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Building with Compressed Earth Block

Desk Research & Primary Findings

Issued on: 30th August 2023

Table Of Contents

 

1. Background

1.2. Overview of Compressed Earth Blocks

Compressed Earth Blocks (CEBs) are a natural infusion of modern technology with one of the earliest elements of man-made structures: the mud brick or adobe block (Bowen 2017). They are essentially moulded adobe blocks produced using mechanical compaction. According to Earth Building and Association of Australia (2022), making CEBs requires dampening the earth and mechanically pressing it along with some sand and a small amount of aggregate binder such as cement at high pressure in a mould, and then setting aside the produced bricks to dry naturally. Studies show that compacted earth has been used before written history, so the utilisation of earth in housing construction is one of the oldest methods used around the world.

Some developing countries are no exception to the adoption and use of CEBs. According to Finnan (2018), the CEB method for construction is not only implemented in Gambia (see figure 1), but also in other African countries such as Burkina Faso, Ghana, and Nigeria as well as Sudan. According to Adam and Agib (2001), various traditional materials have proved to be suitable for a wide range of buildings and have a great potential for increased use in the future, including CEB (See Figure 2). In South Africa, the use of CEBs is gaining popularity. Moreover, Agrément South Africa (2016) has approved the CEB Building system for single-storey buildings.

The production of various types of soil bricks, such as adobe, mud bricks, and fired bricks, is quite prevalent in Lesotho, however, CEB has not been used due to a lack of knowledge (Adam and Agib, 2001). As a result, there is a pressing need for research to be conducted on this particular building material.

1.3. Advantages of Compressed Earth Blocks

From an architectural perspective, Compressed Earth Blocks offer similar form and functional qualities as brick, stone, and other masonry units. Moreover, they are more easily produced than stone and are more durable. Furthermore, the structural integrity of the material allows it to be used as a structural wall system that requires minimal reinforcement or additional framing (Bowen 2017).

The capacity of the material to absorb and radiate solar energy as heat is also one of its great advantages (Bowen 2017). This capacity can be termed ‘thermal buffering.’ This means that the material will absorb heat when it is cooler than its surroundings and re-radiate it when it is warmer than the surroundings. The energy-saving effect of thermal buffering is most marked by reducing the need for cooling, but it also has a comforting comfort effect because it reduces internal temperature swings (Bowen 2017).

The materials that go into making CEBs mostly come from nature. There is a reduction in chemicals that are used in the making of these blocks, therefore the material releases no harmful or toxic gas ( Happoadmin, 2022).

The usage of cement (usually about 4-10% of the soil and sand mix depending on the soil composition) is lesser and has the ability for on-site production, curing, and fixing, thus the cost reduction (Nnadi & Delunzu, 2022). According to Happoadmin (2022), CEBs are about 40% cheaper than conventional materials. Therefore, due to their thermal mass quality, CEBs can save anywhere between 10-15% on cooling and heating costs. Also, the time required to manufacture these blocks is minimal.

Manufacturing of CEBs can provide employment opportunities while inculcating social values in them. The compression machines can be powered or operated by hand, and do not require a lot of energy to produce like brick or concrete leading to low carbon emission (Happoadmin, 2022).

1.4. Disadvantages or limitations of Compressed Earth Blocks

When compressed earth block structures are exposed to prolonged weather conditions such as wind and water without proper roofing, they erode easily; however, adding stabilisers like cement improves the strength. Also, there is a time wait with the construction technique, because after the blocks are pressed, materials must dry; therefore the curing duration typically of 28 days also depends on the material used (pure earth with water, cement, or lime for stabilisation). Lastly, failure to mix soils correctly leads to weak blocks that crack easily (Bowen 2017).

2. Primary Explorative Research Findings

To collect primary data, snowballing, and stratified sampling were convenient sampling techniques for this study because it was imperative to select participants with first-hand knowledge about compressed earth bricks from a wide range of professionals and experts who have worked or are working on producing compressed earth bricks. This chapter presents the findings from one face-to-face, 3 calls, and seven Zoom interviews that lasted between 45 minutes to an hour each held in January and February 2023. A set of questions (check Annex 2 questionnaires for CEB) which included open-ended questions, had been prepared with the aim of gathering information about some specific topics such as availability, accessibility, cost, durability, knowledge, and techniques around producing compressed earth bricks.

2.1. Knowledge and techniques used when building using Compressed Earth Bricks

It was crucial to collect information from individuals who possess direct experience in producing Compressed Earth Bricks outside of Lesotho, as there is limited expertise within the country regarding both the production process and the specific machinery involved. All eleven respondents emphasised similar techniques, such as creating a dry mix of suitable soils with water and a small portion of cement for stabilisation. Respondents emphasised that surface soil isn’t utilised due to its organic content for gardening; instead, subsurface soil is preferred. Respondents stated that samples are examined to verify the accurate percentage of components, with a special focus on clay percentage, which can lead to significant expansion and cracking. Additionally, it’s important to assess the presence of rocks in the soil. Similar to clay, these rocks can also lead to cracks and gaps in the blocks. Respondents also indicated that cement is employed for mix stabilisation. The typical cement-to-earth ratio is around 10:90, which strengthens and stabilises the Earth Blocks.

Respondents stated that the strength of CEBs primarily derives from the pressure applied during production. Even with a lower cement content, such as 5% (5:95), it can yield a 7 MPA earth block, matching the compression rating of an inexpensive cement block. Respondents also described the production process using either a manually operated or diesel-powered compressed earth machine, which can be compact and portable. Finally, a machine can also be designed to produce 3 / 4 blocks simultaneously (see video CEB) The last important step Respondents mentioned about the production was the curing period which takes 28 days before being able to be used to build while placing it in the sun.

2.2. Costs and accessibility

Five respondents highlighted the cost-effectiveness of producing CEBs.This is attributed to on-site production, where the soil is readily available and cement usage is minimal compared to conventional bricks. Moreover, basic mechanical machinery for lower-scale production is relatively inexpensive.

One of the respondents indicated large-scale production costs required an outlay of M66 7049 (EUR 33,352) for machinery such as AECT Impact 2001 – a CEB Machine (see Figure 3). However, in the long run, these are offset by fairly cheap operational costs for energy and raw material consumption and usage.

2.3. Environmental Impact of Compressed Earth Blocks

Another key aspect we needed to grasp in our research was the carbon emitted during production and the overall impact of soil extraction. All eleven Respondents confirmed that Compressed Earth Blocks are less harmful to the environment compared to traditional materials. Specifically, producing CEB leads to fewer emissions and significantly less cement/lime per brick. Respondents pointed out that decreasing cement usage results in a significant  50% reduction in embodied carbon emissions. Additionally, Respondents emphasised that producing Compressed Earth Blocks provides a compelling opportunity to utilise earth extracted and processed directly at the construction site.

This offers a notable advantage compared to other materials in that earth is abundant throughout Lesotho, it reduces transportation costs, minimises transport-related pollution, and provides a solution for the displaced earth that is excavated on construction sites.

2.3. Durability of Compressed Earth Blocks

All eleven respondents affirmed that once cured for 28 days, CEBs exhibit durability. They noted that the material’s quality and solidity increase progressively, resulting in buildings that are recognized to endure for over 60 years. However, no compressive strength data was provided by the respondents to determine the optimal earth-to-cement ratio in terms of cost-effectiveness. This ratio varies based on the soil composition and clay content, which differ between sites.

3. Feasibility of Compressed Earth Blocks

There is an industry for earth-based bricks such as Fired bricks,& loti bricks (see Figures 4a, 4b, and 4c) which in Lesotho are manufactured formally in a factory called Loti Bricks as well as provided informally by artisans who create their furnaces on the roadside, against which we can discuss the feasibility of CEBs. This means that the policy framework for the production of CEBs currently exists which makes it viable as an enterprise. The difference in production processes skews the advantage towards CEBs because of lower emissions and fewer materials with embodied carbon (lime & cement). Lastly, there are no speed skills required in the production of CEBs which makes for relatively affordable and accessible labour requirements.

4. Distribution of Compressed Earth Blocks

The distribution of CEBs is tied to two main factors; accessibility of machinery and earth. For an industrial plant, it will be difficult to move the machinery to the building site, unlike the more compact mobile systems, which do not require transportation and warehousing. Since warehousing and transportation for alternative building materials are well developed in Lesotho, CEB companies can piggyback on these systems to distribute their products all over the country.

5. Unmet needs of Compressed Earth Blocks

The CEB market is untapped despite a history of other earth bricks, for instance, adobe bricks, in Lesotho. The oldest buildings in Lesotho are built from adobe and date as far back as 1843. However, there is no record of compressed earth buildings that we could find in Lesotho, although there is a growing interest in the production and use of this technology, one local artisan has made his own CEB machine (see Figure 5).

6. Conclusion of Compressed Earth Block

From an economic standpoint, there are a few factors that this paper has outlined that are critical to the development of a CEB-based industry. The first is that we do not have price-per-brick data that we can use in comparison with conventional materials to come up with a cost-per-square-meter standard. It is possible to project that, after the initial capital expenditure into the machinery, the material and labour operational expenses are fairly lower than competing fire bricks. There is a less labour-intensive process, a passive curing process, and the potential for on-site production which projects for a cheaper product. Overall, our analysis points to an economically viable option  that will yield a whole set of new jobs, complementary businesses, and alternatives to highly processed conventional materials.

The environmental impact of producing and using CEBs requires some thoughtful analysis since there are aspects of embodied energy and impact offset by some relatively cleaner and raw processes. The embodied energy is in the cement (when and if required) to enhance the compressive strength and durability of CEBs as well as the associated energy required to operate the diesel-operated machinery, though there is also CEB machinery available that is manually operated. However, these costs to the environment are offset by CEBs requiring very few materials that are abundantly available across the country. There are also no toxins associated with the production of these bricks onsite.

