. Used to pin every 3 rows of bales together as the walls are being constructed. Used instead of re-bar because bamboo is a material that can withstand the lateral stresses, but also is renewable. Potential Suppliers - Supplied by the GreenFire Institute, but also are available from McCalif Growers Supplies Inc. located in California (Tel.# 1.800.234.4559).

• Roberts Pins - Metal "bobby pins" approximately 6-8" long that are used to pin chicken wire to bales. Potential Suppliers - Supplied by the GreenFire Institute, but also available from McCalif Growers Supplies Inc. located in California (Tel.# 1.800.234.4559).

• Tar Paper - Used to cover exposed wood before wiring and stuccoing. Potential Suppliers - Local building material suppliers.

• Expanded Wire Lathe - Heavy-duty metal mesh placed around windows and doors before stuccoing. Potential Suppliers - Local building material suppliers.

• Chicken Wire, or Plastering Wire - A minimum of 20 gauge mesh stretched over bales to reinforce stucco sprayed on bales; a minimum of 17 is needed to go over wood. Potential Suppliers - Local farmers coop, or hardware store.

• Hog Rings - Used to tie overlapping chicken wire together. Rings were not used in SPREAD House but later recommended as an easier way to tie wiring together. Potential Suppliers - Local farmers coop, or hardware store.

• Baling Twine - New twine used to retie bales. Can also recycle twine from original bales before they are cut and retied. Potential Suppliers - Local farmers coop, or hardware store.

• Bale Needle(s) - Approximately 2+’ long needle used to retie bales. Potential Suppliers - Three needles were fabricated locally in Spokane by Gene Anderson, but needles have also been available through Out on Bale in Tucson, AZ (Tel.# 1.520.624.1673), as well as Real Goods in Ukiah, CA (Tel.# 1.800.762.7325).

A key principal in application of an exterior or interior coating to bale walls is maintaining the movement of air from inside the building to the outside --- in short, maintaining house breathability. To start with, a stucco cement was used on the exterior wall after it had been prepped. A shot-crete method was used to apply two coats, followed by hand troweling. Both coats were done on the same day. --- Prepping and stuccoing of exterior walls were part of the bale workshop series. A gypsum

plaster was hand applied on the interior walls. Since SNAP was most concerned with the quality of the interior plastering/stuccoing, this part of the project was contracted out.

Several problems did arise with the exterior stuccoing: 1) Despite being the third week of September, hot weather made it difficult to keep the applied stucco consistently moist. Some cracking did take place. 2) Since the exterior stuccoing was part of the workshop series, most people did not know how to stucco. Though not terribly difficult, some variations in quality were apparent. To correct both the above, touch-up stuccoing was later done on the outside, as well as Thoroughseal applied to cracks. Unfortunately, when it came time to paint with a fog coat (mixture of white cement, lime & colorant), the Thoroughseal and the initial stuccoing did not take the colorant equally. The walls were blotchy. Hence, a decision was made to use an exterior latex paint applicable on masonry and wood. Using the latex paint on the outside made it necessary to use a less permeable, high solids content, vapor barrier paint on the inside. In order to get a low VOC (Volatile Organic Compound) paint fitting the necessary requirements, the paint was ordered from Best Co. in Seattle, WA. If there had not been a problem with the exterior fog coat, then a low VOC, regular latex paint would have been used on the interior. --- It also was possible to leave the gypsum plaster unpainted, but since the house was to be (is) a rental, SNAP wanted to be able to clean the walls easily. Unpainted gypsum plaster is fairly porous, and would have been difficult to clean on a regular basis.

Conventional 2"x 4" framing was used to construct the interior walls. The main difference between the SPREAD House and a conventional house is the wall height which measures 100+" from the floor to top of top plate. In this case, the exterior wall height (height of the stacked bales) dictated the interior wall height. The variance of the interior walls from the normal 4’x 8’ construction unit created greater waste of both 2"x 4" studs, as well as drywall. --- The trade off is the additional 4+" in the ceiling height, though seemingly minimal, really does make the house seem more spacious. --- Interior partition walls were connected to the bale walls with wooden dowels.