The sociopolitical conditions forebear a high potential for the development of the CEB industry. All of the raw materials are unregulated and the process does not emit any toxins that would require further approval. Competing materials like fired bricks have created a context for digging earth for manufacturing bricks and created a marketplace for alternatives to cement blocks. The demand for these materials should not be an issue since CEBs can be seen as an alternative to fired bricks and adobe blocks which have been used for a long time in Lesotho.

7. Recommendations for Compressed Earth Blocks

Our classification of the audience for the potential of CEBs is in the state, development partners, and the private sector. To the state agencies and development partners in the green economy, this paper recommends that a rating system be developed( see Annex 1 Material Specification) to illustrate the environmental benefits of using CEBs above alternatives. Secondly, once this industry is developed, a levy on imports may be used to discourage direct competition for CEBs to curb the overall carbon footprint and cost of importing a building material we can produce locally.

Development partners include NGOs, academic institutions, and private donor institutions with an interest in the spectrum between the basic need for shelter to the development of industry. From a technical perspective, this paper recommends that in-depth research be conducted into the performance of CEBs to support their readiness for the market. With the support of NGOs and donors, better regulations may be placed on where and how to mine the earth used for CEBs and other similarly resourced bricks to ensure environmental security for future communities.

Lastly, the private sector will play a key role in maximising the benefits of CEBs’ use in construction at all levels of the industrial hierarchy. At the top level, advocacy for CEBs in line with job creation, environmental impact (positive and negative), and built industry value chain development needs the participation of influential individuals and associations (Private Sector Foundation of Lesotho and the Lesotho Chamber of Commerce and Industry). Investment into the industry from financial institutions is also key to the mobilisation of the use of CEBs through funding the required infrastructure, marketing, and labour.

Compressed Earth Blocks are economical, produce low-emissions, and are primarily locally producible building materials. They are a good alternative for low-cost housing since Adobe alternatives have been used in Lesotho in the past. There is an opportunity for the mass production of these blocks which in turn will generate manufacturing jobs. To raise awareness and create demand for this building material a highly visible and utilised demo building made from CEB should be built to train community members on how to make CEB and build with it and gauge the interest in the material once it’s known. The presses can then be left with communities as income-generating activities to make CEBs and sell them; in this way, the economy will circulate amongst the communities.

8. Appendix

Respondent NoName of CompanyNumber of Years of ExperienceProfession/ Qualifying criteria
Respondent 1Dwell Earth30 yearsSeller of CEB machinery and trainer of producing CEB
Respondent 2Blessman International (Compressed earth block constructor)5 yearsBoard of Directors of Blessmen
Respondent 3Blessman International (Compressed earth block constructor)7 years Constructor and offers technical guidance on Compressed Earth Block
Respondent 4Individual Contractor30 yearsBuilder and producer of CEB in Lesotho
Respondent 5Blessman International (compressed earth block constructor)15 yearsConstructor of Compressed Earth Block
Respondent 6Entrepreneur3 yearsCompressed Earth
Respondent 7Natural Building Collective14 yearsFounder facilitator and trainer
Respondent 8Limkokwing University of Creative Technology 20 yearsHead of Dept of  Architecture
Respondent 9MMA Studio5 yearsArchitect
Respondent 10Natural Building Collective9 yearsFacilitator/Trainer/
Builder
Respondent 11Morija Museum and Archives15 yearsDeputy Curator

9. Bibliography

Adam, E. A. & Agib, A. R.A. 2001. Compressed Stabilised Earth Block in South Sudan. https://unesdoc.unesco.org/ark:/48223/pf0000128236/PDF/128236eng.pdf.multi

Agrément South Africa .2016. 2011/397 (Amended December 2016): Compressed Earth Blocks Building System. https://agrement.co.za/active_certificate/2011-397-amended-december-2016-compressed-earth-blocks-building-system/

Arumala, J. O & Gondal, T. 2017. The Construction and Building Research Conference of the Royal Institution of Chartered Surveyors. https://www.rivendellvillage.org/Compressed_Earth_Building_Blocks.pdf.

Bowen, M. 2017. A Best Practices Manual for Using Compressed Earth Blocks in Sustainable Home Construction in Indian Country. https://www.huduser.gov/portal/sites/default/files/pdf/Compressed-Earth-Blocks.pdf

Building Impact Zero Network. 2017. Design and Build with Compressed Earth Blocks. https://www.bi0n.eu/our-work/1-design-and-build-with-compressed-earth-blocks

Contributing Writer. 2012. BENEFITS OF COMPRESSED EARTH BLOCKS: Interview with Dan Powell of EarthTek. https://greenbuildingcanada.ca/2012/benefits-compressed-earth-blocks-dan-powell-earthtek/

Earth Building Association of Australia. 2022. Earth Building. https://www.ebaa.asn.au/about/earth-building/

Finnan, D. 2018. Innovative Compressed Earth Bricks boost Gambia’s construction industry. https://www.rfi.fr/en/africa/20180727-innovative-compressed-earth-bricks-boost-gambias-construction-industry

Guillaud H, Odul P, & Joffroy T. 1995. Compressed Earth Blocks: Manual of design and construction. Volume II. Hoehl-Druck, Bad Hersfeld. Germany

Happoadmin. 2022. Compressed Stabilised Earth Blocks (CSEB) – an alternative to Clay Bricks. https://happho.com/compressed-stabilised-earth-blocks-alternative-clay-bricks/

MecoConcept. 2022. Compressed Earth Blocks. https://www.mecoconcept.com/en/green-building/compressed-earth-blocks/

Nnadi, E.O.E, & Delunzu, V.U. 2022. Cost- Cost-benefit analysis of Using Stabilized Earth Block to Conventional Block Use in Housing Construction. https://www.irejournals.com/formatedpaper/1703280.pdf

Taos. 2023. Taos Pueblo. https://taos.org/explore/landmarks/taos-pueblo/

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Information Library

Building with Straw and Grass

Desk Research & Primary Findings

Issued on: 30 August 2023

Table of Contents

1. Background

1.1 Overview of Straw and Grass as a Building Material

Grassland vegetation has dominated Lesotho’s landscape for the last 23,000 years or more, as documented by Oppong 2008. However, over time Lesotho’s grasslands have been substantially transformed by human activities to provide shelter and insulation before industrialised roofing and brick materials were introduced, according to Oppong (2008). Grass and straw have been used since the early 1600s for roofing and to build walls by mixing clay with cereal straw or grass and laid up on top of one another into a free-standing wall. Today the materials are most commonly found in rural villages, lodges, guest houses, and historical buildings as a homage to traditional methods of building and roofing.

However, in recent years migration patterns within the country and outside have resulted in the material being replaced with modern alternatives such as metal roofing and concrete blocks especially in urban, peri-urban, and to a small extent in rural areas. The apparent shift from using the material has been due to the fact that grass and straw  is viewed as low-cost, and it is associated with traditional housing, mostly used by people in rural areas with little or no source of income to afford modern materials (Oppong, 2008).

According to Oppong (2008) although thatched roofs have been common in Lesotho since ancient times, in the present day, the lack of incorporation of thatch roofing and the use of compressed straw in a more modern architectural world to meet the housing needs in the country reduces the prospects for sustainable development.

2. Types of Straw and Grass used as a Building Material in Lesotho

In Lesotho, there are two varieties of grass suitable for roofing and insulation: cereal and natural/wild grass, found in different regions. Lesotho can be divided into four major ecological zones namely; the Highveld Grassland, Afromontane(foothills), Afroalpine(lowlands), and Senqu Valley, which are home to a variety of grasses and agricultural produce.

2.1. Cereal straw

Due to the unique climate and soil conditions in Lesotho, the most common cereal crops are maize, wheat, and sorghum which are the primary grains consumed locally. There are byproducts from the harvesting of these crops that can be incorporated into the built industry, particularly as roofing materials and for insulation. In Lesotho, wheat straws have been used for roofing, particularly in the highlands of Lesotho. This is due to the fact that highland districts such as Thaba-Tseka, Mokhotlong, Qacha, and Quthing were identified as the top-producing regions for straw in the country [1] (The Lesotho Vulnerability Assessment Committee’s Crop Estimates report for, 2022).

However, the introduction of compressed straw as an insulation material has not been instigated in Lesotho. The compressed straw buildings were first constructed in the late 1800s in Nebraska, USA with the development of steam-powered balers. Even in earlier days, walls made from either tired bundles of straw coated with clay or compacted loose straw mixed with clay have been constructed for centuries throughout Asia and Europe. With the growing awareness of the strong and risky effects on climate, the notion of both reducing carbon costs and carbon sequestration has led to the effective use of compressed straw as a building (Sarath, C & Kumar. B, 2012). Therefore, there is an opportunity to explore compressed straw as a possible building technique for contemporary building standards and preferences in Lesotho (See Figure 1 which shows compressed straw).

2.2. Wild grass

In Lesotho there are four different types of wild grass available that can be used for thatch: qokoa (Hyparrhenia tamba), mohlomo (Hyparrhenia hirta), tsaane (Eragrostis chloromelas), and lehlaka (Phragmites australis), available in different districts in different quantities (Kose, 2021). It is important to note that some of the naturally growing grasses, like qokoa and mohlomo, are legally protected and are prone to sociopolitical controls that may influence their availability for use in the built industry. Another important issue to note is that some of these grasses may be farmed, which again has an impact on the availability of the grass. These socio-political aspects of grass use in the building industry are explored in detail later in this paper (See Figure 2, which shows the Agro-ecological zone).

2.2.1. Highveld Grassland ( Lowlands)

This zone spans from the western lowlands of Lesotho starting at the lowest point (1400 m.a.s.l) which includes the Southern region of the Senqu Valley and extends to about 1800 m.a.s.l. Its main vegetation consists of grass species, the bulk of which are Hyparrhenia Hirka mohlomo and qokoa.