The floor of the house is a colored concrete slab scored at 2’ x 3’ intervals and then grouted with a contrasting color. Under the slab, from top down, is the circulating hose for the heating system secured to wire mesh that reinforces the concrete slab. This is placed on top of a layer of sand spread over a 6-mil layer of plastic and 2" foam board insulation. Underneath is a layer of pea-gravel with 4" perforated pipes running through the gravel to act as a radon barrier. ---Recycled glass cullet, a substitute for pea-gravel, was the only major element not used that the project wanted to use due to lack of local availability. The cullet was approved though as a radon barrier by both a structural engineering firm and the City Building Department. (As noted earlier in the "Foundation" section, it is critical to make sure that the code requirements for the foundation and heating system work with one another.)

The SPREAD Project ended up confronting several problems - logistical and other, related to the flooring. First, dollars and time would have been saved if both the concrete grade beam and slab had been poured together before the construction of the exterior walls (including the bale walls) and roof. In an attempt to accommodate apprenticeship programs, plus the decision to use handmade pavers in the living room - dining room area, the slab was not poured until after the outside structure was in place. Unfortunately, involvement of one of the apprenticeship programs fell through, as well as the interior use of the pavers. --- Handmade pavers were used though to make up the finished floor of the porch.

Next, the coloring of the slab ended up being molted. Best guess why the molting took place, is the fact that since the slab was poured later in the process, and covered up with plastic several days after being poured to protect it from being damaged, moisture evaporating from the drying slab was captured. The failure to release the moisture directly into the air seemed to have created some type of chemical process that caused the molting effect, as well as opaque areas to appear. ---- The molting did work to the project’s advantage by creating a more unusual floor than anticipated. The opaque areas disappeared after utilizing a different floor sealant than the one initially tried.

The heating system in the house is a radiant hydronic system located underneath the concrete floor. The slab is warmed by hot water circulating through reinforced polymer tubing laid out like four wings of a butterfly. The hottest water first circulates closest to the foundation wall with sub- sequent loops moving closer to the mid-

dle of the house. The whole system is heated by the natural gas hot water heater which also provides hot water for everyday usage. --- The hydronic system allows for slow recovery if the house is cooled substantially, but retains heat well and makes the concrete much more comfortable.

In completing the house interior, the SPREAD Project utilized recycled materials from a house being torn down. Recycled kitchen and bathroom cabinets were refinished and new counter tops built before being installed, as well as several interior closet doors found a new home. In addition, the project reused fiberglass insulation in several places where additional insulative material was needed.

Other materials of interest used in the house include a low VOC (Volatile Organic Chemicals) interior paint, a variety of fluorescent (energy efficient) lighting, and blown in cellulose insulation of approximately R40-R45 in the attic.

A critical design element of the SPREAD House is the porch. It is the transition between the inside and outside spaces, as well as private and public realms. It extends the house into the neighborhood. Some key elements which make the porch more unique are the handmade soil-cement pavers used for the flooring made from 5 parts soil/ 2 parts clay/ 1 part cement. These pavers were made onsite during one of the summer workshops. The other element(s) are the two salvaged wood columns used to support the porch roof.

Designing and completing the landscaping for the SPREAD House was done in stages. As previously mentioned, a design workshop was held in April 1996 at which time four alternative plans were drafted. From those four plans, a working design was created which has served as a guide to final landscaping decisions. Some deviation took place between the landscape plan and what actually has taken place on site. Reasons for the differences include the inclusion of raised beds to the south of the house which were designed and constructed by Spokane Community Gardens in the fall of ‘97. Then in the following spring, SCG provided the family with packets of vegetable and flower seeds. Some vegetation planted around the house was also altered because a number of local flowers, shrubs and trees were dug up and donated from several people’s homes. A decision to change several tree species was made because of the concern of ultimate height of trees and proximity to house.

SPREAD landscaping did run into one major problem that took some time to resolve. Since the house is situated on a hill above the street level, a set of stairs providing secondary access from the street level to the house was incorporated into the landscaping. There was a question whether these stairs should fall under local building codes, or whether they are a landscaping element and should be treated as such. In a private dwelling, these stairs would most likely be considered a landscaping element and therefore not subject to the "rise and run" codes or handrail codes that relate to stairways. However, since the SPREAD House is publicly funded and may be occupied by a low income household utilizing a HUD certificate, the home needed

to meet the HUD Housing Quality Standards.

--- Given the oversight, the stairs could not be treated as a simple pathway landscaped up the hill, but had to include a continuos handrail plus be uniform in construction.