Mohlomo typically grows on mountains and between mountain slopes. According to the Ministry of Natural Resources World Wetlands Day report in 2004, mohlomo is considered to have the best quality among all types of wild grass for thatch in Lesotho, and its quality is comparable to that of thatch used in South Africa. It can last for 20 years or more (See Figure 3).

Qokoa, on the other hand, has larger stalks, is less durable, and rots more easily. It is also available in the northern parts of Lesotho

Tsaane is found in the Southern regions of Lesotho. It is characterised by short stalks which make it less durable because it allows water to penetrate in the house.

2.2.2 Afromontane Grassland Zone ( Foothills)

This zone ranges from 1800 m.a.s.l to around 2500 m.a.s.l in altitude. Geographically, it ranges from the upper Senqu Valley to the watershed, covering most of the Maloti Mountain range in the centre of the country. The foothills also include parts of the Drakensberg mountain range in the north as well as the eastern side of the Senqu Valley. It has a wide range of grasses mainly mohlomo and qokoa and it grows successfully due to the volcanic soil and warmer temperatures. They are a significant region for the natural growth of a variety of grasses that can be used in the built industry.

2.2.3 Wetlands Zones

The wetlands are mostly in the lowlands, particularly in the Districts of Berea and Maseru which is where water reed (Phragmites australis) commonly known as lehlaka can be found. It is a highly durable building material, lasting up to 20 years or more.

3. Application of Straw and Grass

Historically, a typical grass-thatched hut was constructed on a circular foundation dug into the ground. Long, flexible poles were inserted into the foundation (Mokorosi, 2017), as shown in Figure 4 with the top bent inwards and tied together to create a hemispherical shape. Thinner poles or split poles were woven in and out of the larger poles, and grass was used for thatching. The grass would usually extend to the ground, forming a beehive-like structure for the hut (Casalis, 1861; Dreyer, 1993; Mokorosi, 2017). Mud was sometimes applied to the outside of the huts as well (Casalis, 1861, See Figure 4)

In the 1900s, there was a shift away from grass-thatched huts to more durable materials such as stone, earth, and timber. These materials were all locally sourced, and water and cow dung were used as binders. Traditional huts began to feature stone foundations and walls, with thatch being used primarily as a roofing material (Mokorosi, 2017). During the 20th century, the most common traditional house type in Lesotho was the rondavel, which could be either circular or rectangular in plan (Anderson & Stovre, 1997; Liechti & Hill, 2019, See Figure 5a and 5b).

According to a report by New Media (2020), various techniques and equipment are employed when building with thatch, and specific dimensions and angles need to be followed when roofing with thatch. The report states that a thatched roof should have a minimum pitch of 45 degrees and a minimum of 35 degrees over dormer windows. To achieve a smoother thatched roof, the Thetho tool, also known as deskspa (Language used by Basotho thatchers), is used. The smoother the finish, the better the water will run from it, preventing leakages and prolonging the roof’s lifespan.

As per Premier Guarantee (2022), wild thatch is first placed in position and then raked to give it a “poured onto the roof” appearance. For new work, the overall thickness of natural thatch is 400mm, while cereal straw has a much neater and trimmed look. During installation, the thatcher dresses and knocks the thatch into shape, and the overall thickness for new cereal straw work ranges from 300-450mm (Premier Guarantee, 2022).

Additionally, straw and reed can be used for insulation by placing the materials directly onto the rafters in order to provide support and insulation for the corrugated iron roofing. While this material is most abundant in wet lowland areas, it has become increasingly scarce in recent years due to the degradation of wetlands, particularly in Koro-koro and Qalabane (Ministry of Natural Resources, World Wetlands Day, 2004) (See Figure 6).

4. Advantages of Straw and Grass as Building Material

According to Stronbach & Walter, 2022, building with straw and grass significantly reduces both embodied and operational carbon compared to construction with  conventional  materials due to the absence of energy required during its harvesting process. Also, straw stores CO2 which remains locked up in the structure of straw buildings. It is also thermally efficient, renewable, biodegradable, and readily available in Lesotho, particularly cereal straw and Mohlomo and Qokoa grasses.

In comparison to all other roofing materials such as metal sheets, thatch has a higher insulation value as can be seen in the Material Specification Table in Annex XX[1] . As a result, buildings with grass and straw walls are more thermally efficient, reducing the amount of energy required for heating during winter and cooling in summer. This not only benefits the environment but also provides economic benefits by reducing the consumption of fossil fuels such as paraffin and charcoal used for heating in Lesotho’s long and bitterly cold winters. The density of  compressed straw in construction influences the air gaps between the stalks and between the bales themselves and therefore the thermal conductivity efficiency. Compressed straws are high-performing insulators and experience minimal decomposition over time (Marlow, 2021).

5. Disadvantages of Straw and Grass as Building Material

Stronbach and Walter (2015) reported that grass and straw  are vulnerable to fire. Lightning strikes and open-flame cooking fires are often the culprits. In the absence of building standards about thatch in Lesotho, we referenced South Africa’s thatched roof construction law and standards (SANS 10407). It states that insurance premiums for grass and straw buildings are much more expensive than other roofing materials such as clay tiles, due to their vulnerability to catching fire which can also affect neighbouring buildings.

Additionally, Marlow (2021) pointed out that the quality of straw and grass is dependent on good weather during germination, cultivation, and harvest, which is often reliant on hard-to-find casual labour and old manual equipment. Consequently, harvesting and processing costs are increasing, and the quality of the grass and straw is often poor, necessitating the use of expensive thatch sealants. As a result, many building owners are turning to alternative materials, leading to a decline in demand for thatch roofing.

The issue of durability is another concern for thatch roofing, despite that a well-maintained thatched roof can last up to 20 years, which is comparable to or longer than other competing materials. However, due to improper drying, a lack of access to superior grass species, and possible termite infestation, many thatched roofs may require replacement more frequently than the expected lifespan of 20 years, leading to a shift towards corrugated iron as a cheaper and faster to install alternative. Additionally, thatch is vulnerable to damage from hail, further exacerbating problems with thatched roofing (Marlow, 2021).

6. Primary Explorative Research Findings

6.1 Research Methodology

To collect primary data, a stratified sampling technique was used based on different qualifying criteria which were all aligned with the number of years of experience from 10 years or more. The selection criteria of the interviewees were based on their qualifications, skills, and knowledge because it was imperative to select participants with a first-hand understanding of thatch from a wide range of occupations. The participants were not paid to take part in the interviews. A set of questions, (see here research questions on thatch)[2]  was prepared with the aim of gathering information about some specific topics such as availability, accessibility, cost, durability, and knowledge around construction techniques with thatch.

The chapter is divided by topic and summarises  the information  collected from the interviews, presenting the key findings. A total of  11 interviews with thatch experts and professionals have been conducted from January to June 2023; the researchers conducted face-to-face interviews, which lasted around 45 minutes each, to gain insights into people’s experiences, opinions, and facts about thatch in Lesotho. The respondents represented the entire spectrum of the thatch industry in Lesotho ranging from government officials through skilled professionals and built industry experts. On average our respondents had 24.5 years of experience ranging from 7 years to 41 years.

6.1.1. Availability of Grass & Straw in Lesotho

Seven of the Respondents confirmed our desk research findings that the different grasses in Lesotho can be found in the three ecological zones: Highveld Grassland, Afromontane Grassland, and Afro-alpine Grassland. The Respondents  stated that the availability of grass and straw is highly dependent on the season. The Respondents further stated that grasses are available in abundance during the Spring harvesting season when the grass is dry, while cereal straw is available in Winter, particularly in June and July.  Although the majority of respondents said that the three kinds of grass (Qokoa, Tsaane & Mohlomo) are available in abundance.

 Three of the respondents  opposed that viewpoint and claimed that both grass and cereal thatch are deteriorating in quality and quantity. The respondents further mentioned the changing climate, combined with insufficient management of this resource and land use, has resulted in the need to import thatch from South Africa particularly to build and maintain some of the historical buildings and lodges. Also,  respondents  indicated that, in recent years  the government has shifted from using grass as a roofing material to using modern building materials when building public infrastructure like the new museum.

Respondents also stated that overgrazing and deforestation have led to a reduction in the production of natural grass for thatch.

6.1.2. Cost of Grass and Straw in Lesotho

Our goal was also to understand the short and long-term costs of using grass and straw. These covered the purchase of the raw materials, the cost of labour, the ongoing cost of maintenance as well as any reduction in heating costs given the postulated thermal efficiency of thatch. Six of the Respondents, who are experts in roofing & ministries, indicated that the use of thatch is expensive in the short term due to the costs of labour and cost of material since grass is only available at no cost for the residing local communities and not to external parties residing outside of the communities. Additionally, Respondents further stated that the majority of the suppliers stockpile the material in order to raise the prices while also reducing the size of bundles.

In contradiction to our desk research which found that Lesotho’s quality of grass and straw matched South African standards,  two Respondents outlined that poor  quality material and lack of skilled labour in Lesotho to build large structures has resulted in the Ministry of Tourism importing these resources from South Africa to  build  the Thaba Bosiu cultural village. The Respondents indicated that the cost of labour sourced in Lesotho is expensive, costing  M400.00 (EUR 20)  per square metre.  Compared to metal or clay roofing which incurs labour costs of M45.00 (Euro 2.25)  per square metre respectively.

However, five of the Respondents argued that there are short-term and long-term benefits of using this material in that there are short-term benefits as the material is essentially cheap, costing M10.00 (Euro 0.50) per bundle. The Respondents further stated that the material is free for the suppliers residing in areas where the grass is available  because grassland is held communally. The use of resources is regulated by chiefs and village councils who allocate pieces of land, called ‘litema’, to individual households to harvest  for free. Additionally, the Respondents expressed that  buying the material from individual households who are the primary suppliers of the material in Lesotho makes the buying price  cheap mainly because a lot of suppliers are not formally employed, they have resorted to selling thatch as a way of supporting their families therefore the price is negotiable. The Respondents further outlined that because wheat is already being cultivated in the country each household can grow it, making it free. Furthermore, the Respondents indicated  that there are long-term benefits that involve an 80% reduction in the cost of heating materials due to their thermal efficiency.

6.1.3. Quality & Durability of Grass and Straw in Lesotho

Eleven  of the Respondents explained that the different types of grass have different qualities and characteristics that affect the lifespan and maintenance of thatched roofs and insulation. The respondents stated that in the previous years, Mohlomo was considered to be the best quality among the different types of grass with an expected lifespan of about 20 years without requiring any maintenance. However, the eleven Respondents expressed that in recent years the quality of Mohlomo  has deteriorated and needs maintenance after approximately 3 to 5 years due to the poor quality of grass species and the harsh weather conditions. Respondents also articulated that cereal straw is also no exception as the amount of yield and quality have decreased meaning that regular maintenance of roofing is needed every 8 months or so. The Respondents asserted that the  quality of  Qokoa and Tsaane has also been negatively affected by changing climatic conditions and land degradation.

To address this, Respondents declared that modern materials like thatch sealer (a solution that has to be sprayed on both sides of the thatch to prevent moisture from entering into the structure) have been used to improve its longevity, but it comes at a high cost of M4,000 (EUR200) for 20 litres which is the amount that is needed for a typical standard size rondavel.

6.2 Knowledge and Techniques of Grass and Straw in Lesotho

All of the eleven Respondents indicated that there is a shortage of skilled thatchers and that the trade is dying out. Additionally, the Respondents further showed that due to the informal nature of these artisans, little information exists on the availability of skilled thatchers, and there is no database or Trade Association, or formal entity for thatchers.  Also, the Respondents made further indications that the new generation shows little interest in learning this technique. The Respondents further confirmed that the lack of or no skilled labour capable of roofing large structures results in skilled thatchers being sourced from South Africa. Therefore, a list of skilled Thatchers’ is needed to help formalise the sector and encourage young people to take up the thatching trade within the built environment by providing it as a trade in the vocational and technical schools.

7. Feasibility of Grass and Straw

Lesotho’s thatch market is highly dependent on the demand  for cultural and tourism-related buildings such as lodges and restaurants which contribute highly to the economy and to the preservation of  Basotho’s culture. However, skilled thatchers are scarce and overly expensive if you find one, making it a costly material in the short term that is not available throughout the year and production is highly susceptible to climatic change.

8. Distribution Patterns of Grass and Straw

Community members are the primary distributors of thatch; as mentioned above they are given rights by the Chief as the land is held communally in the country and regulated by them. It’s usually sold informally on demand when someone needs it, and not sold in any markets or hardware stores.

It is not a fragile material, hence it is easy to transport and does not require special packaging. When stored properly, thatch can last for a long time without going rotten.

Distribution patterns depend on policymakers and decision-makers as  areas where it’s available need to be mapped out, and regulations on who can have access to the land on which it grows need to be developed before it can be distributed to the public on a large scale.

9. Unmet needs of Grass and Straws in Lesotho

The main unmet need regarding the grass and reeds for thatch is the lack of documented information about the location of natural thatch resources (such as water reeds and wild grass for thatch), which makes it challenging to determine their availability in the country.

Furthermore, the traditional knowledge and techniques used in thatch roofing are often not recorded and are only known by a small group of elderly community members. Unfortunately, some of these skilled thatchers pass away without transferring their knowledge to the younger generation, making these techniques even more scarce.

10. Conclusion

The fact that the grass for thatch is not readily available to the mass market, and thatchers are not recognized as a formal profession, thatch remains a cottage artisanal industry in Lesotho. The decrease in the use of thatch for roofing and insulation has led to an increase in the use of modern building materials that are not sustainable: economically, environmentally, and socially. This is because of the notion that thatch is not available in the country due to no mapped-out areas showing its availability and accessibility.

Additionally, the lack of a documented list of  skilled personnel with knowledge of the material has contributed to the shift away from using this material. However, thatch roofing and straw insulation as well as compressed straw bales offer plausible alternative solutions in the development of sustainable housing in Lesotho to meet the outstanding housing needs. Hence, there is a need to revive this material to promote its thermal efficiency, which results in an 80% reduction of costs in heating and cooling and also lower carbon emissions from the extraction process and the use of the material.

11. Recommendations

It is important for the government and other relevant stakeholders to conduct a comprehensive survey to document the knowledge and techniques applied when roofing with thatch, map out the areas of availability and accessibility of natural grass for thatch, and provide training and formalisation of the skillset of thatch. This will not only preserve this valuable cultural heritage but also create job opportunities, promote the use of sustainable and locally available materials, and contribute to Lesotho’s efforts to reduce carbon emissions by lowering the use of alternative heating fuels due to the thermal efficiency of the material. Also, little or no energy is used when harvesting and building using the material. Furthermore, there is a need for advocacy and awareness-raising campaigns to promote the use of thatch as a roofing and insulation material in urban, rural, and peri-urban areas and its benefits to the environment and the economy.

In addition to mapping out areas where thatch is available, it would also be important to create a database of skilled thatchers to preserve and pass on their knowledge to future generations. This could be done through apprenticeships, training programs that can last up to 8 weeks, and certification courses, which would provide a path to formalise the skillset and make it a viable career option for younger people. By promoting the use of thatch as a sustainable and cost-effective roofing material in the long run, and providing the necessary support and resources for its cultivation and preservation, the country can create a thriving industry that benefits both the economy and the environment.

Different approaches need to be adhered to in order to lower the cost of using the material through preservation and exchange of skills which will help lower the need to hire external labour outside of the country and to import thatch while also leading to the abundance of the material through improved conservation majors.

12. Appendix

Appendix A: Table of Respondents

Respondent NoName of Company/ ProfessionNumber of years of ExperienceProfession
Respondent 1Entrepreneur30 yearsSkilled thatcher
Respondent 2Ministry of Tourism22 yearsDirector Tourism
    
Respondent 3Ministry of Environment13 yearsEnvironmental Spet
Respondent 4Entrepreneur22 yearsThatch supplier
Respondent 5Entrepreneur7 yearsArchitectural designer
Respondent 6Building and Design services35 yearsHead of Architecture
Respondent 7Entrepreneur30 yearsSkilled thatcher
Respondent 8Entrepreneur40 yearsSkilled thatcher
Respondent 9Entrepreneur12 yearsSkilled thatcher
Respondent 10Entrepreneur17 yearsSkilled thatcher
Respondent 11Thatch supplier41 yearsThatch Supplier


 

13. BIBLIOGRAPHY

 Ashour, T. &  Wu, W. 2011. Using Barley Straws as Building Material. https://www.researchgate.net/publication/287478964_Using_barley_straw_as_building_material

Casalis, E., A., 1861. The Basutos. J. Nisbet. Retrieved from: https://doi.org/10.5479/sil.262374.39088000167106

 Chen, J. Elbashiry, E. &  Yu, T. 2017. Research progress of wheat straw and rice straw cement-based building materials in China https://www.researchgate.net/publication/318480337_Research_progress_of_wheat_straw_and_rice_straw_cement-based_building_materials_in_China

Dreyer, J. 1993. The Basotho hut: From Late Iron Age to the present. South African Journal of Ethnology, 16(3) https://journals.co.za/doi/pdf/10.10520/AJA02580144_730

 Lesotho Vulnerability Assessment Committee Crop Estimates, 2022. https://drmims.sadc.int/en/organizations/lesotho-vulnerability-assessment-committee-lvac

 Marlow, C. 2021. Traditional Straw Thatching in Time of  Shortage. https://historicengland.org.uk/content/docs/advice/traditional-straw-thatching-times-of-shortage-context167-mar21/

Ministry of Natural Resource, 2004. World Wetlands Day. https://www.ramsar.org/news/world-wetlands-day-2004-lesotho

 Mokorosi, S. A. 2017. Basotho Traditions: Indigenous Architecture and Creativity. Morija Printing Works. https://searchworks.stanford.edu/view/13170501

Oppong, R. 2008. A Trio Sub- Saharan African Compendium: “Losing the sense of thatch” http://dev.ecoguineafoundation.com/uploads/5/4/1/5/5415260/thatched_roofs.pdf

Premium Guarantee, 2022. Thatched Roofing: Interaction with Modern Construction Techniques. https://www.premierguarantee.com/our-services/structural-warranties/

Stronbach, B. & Walters, W. 2015. An overview of grass species used for thatching in the Zambezi, Kavango East, and Kavango West Regions, Namibia. researchgate.net/publication/286447092_An_overview_of_grass_species_used_for_thatching_in_the_Zambezi_Kavango_East_and_Kavango_West_Regions_Namibia

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Building with Sheep Wool

Desk Research & Primary Findings

Issued on: 30th August 2023

1. Background

1.1. Overview of Wool

Baumgartner (2021) explains that Lesotho has a rich history and tradition in its wool industry, with high-quality wool produced by the nation’s sheep since the 1800s. The industry has a well-established network that connects local producers with brokers in South Africa who purchase the raw product for processing and sale. According to Forrester (2021), wool is the backbone of Lesotho’s rural economy, with producers ranging from smallholder farmers to breeders of large flocks with superior genes. Currently, there are over 1.2 million sheep with a significant potential for industry development. On average, one sheep produces nearly three kilograms of wool annually. Primarily, Lesotho exports raw wool to warehouses in Port Elizabeth, South Africa for grading and processing for readiness for the international market. 80% of the wool is the exported to China, while the remaining 20% is exported to European countries labeled as South African wool, along with South African wool (The Reporter Newspaper, September 22, 2022).