Recycled materials were used in landscaping the site. Both the stairs and the handrails were constructed out of recycled material. The former out of recycled concrete pavement and blocks, while the latter was out of recycled 1 1/4" galvanized piping. Also, the patio area to the south of the house was created out of recycled concrete sidewalk.

A storage shed, located in the northwest corner of the property, is partially constructed out of recycled materials. Framing members of the building come from a torn down building. The shed siding is Hardiplank, a wood chip and cement composite board.

Prevalent throughout the project was a strong desire to provide training and educational opportunities for building officials, owner/builders, and local apprenticeship programs in the areas of alternative building practices and materials. --- By the end, opportunities for people to learn included straw bale construction and landscaping workshops, volunteer work days, media coverage, and word of mouth --- all of which "spread the word," resulting in people stopping by almost daily to check out the project and its progress. The largest crowd, approximately 350 + people, showed up on site at the public open house held on a Saturday in December. Another 50 people were present at the official ribbon cutting ceremony later in the week. --- Not bad for the old Three Little Pigs story!!!

Since the most unique dimension of the SPREAD Project is the use of straw bales, a building official seminar, an evening presentation and discussion, and a three-weekend workshop series were organized and held from the end of August until the end of September.

First, the Building Official Seminar took place on the Friday prior to the first weekend workshop. The 1/2-day session for only building officials and inspectors --- no press allowed --- was organized and run by Ted Butchart of the GreenFire Institute. Officials throughout the Inland Northwest were given the opportunity to learn first hand about straw bale construction, ask pertinent questions, and see a project in progress. --- Holding such a seminar is key in helping to overcome institutional barriers to new (and old) materials & technology in an informative, non-threatening manner. As was mentioned in the "Permitting Process" section, such workshops are "instrumental in changing attitudes towards straw-bale construction amongst Building Department personnel throughout the region."

Second, involvement with the public was kicked off by a Friday evening slide presentation and discussion on straw bale construction and the SPREAD Project following the Building Official Seminar. Cosponsored by SNAP, SPREAD Home Project and the Spokane Unitarian-Universal Church Social Justice & Environmental Committees, the evening event gave both those who were participating in the hands-on workshops, as well as interested members of the community, an opportunity to learn about both the local project, and those in the Northwest and beyond.

Straw Bale Workshop Series

The straw bale series consisted of three-workshops (wall raising, stucco prep and stuccoing) held every other weekend, and taught by straw bale professionals from western Washington, southern BC and northern Idaho. In setting up the series, basic criteria was established that helped to identify people who would most likely benefit from the series, and who would help to continue the educational and training process in the future, especially for low-income individuals and women. Specifically, a designated number of workshop invitations were sent to affordable housing agencies, such as Habitat for Humanity, as well as to S.N.A.P. clients, a women’s alternative career program, cooperative extension educators and building officials, as well as extended to a grass-roots group in British Columbia. A maximum number of 30 attendees was set per day. Registration was based on first come, first served. Since all spaces were not filled by the initial invitees, the workshops were opened up to any interested individuals who wanted to participate.

Photo # 10 - Learning some basics before wall raising.

On the second weekend of the series, the workshop was split between wall prepping - primarily the exterior, but also portions of the interior, and making soil cement pavers.

Initially on-site manufactured pavers were to be used inside in the dining room and living room areas. On account of equipment and time constraints, the soil/cement pavers were instead incorporated into the construction of the outside porch.

Finally, the exterior stuccoing was tackled on the third weekend.

Landscaping activities were kicked off in April 1997 before ground breaking and wrapped up in July 1998. Landscaping of the site was an integral part of the project. As mentioned earlier, the landscaping facet of the project commenced with a Design Charette or Workshop.

Once the primary construction was completed on the house, follow-up landscaping activities ensued. Several work parties were organized in the fall of ‘97. The Spokane Community Gardens constructed several raised beds, some trees were planted, and the patio, porch and stairway were tackled. Landscaping projects were postponed until spring, once cold weather truly set in and the ground became frozen.

Finally, in the spring of ‘98, several work days were organized to prepare the ground for seeding by a professional landscaper. (Two different types of lawn seed were chosen: 1) a short variety mix for the hillside that does not need to be mown; and 2) a more conventional lawn mix for the flat areas surrounding the house. ) Shrubbery, flowers, vegetable seeds and starts, and trees, many thinned out and donated from people’s yards and gardens, were also planted. Finishing touches to SPREAD’s landscaping came with the construction of a fence to provide privacy between the neigh