The observation was that wool is currently not utilised for insulation in buildings in Lesotho. According to the International Wool and Textile Organisation (2020), wool has diverse uses, which depend on the coarseness of the fiber and its other characteristics, including fiber length and crimp. Besides widespread use in the textile industry, there is an opportunity to use the insulation properties of wool in buildings which necessitated this research into the viability of the use of wool, in particular the lower grades of wool that are less attractive for the textile industry, and can be used as an insulation material in construction industry instead (The International Wool and Textile Organisation, 2020).

1.2. Wool as a building material

According to Renz (2022), wool has become increasingly significant in the construction industry due to its many natural properties. According to SANS 10400, XA building towards more sustainable and less resource-intensive building practices will reduce energy consumption. The goal is for all new residential and commercial buildings to contribute an estimated 3,500 MW of electricity savings. As nature has often inspired technological innovation and intelligent design, sheep wool is now at the forefront of these advancements (Renz, 2022). Renz (2022) further adds that the rising popularity of wool as an insulation material in construction is due to increased awareness regarding the health benefits and performance of natural fiber insulation. The thermal insulation is typically measured by its thermal resistance often referred to as the  R-value which determines the type of insulation that is required. According to SANS 10400 XA, Lesotho’s climate  requires a minimum R-value of 3.7 for insulation purposes. This would support the cause for effective insulators such as sheep wool. The table in Annex 1 Material Specification relays a comparison of wool’s thermal performance against other conventional materials.

This research explores the possibility of using wool as a brick and an insulating material in Lesotho, looking at its availability, durability, cost, and thermal efficiency

1.3. Wool bricks

Fecyt (2010) reports that researchers from Spain and Scotland conducted a study on the use of sheep wool in various composite materials, such as adobe bricks and cement mortar, and made several significant findings. The research revealed that wool fibers can enhance the strength of compressed earth bricks, decrease the occurrence of fissures and deformities due to contraction, reduce the bricks’ drying time, and increase their resistance to flexion (refer to Figure 1). Remarkably, these wool bricks can be produced without firing, resulting in energy conservation. Also,  bricks are considered a sustainable and healthy alternative to conventional building materials, which is why wool bricks are gaining more attention in research (Fecyt, 2010).

2. The advantages of Wool

Wool is a sustainable and renewable material that is also natural. It does not cause any harm to human health and is non-irritating to the eyes, skin, or lungs. Unlike rock wool or fiberglass wool, which is hazardous to install, wool fibers are much safer to handle. Wool is breathable and can absorb and release moisture without compromising its thermal performance, making it ideal for insulation (Denes, Manea & Florea, 2019). Additionally, wool is fire-resistant and can extinguish itself in the event of a fire. It can also absorb volatile organic compounds (VOCs) from the environment, making it an excellent choice for indoor air quality. Wool is static-resistant and does not attract lint and dust, making it resistant to dirt. It is an effective insulation material for both thermal and acoustic purposes, as it absorbs noise and reduces noise levels. When wool fibers absorb moisture, they generate heat, which helps to prevent condensation in structures and minimize the risk of mold and mildew formation (Denes, Manea, & Florea, 2019).

A sustainable and renewable material, sheep’s wool insulation has no adverse impact on the environment. It boasts an R-value of approximately 3.5 to 3.8 per inch of material thickness, which is 0.3 to 0.6 points higher than fiberglass, cellulose, or mineral wool. A higher R-value indicates that a material is more effective at resisting the flow of heat (Denes, Manea & Florea, 2019).

Sheep’s wool insulation is a versatile and eco-friendly option available in various sizes and thicknesses, including slabs, batts, and rolls. It is a completely natural product that requires 15% less energy to manufacture compared to glass wool insulation, making it more sustainable. Thanks to its high nitrogen content, sheep’s wool is one of the few fibers that are naturally flame-resistant and self-extinguishing. Instead of igniting, it will simply smolder and singe away, reducing the risk of fire (Denes, Manea & Florea, 2019).

3. Disadvantages of Wool

The installation of sheep’s wool insulation can be costly. For example, in Europe, it can cost approximately €62 (equivalent to M1240) per square meter to achieve the recommended thickness of 300mm. This is considerably more expensive than mineral insulation, which costs around €17 (M340) per square meter (Tiza, Singhs, Kumar & Shetta, 2021). Another disadvantage of wool insulation is related to its cleaning and preparation process. To make it effective and suitable for use, wool must undergo treatment and cleaning that involves the use of harsh chemicals for disinfection and to address possible scab mite infestations (Tiza, Singhs, Kumar & Shetta, 2021).

4. Primary Explorative Research Findings

To collect primary data, snowballing was a suitable sampling technique for this study, because it was imperative to select participants with first-hand knowledge about wool from a wide range of participants. This chapter presents the findings from the face-to-face interviews that lasted between 45 minutes to an hour each held in January and February 2023, undertaken with professionals who work with wool. A set of questions, (see Annex 4 questionnaires wool) had been prepared with the aim of gathering information about some specific topics such as availability, accessibility, and cost of using wool as an insulating material. With regards to wool, we only had one interview which was with  the Wool and Mohair Association. This was because the Association is the central selling point of wool where it’s all collected from all 10 districts and they have information about the different grades of the material in the country and the amount collected yearly and sold.

4.1. Availability of Wool

The purpose of this exercise was to know where wool is available in the country and in what quantity and  to know the season of shearing and the quantity of wool sheared. Ten  Respondents (Wool and Mohair Association) revealed that the shearers are divided into government shearing sheds, estimated at around 155 sheds, and privately owned shearing sheds around 80+ in different districts. The respondents further indicated that in the Maseru district only there are 21 privately owned shearing companies which indicates an abundance of wool in the country. The Respondents further claimed that the amount of wool sheared in the country increases every year due to the rising reproduction of sheep, with farms in the Districts of Mokhotlong and Quthing producing the highest amount of high-quality wool. The Respondents stated that in 2020/21, the amount of wool collected was 1,000,283kgs and in 2021/22 the amount quadrupled to 4,379,590kgs.

Seven of the Respondents claimed that low-grade wool is not exported because there is no market for it abroad. As a result, it is sometimes disposed of as waste. Others said that low-grade wool is sold locally through the informal market by the roadside, mostly during the shearing months of August to December.

Three of the Respondents (supervisors of shearing companies  stated that as much as wool is available in abundance all the wool is sold and exported to already existing clients. They added that low-grade wool (for instance, black wool) is still sold to international markets such as China, where the value fluctuates around M70/kg (EUR 3.50) depending on the market.

4.2. Cost of Wool

Ten Respondents confirmed that there are 41 different grades of wool. Each has its own selling price, ranging from approximately M70/kg (EUR 3.50) for low-grade wool to M510/kg (EUR 25.50) for high-grade wool. The Respondents further claimed that the most expensive wool is lamb’s wool due to its softness. Other factors that influence the price include length, tenderness, and microns (measurement of the diameter of wool fiber).

5. Feasibility and Viability

Wool is Lesotho’s leading agricultural commodity export. And yet, the market has not introduced the utilization of wool as an insulation material, because most of the wool produced in Lesotho is auctioned and brokered to the South African textile industry. However, there is a quantity of low-quality wool that remains unexported. The exact amount of this unexported wool is unknown. Thus the question of the possibility of wool being a feasible and viable material for the local construction industry remains unanswered.

6. Distribution patterns

Wool already follows a certain chain of supply in the country from local to international market making it difficult to open up different distribution patterns from the one that’s already existing. Also due to its scarcity, it is not deemed profitable to join a different supply chain.

7. Unmet needs

Lesotho’s wool is exported because there are no manufacturing industries to process wool in the country. The exportation of Lesotho wool into South Africa means that the potential taxation and other economic benefits such as processing wool and mohair in Lesotho are lost to South Africa. Besides that, research into sheep wool as a building material in Lesotho has not been explored, meaning that the market of wool in construction does not have facts supporting its establishment.

8. Conclusion

When assessing wool as a potential resource in the built industry in Lesotho, it is important to consider the following factors: distribution patterns, development and marketing of wool in the built industry, wool harvesting innovations (from shearing of wool and standard separation of wool) cost and the availability of the material. Moreover, it seems as though there is a high potential for increased wool production in Lesotho with endless job opportunities and circulation of money within the country. The serendipity of pursuing this is expansion and growth in the built industry which will have long-term benefits to the environment.

Using wool in construction is not only good for the environment, but has the potential to bring a paradigm shift in Lesotho’s architectural landscape. Wool presents a green alternative to use as an insulation material which will result in the reduction of operational costs in the long run. We also need to emphasize the health benefits of working with and living in wool-insulated houses over alternatives like rock wool and fiberglass. However, the unavailability and high cost of buying both high and low-grade wool and an already existing market with different international countries, hinder the use of wool as an insulation material in the country.

9. Recommendations

We recommend that deeper insight into the wool data be established to determine the amount of low-grade wool that is available because it is currently unknown and to highlight the economic benefits of using it in the built industry. Since there is a well-established competing textile industry, we can focus on poorer grades which are known to be ignored by the export industry. To get wool and have ownership rights to the wool produced in Lesotho; establishing a wool testing laboratory in Lesotho will serve as an important step towards providing sampling and testing services in Lesotho. This will therefore encourage Lesotho wool and mohair farmers to sell locally. The initiative will ensure that a greater portion of wool and mohair products are produced and processed in Lesotho and a possibility of wool residue collection obtained during processing, before being exported. This will also encourage an increase in sheep husbandry that is relatively widespread in Lesotho, resulting in a wool increase. This will also serve as an entry point to the possibility of using wool for construction purposes. While the health and environmental benefits of using wool as a building material have been stated, it is important to place it in the context of conventional alternatives. Our regulatory bodies do not currently enforce the use, or banning, of alternatives such as fiberglass. This paper and follow-up discussion will create a platform from which the public can be informed of better materials for their homes and offices. This renewable resource is part of a larger food security value chain and it is recommended that the agribusiness sector is approached for collaborative exploration into these mutual benefits.

10. Appendices

Appendix A: Table of Respondents

RespondentsName of the organizationNo of years of ExperienceProfession
Respondent 1Wool and Mohair Association15 yearsMarketing Officer
Responden2Builders City14 yearsSalesman
Respondent 3Ez build18 yearsSalesman
Respondent 4Cash Build7 yearsSalesman
Respondent 5Archi Plan12 yearsArchitect
Respondent 6Qeme Shearing Organization25 yearsWool shearer
Respondent 7Ha Abia Shearing organization30 yearsWool Shearer
Respondent 8Ministry of Local Government17 yearsDirector of Housing
Respondent 9Ha Mantsebo Shearing organization21 yearsWool shearer
Respondent 10Entrepreneur16 yearsIndividual Wool seller

 

11. Bibliography

Baumgartner, P. (2022). Finding a way forward: Sector reforms in Lesotho’s wool and mohair industry. https://www.ifad.org/en/web/latest/-/finding-a-way-forward-sector-reforms-in-lesotho-s-wool-and-mohair-industry. Retrieved 09/12/2022

Denes, O., Florea, I., & Manea D. L. (2019). Utilization of sheep wool as a building material. https://www.researchgate.net/publication/332595258_Utilization_of_Sheep_Wool_as_a_Building_Material. (Accessed: 12/12/2022)

FECYT – Spanish Foundation for Science and Technology (2010). Bricks made with wool. https://www.k-online.com/en/Media_News/News/Bricks_made_with_wool

Forrester, N. 2021. The Magic of Wool in the built environment. https://archipro.co.nz/articles/building/the-magic-of-wool-in-the-built-environment-archipro-nz. (Accessed: 09/12/2022)

Global Market Estimates. 2022. Global Building Wool Insulation Market. https://www.globalmarketestimates.com/market-report/global-building-wool-insulation-market-2965. (Accessed:10/12/2022)

Home Logic: Solutions for Homes (2021). Sheep wool insulation Pros and Cons https://www.homelogic.co.uk/sheep-wool-insulation-pros-and-cons. (Accessed: 12/12/2022)

Innovative Applications in Architecture (2012). Material Strategies: Wool in Architecture. https://arch5541.wordpress.com/2012/11/25/wool-in-architecture/. (Accessed: 08/12/2022)

Korjenic A, Klarić, S, Hadžić A, Korjenic S. (2015). Energies: Sheep Wool as a Construction Material for Energy Efficiency Improvement. http://www.mdpi.com/journal/energies . (Accessed: 12/12/2022)

Renz, A. (2022). Sheep Wool Insulation: A Low Carbon Solution. https://buildersinsulation.co.uk/sheep-wool-insulation-a-low-carbon-solution/. (Accessed: 12/12/2022)

International Fund for Agricultural Development (2019). Spinning yarns – Investing in wool and mohair in Lesotho. https://www.ifad.org/en/web/latest/-/story/spinning-yarns-investing-in-wool-and-mohair-in-lesotho (Accessed: 10/12/2022)

International Wool and Textile Organisation (2022).Wool Notes. https://iwto.org/wp-content/uploads/2020/04/IWTO_Wool-Notes-Web-min.pdf (Accessed: 10/12/2022)

Legge,A.( 2018). A Smart, Natural Wool Insulation for Healthy Buildings. https://havelockwool.com/2018/04/a-smart-natural-wool-insulation-for-healthy-buildings/  (Accessed: 12/12/2022)

Manchee, L. (2020). Keela Permaculture Farm: Cleaning and Using Sheep Wool for Insulation. https://www.keelayogafarm.com/2020/07/29/cleaning-and-using-sheep-wool-for-insulation/ (Accessed: 12/12/2022)

Remi Network (2017). Sheep’s wool insulation is seen as a sustainable option. https://www.reminetwork.com/articles/sheeps-wool-renewable-sustainable-building-insulation/ (Accessed: 08/12/2022)

Romania Insider (2019). Agriculture minister says RO will see first wool-insulated houses this year. https://www.romania-insider.com/agriculture-minister-says-ro-will-see-first-wool-insulated-houses-this-year. (Accessed: 12/12/2022)

ScienceDaily (2010). Bricks Made with Wool. https://www.sciencedaily.com/releases/2010/10/101005085503.htm. (Accessed: 09/12/2022)

The Reporter Newspaper (2022). Lesotho wool cleared for sale to China. https://www.thereporter.co.ls/2022/09/22/lesotho-wool-cleared-for-sale-to-china .(Accessed: 10/12/2022)

Tiza, T. S., Singhs, S., Kumar, L. & Shetta, M. Assessing the Potential of Bamboo and Sheep Wool Fibres as Sustainable Construction Materials: A review https://www.sciencedirect.com/science/article/abs/pii/S221478532103916X

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Building with Packaging Waste

Desk Research & Primary Findings

Issued on: 30th August 2023

1. Background

1.1.Overview of Waste as a Building Material

The world’s industrial development and economic growth have resulted in a significant increase in solid waste, including plastic, cans, glass bottles, and paper, which pollute the environment by ending up in oceans and landfills (Vicelj, Sandanayake & Yap, 2022). Lesotho is no exception as it is facing a massive waste disposal management crisis that it cannot manage, with only 20% of waste being collected, and the remaining 80% being dumped illegally, plus an increasing amount of waste generated by growing commercial and household activities.

The Lesotho government’s strategy, as outlined in the National Environmental Policy 1998 and the Environmental Act 2008, is to design environmentally friendly waste disposal and treatment systems that encourage recycling. The building sector is constantly evolving in its use of materials with regard to sustainability. There is a need to use cost-effective, environmentally friendly materials and technologies that lessen the impact of construction in terms of its use of non-renewable resources. Hence, Lesotho has an opportunity to use waste materials such as glass bottles, cans, and plastics as construction materials, to address the need to manage waste (UNDP, 2021).

2. Categories of Waste Material for the Built Industry

Explored in this paper are four common waste materials; glass bottles, metal cans, plastic waste, and paper. All four were analysed according to the following areas:

  1. Potential and/or evidence of use as a building material
  2. Locally available
  3. The potential of a sustained “affordable” supply of the material
  4. Environmental impact on the re-purposing of the waste into building materials

2.1 Glass Bottles Used as a Building Material

To address Lesotho’s housing needs and waste management issues compounded by rural-urban migration and using glass as a building material can be a viable solution (UNDP, 2021). This technique has been used for centuries, with the ancient Romans using empty glass vessels to reduce concrete usage and lighten the load of upper levels of structures (Fatima, 2017). William F. Peck constructed the first glass bottle house in 1902 using 10,000 bottles  (See Figures 1.1 & 1.2). Glass houses in South Africa by Kevin Kimwelle assisted the government in providing secure housing with construction that comprised 80% recycled materials.

2.1.1 Techniques Used When Building with Glass

According to Fatima (2017), glass bottles are to be collected and sorted. About 14,000 bottles of uniform size are needed to make a two-bedroom bottle home. The walls can be made in many different ways, but are typically constructed by making a foundation filled with reinforcing bars (rebar); preferably metal that can be set to add stability to the structure. The walls are usually one or two bottles thick (Fatima, 2017). These walls function as a thermal mass when the glass bottles are filled with dark materials such as sand so as to absorb the solar radiation during the day and radiate it into the interior during the night. This feature can be pleasant in cooler climates but can turn a room into an oven in hot climates.

2.1.2. Advantages of Glass Bottles Buildings

The benefits of building with glass are that it is low cost, decreases the use of binding material and reduces landfill mass by making the bottle a renewable material (Fatima, 2017). Furthermore, glass bottles offer various aesthetics due to their opacity and color selection which creates an alternative to plastering. Fatima (2017), further states that the use of glass bottles could help increase the accessibility to houses due to their near-modular nature in comparison to conventional building methods.

Housing for economically disadvantaged households could be made more affordable by using glass buildings, which are estimated to cost only a third of the cost of a house made of concrete and bricks (Rukami, 2021). Glass bottle walls offer excellent thermal insulation because of the hollow bottles. A single layer of bottle walls can provide the same lagging as a three-layer brick wall. The walls also allow natural light to pass through when not filled with dark materials, providing natural lighting to the room if necessary (Rukami, 2021). It is also a waterproof and impervious material, making it a suitable material for building homes. Sharma (2017) suggests using glass bottles to build small houses as a means of reducing the amount of waste going to landfill.

2.1.3. Disadvantages of Glass Bottles

Without tempering or structural support, glass has poor resistance to impact, and is therefore unable to withstand an immediate load, which may result in breakage upon pressure or impact. Furthermore, it requires frequent cleaning, and in high-rise buildings, maintaining and cleaning the exterior can be difficult. The extensive use of glass may give rise to both real and perceived security concerns (Khanlari, Tuncer, Afshari & Socen, 2023).

As mentioned above, a glass wall is also an excellent conductor of heat with the potential of creating hotspots through a lens effect. In contrast, cold nights can also result in considerable heat loss because of the nature of glass.

2.2. Metal Cans Used as a Building Material

According to the UNDP (2021), metal cans make up 15% of waste in urban areas in Lesotho. As reported by Amosu in 2002, Michael Hönes, a German national who relocated to Lesotho, is credited with introducing the technique of utilizing cans in construction, and he is believed to have built the first can building in the country. (See Figure 2.1 and Figure 2.2)

2.2.1. Application of Metal Cans

A popular way of utilizing cans in construction is by using the earthship wall technique, where the cans are horizontally stacked in a concrete matrix. The cans are laid side by side in alternating rows like bricks, with the concrete being thick enough to hold the cans in place. This method involves repeating the pattern of can-concrete-can until the wall is finished. To finish off the wall, it is typically covered with a layer of cement or adobe mixture, which varies depending on the location of the wall, such as a bathroom or bedroom (Khanlari, Tuncer, Afshari, & Socen, 2023). Alternatives to these include flattening the cans to layer them.

2.2.2. Advantages of Metal Cans

The process of creating blueprints and assembling the structure is relatively quick, which contributes to its affordability (Khanlari, Tuncer, Afshari & Socen, 2023). Additionally, metal cans provide good insulation, which can increase energy efficiency and lead to lower heating and cooling costs. Metal cans are highly durable building materials that can withstand severe weather conditions, including high winds, heavy snow, lightning, and hail. Moreover, metal can structures are an eco-friendly option compared to other building materials, as they are fully recyclable and require less energy to produce. Constructing tin can walls does not require advanced construction skills (Parker & Akbari, 2013).

2.2.3. Disadvantages of Metal Cans

According to Khanlari, Tuncer, Afshari & Socen (2023), the metal can wall technique is not load-bearing. Without support, metal cans can also buckle under pressure and collapse if they are not filled with earth or sand. In addition to this, most cans are prone to weather and atmospheric conditions[1] [2]  which could lead to corrosion if otherwise left unshielded. Another consideration is that of soundproofing in which case metal cans perform rather poorly against rain, hail, and even windstorms.

2.3. Plastic as a Building Material

Solid plastic waste has properties that make it a viable alternative building material. Plastic waste in Lesotho constitutes 69% of the solid waste, and due to high economic activity, it is available and accessible in many urban areas (Kumar, Biswas & Debarashi, 2020). This type of waste increases rapidly and is projected to continue to do so until there are controls in place for their use. There are two forms of plastic that are explored in some detail; plastic bricks which are repurposed recycled plastic material formed into standard-sized bricks and plastic bottles are used whole or in part for their structure and ability to hold other earth and other materials.

2.3.1. Plastic Bricks as a Building Material

These are already produced in Lesotho using a specialized manufacturing process to make standard-sized bricks. In order to make the bricks, plastic waste is first collected and separated by type. It is then treated, cleaned, and dried to remove any debris and moisture. The plastic bags and bottles are then melted at a temperature between 120-150 degrees Celsius, in a closed vessel to prevent the release of toxic gasses (Kumar, Biswas & Debarashi, 2020). Once the plastic is melted, river sand is added to the mixture and thoroughly mixed. According to Kumar (2020), the mixture is then poured into molds and left to cure for 2 days before being removed. (See Figure 3.1 & 3.2 ).

2.3.1.1. Advantages of Plastic Bricks

Utilizing plastic waste to produce bricks offers benefits such as reducing the amount of plastic going to landfills or ending up in Lesotho’s rivers and lakes and cutting down the need for resources used in other building materials like clay and cement. The built industry’s carbon footprint is thus reduced, with the potential to drive the growth of waste plastic bricks in the market (Kumar, Biswas & Debarashi, 2020). The demand for plastic bricks has increased exponentially due to rapid urbanization in recent years, making waste plastic in brick production a viable new business and employment opportunity. By replacing clay or cement with waste plastic, the strength and durability of bricks are not severely compromised (Kumar, Biswas & Debarashi, 2020).

The production cost of plastic bricks can be reduced by reusing waste polyethylene, which is more cost-effective and eco-friendly than using costly brick earth. Digging brick earth can have environmental consequences, and utilizing plastic waste instead can help address this issue (Kumar, Biswas & Debarashi, 2020). Plastic bricks have a smooth finish, low water absorption value, and are resistant to problems such as efflorescence, making them a desirable alternative to traditional bricks (Kumar, Biswas & Debarashi, 2020).

2.3.1.2. Disadvantages of Plastic Bricks

As per Kumar (2020), plastic bricks may be used in partitioning and exterior use only. Their average compressive strength when using the process above is 5MPa which means they cannot be used as load-bearing bricks. Secondly, the manufacturing process for these bricks yields toxic gases which contribute to air pollution. It is a process that requires high temperatures which also have environmental implications. Lastly, because of the mechanical nature of this process, there is specialized equipment that requires the importation of materials to Lesotho and skills to execute properly.

2.3.2. Building with Plastic Bottles 

According to Froese (2017), it is possible to utilize plastic bottles as a substitute for bricks by filling them with either soil or sand, which enables them to function as building blocks for walls or pillars. Varying sizes and orientations of PET bottle walls can be constructed, and when filled with sand, these walls can bear up to 4.3 N/mm². While the plaster is responsible for two-thirds of the load, the bottles bear one-third. The space between the bottles is filled with plaster made of either clay or a cement mixture. Since only locally sourced materials are used, these houses are inexpensive and can be afforded even by impoverished families. Moreover, the construction process is relatively fast, and the first bottle house in the country was built in Mokhotlong (refer to Figures 4.1. and 4.2).

2.3.2.1. Advantages of Plastic Bottles as a Building Material

In Lamba’s (2021) research, it is noted that utilizing plastic bottles as building materials provides various advantages such as durability, lightweight, water resistance, high elasticity, strength, corrosion resistance, and affordability. Compared to brick walls, plastic bottle walls filled with sand require less equipment and material costs, and also require less labor (Lamba, Kaur, Raj & Sorou, 2021). Reusing plastic bottles in construction projects has been shown to be effective in saving energy and reducing CO2 emissions by decreasing the percentage of cement used in manufacturing concrete blocks, according to Mojtaba et al (2012). The use of plastic bottle buildings has been recognized as a green project in the architecture and construction industry (Mojtaba et al, 2012) by elongating the life cycle of the material.

Furthermore, bottle houses are designed to be bioclimatic, which means that they are warm inside during cold weather and cool inside during warm weather (Mojtaba et al, 2012). The separation of various cost components indicates that using local labor to make bottle panels can result in a 75% cost reduction compared to building walls with bricks and concrete blocks (Lamba, Kaur, Raj & Sorou 2021).

The attribute of flexibility is known to enhance a building’s ability to withstand unexpected loads. Plastic bottles, being non-fragile, can exhibit flexibility and withstand sudden loads without failure, thereby improving the building’s load-bearing capacity. Moreover, plastic bottle walls have a water absorption rate of zero percent (Lamba, Kaur, Raj & Sorou, 2021).

2.3.2.2. Disadvantages of Plastic Buildings

There are concerns regarding the durability of recycled plastic bottles due to photodegradation caused by exposure to UV light. This degradation process can lead to reduced strength and increased brittleness over time, as well as the release of harmful toxins and microplastics that could potentially affect the health of occupants or contaminate groundwater (Sharma & Chandel 2017). Some argue that using plastic waste to create building materials may exacerbate the issue of plastic waste. It is important to note that plastic is a combustible material and can release toxic gasses in case of fire, posing a risk to occupants and the environment (Sharma & Chandel. 2017)

Unplastered or unrendered plastic bottle houses may have an unconventional appearance that is sometimes associated with poverty, and building and planning regulations may not permit them in certain jurisdictions, as pointed out by Sharma & Chandel, 2017.

2.4. Cellulose Paper Fiber

Energy efficiency in buildings is an important factor for the extreme temperate climate in Lesotho. The building and construction sector accounts for 30% – 40% of worldwide energy consumption, with a large part belonging to the need to heat and cool buildings. There are traditional insulation materials such as glass fiber, stone wool, expanded polystyrene, and polyurethane foam (Hurtado, Antoine & Virginie, 2015). While they are efficient in maintaining thermal comfort to the interior of a building, they are made with non-renewable resources and have a high embodied energy. Consequently, this has resulted in  an increasing interest in alternative insulating materials that come from renewable or recycled fiber such as cellulose (Hurtado, Antoine & Virginie, 2015).

Cellulose is an eco-friendly thermal insulating material that has been around for centuries and has been used to insulate unfinished attic floors and existing closed walls. More than 70% of modern cellulose insulation is made from recycled newsprint, cardboard, and other paper types (Hurtado, Antoine & Virginie, 2015). However, in Lesotho cellulose insulation has not been widely used in comparison to the more traditional insulation materials.

2.4.1. Advantages of Cellulose Paper Fiber

Cellulose fiber has a low environmental impact, low embodied energy, and has similar insulation properties to synthetic materials. Greenhouse gas emissions and embodied energy of the buildings are reduced by up to 15% by replacing the rock wool insulation material with cellulose fiber (Hurtado, Antoine & Virginie, 2015).

The use of lightweight cellulosic paper as reinforcement in low-cost building materials is an interesting strategy for managing these by-products. Their functional properties, environmental and socio-economic benefits, and overall availability propose an appealing alternative. The indoor air humidity and comfort are affected appreciably by the transport of moisture between hygroscopic insulation and the indoor air. The indoor moisture buffering effect can be enhanced by employing high-density cellulose fiber insulation on the inner side of the buildings (Hurtado, Antoine & Virginie, 2015).

2.4.2. Disadvantage of Cellulose Paper Fiber 

Cellulose insulation is known to absorb moisture easily, which can be a severe problem if a pipe bursts or if there is a bad leak in the plumbing. While other forms of insulation hold the excess moisture on the surface, cellulose absorbs it entirely. In fact, cellulose can absorb as much as 130% moisture by weight.

Furthermore, the material dries very slowly once the water is absorbed, leading to settling, deterioration, and mold growth. Too much water absorption can even destroy the chemical fire treatment for which cellulose is so well known (Hospodarova, Stevulova, and Sicakova, 2015)

It is prone to sagging and settling, a problem further exacerbated by the fact that it is several times heavier than comparable insulating materials, like fiberglass. The greater weight of cellulose naturally means that it is affected by gravity more than other materials, reducing the R-value of the insulation as the material sags and settles over the years (Hospodarova,  Stevulova, and  Sicakova, 2015)

3. Primary Explorative Research  Findings on Packaging Waste

3.1. Research Methodology

To collect primary data, stratified and snowball sampling were convenient techniques for this study. It was imperative to undertake interviews with professionals and experts with over 10 years of experience, knowledge, and skills working with packaging waste, and the built industry in particular. This chapter presents a total of 15 interviews conducted from January to June 2023, the researchers conducted face-to-face interviews that lasted between 45 minutes to 1 hour each. Qualitative surveys (Check here for the Research Questions)[1]  were used to gain in-depth information, experiences, and narratives about some specific topics such as availability, accessibility, cost, durability, and environmental impact of extraction.

3.1.1. Availability of Packaging Waste

The purpose of the interview was to understand the availability of collected and unaccounted waste (cans, paper, plastic, and glass) in urban areas. Also to know the availability of plastic bricks produced in the country and the chain of supply of plastic needed to make the plastic bricks. To know the number of companies already building using plastic bricks.  Fifteen of the Respondents showed that the proximity to urban areas does not guarantee the availability of waste (plastic, cans, paper & glass). Using Maseru as a case, the respondents stated that this is because only 20% of household waste is picked up by companies that get paid to collect it. The majority of the rest is collected by the Maseru City Council to take it to a landfill. This waste is accessible to select companies given authority by the officials and this limits who and what can be done with it.

Additionally, the respondents stated that of the waste collected, 69% of the  plastic is sold to  KHY Plastic recycling company. The Respondents indicated that waste (plastic, paper & cans) is seen as a means of income which in turn reduces the supply of waste to be used for building. Furthermore, the respondents stipulated that of the 80% unaccounted waste, burning is one of the biggest culprits, followed by illegal dumping. Respondents further specified limitations to waste available for the built environment has resulted in plastic bricks companies capping production at 500 units per week. This fails to meet the demands in the construction of houses. Therefore, proper management of waste is  required, as well as introducing community members to other uses of waste especially in the built environment.

3.1.2. Cost of Packaging Waste

It was important to know the costs incurred during the collection, production, building and the selling price of the material. In costing these materials the respondents only considered plastic bricks since all other options were either theoretical or at the testing phase. Three Respondents showed that the overall cost of production, from collection to processing and building, is relatively cheap with variations by the type of waste and location. This is because waste is free when collected from illegal disposal sites and around villages. Also, the respondents (plastic brick suppliers) stipulated that there are existing alternative and competing marketplaces for trading plastic, paper, and cans while  glass waste remains untapped and has been known to be given out for free. After selling to the KHY Plastic recycling company, surplus plastic costs M0.50 (EUR0.025) when it’s coloured and M1.50 (EUR0.075) when it’s white or transparent. This is the range of costs during the acquisition phase.

Additionally, during the production phase, three of the Respondents who manufacture plastic bricks disclosed that when producing plastic bricks they use open fires as they have not invested in buying machinery to keep initial investment capital costs low.  Additionally, the Respondents indicated that the associated operational costs in producing the plastic bricks are cheap or free at this proof-of-concept stage. The Respondents indicated that they recognize that this limits production and they would need to significantly invest should they pursue growth via industrial production. This would require a minimum capital investment of M75 000 (EUR 3750) at the time of the interview to buy machinery. Lastly, labour costs are kept relatively low because there is minimal skill required under effective supervision.

Furthermore, it was important to know the selling price of plastic bricks from the already existing producers of the bricks in the country before advocating for it in comparison to conventional building materials. Twelve of the Respondents showed that in comparison with conventional paving bricks, plastic bricks are  more expensive stipulating that paving bricks are M5.00 (EUR0.25) while concrete paving bricks are M2.50 (EUR0.13) each,  but there are long-term benefits of using plastic bricks because the bricks require less maintenance and replacement, unlike conventional paving bricks.

3.1.3 Environmental Impact of Packaging Waste

It was important to  know the impact of the production of plastic bricks, changing climatic conditions, and the benefits of using waste as building materials to the environment. Nine of the Respondents showed that the use of plastics, cans, glass, and cellulose paper  has a tremendous impact on the environment due to the changing climatic conditions. Respondents  emphasized that using plastic, paper, metal cans, and glass reduces the amount of waste and protects the environment from waste through repurposing of the materials.

Also with the changing climatic conditions, plastic bricks can be used to build bridges and roads as the plastic bricks are water resistant unlike concrete blocks and  paving bricks which are easily damaged by floods. Additionally, Respondents showed that because of the cold winters that are experienced in the country cellulose insulation could contribute to thermal efficiency. Three of the Respondents conveyed that during the production phase of plastic bricks,  there is a documented negative impact, in that the plastic is  burned  using wood or charcoal which leads to the emission of toxic gasses into the atmosphere. As a result, some Respondents are trying to shift away from burning plastic to purchasing the required machinery.

4. Feasibility of Packaging Waste

The respondents indicated that waste as a building material may cover an unfulfilled need for proper structures and affordable housing for urban populations since urban areas are where packaging waste is more readily available than in rural areas. The opportunity they see is a reduction of poorly constructed houses and slums. They also mentioned that due to concerns about the inability of packaging waste materials to be load-bearing, most packaging waste solutions can be incorporated with traditional construction materials for their superior thermal performance.

However, the Respondents expressed a concern regarding a shortage of skills needed to produce and use packaging waste products. Due to the theoretical or illustrative nature of these houses and products in Lesotho and South Africa, there is a concern from potential investors and entrepreneurs.  At this stage, both on the supply side and demand side, Basotho’s perception of waste as a building material is that it is not a feasible value chain. The Respondents indicated that the competing industries such as KHY plastics, Mookoli scrapyard, and Ha Mokotso which takes 72 tonnes 12 times in a month perhaps because of their stage in maturity, have cornered the collectors and distributors market which bodes poorly for the built industry.

5. Distribution of Packaging Waste

20% of the waste in Lesotho goes to collection systems and recycling companies and 80% goes to illegal dumpsites. It could be diverted directly to entrepreneurs working towards promoting sustainable building materials as a way to design environmentally friendly waste disposal methods. Plastic, paper, and metal cans don’t require specialized transportation, care, or packaging which means processing plants and collection services can be set up for construction sites fairly easily. Glass bottles, however, are fragile, and require care and packaging. The largest bottleneck to the distribution of packaging waste is the legal framework which dictates who can pick it up from landfills under current policy.

6. Unmet needs on Packaging Waste as a Building Material

Exploring waste as a building material has not been introduced in full capacity as yet in the country as only a few unregistered companies have started using waste in the building industry, therefore its potential to be used and seen as a viable building material in Lesotho remains unknown. Also, the lack of documented reports about the exact number of plastic bottles, cans, and glass bottles going to landfill remains undocumented. The 80% of unaccounted waste  could play a role in using waste as a construction material at an industrial scale. The lack of building codes especially for the use of recyclable construction material such as waste is a major restraint in the growth of the industry.

7. Conclusions

A significant consideration when looking at these packaging waste materials is the life-cycle cost to the environment in their production and use. By lengthening the life cycle of these materials, we’re effectively reducing the burden of its environmental impact by averaging it over a longer lifespan. This research was conducted comparative to currently used alternatives and the embodied carbon in these materials cannot be ignored. However, since we are considering these materials under the current policy in Lesotho, with the vision that the importation of many of these materials may change in the future, we cannot explore a quantitative approach to the environmental cost-benefit analysis of using them as an alternative.

Millions of metal cans, plastic, paper, and glass  bottles are discarded every year into landfills, illegal dumping sites, or rivers. Sustainable reuse of packaging waste is mutually beneficial for both the environment as well as the construction industry. These construction techniques and materials and the associated benefits need to  be promoted through educating the local community since they are the ones who will benefit the most from this low-cost construction. However, concerns linger over the viability and sustainability of businesses around their use in the built industry.

8. Recommendations

There are two considerations to make when assessing whether there is a feasible application of packaging waste as construction material. The first is whether businesses in this value chain are viable, and the second is whether they are sustainable. Since the only material explored beyond the demonstrative and proof-of-concept stages is the plastic brick, we shall focus on it in our recommendations.

From an environmental perspective, it is prudent to rule out the possibility that the impact of toxic byproducts does not outweigh the benefits of extending their life cycle. From an economic point of view, there are existing industries, such as fashion and homeware(Pheha Plastic), that pull some away from the supply base. But, from an optimistic perspective, this means there are supportive services around the transportation, distribution, and warehousing of packaging waste which can be diverted through better incentives from the built industry. The pricing of plastic bricks needs to be adjusted to scale since the current plants are too small to create a product that can compete with traditional bricks.

Colombian-based Conceptos Plasticos suggested that entry into the plastic brick construction industry should target institutionally supported and large projects. They mentioned that due to the high prices, it would be necessary to lobby large NGOs and international partners in Lesotho to back the use of plastic bricks by looking at their extended life-cycle in the built industry. Since these multilateral and multinational organizations have varied interests in Lesotho, it might be a strategic approach to highlight the socio-economic, financial, and environmental benefits of plastic bricks which checks boxes for their own in-country operations. They added that large construction projects like schools, pavements, and shelters would make for a compelling financial case due to the economies of scale.

As a secondary recommendation, processing cellulose paper seems like a low-hanging fruit for institutions to explore to create a competitive product in the insulation space.

Government is a key actor in the value chain of packaging waste and there are several things that can be done by the government in order for packaging waste to potentially become a feasible and accessible building material:

  1. Building codes can be amended to promote and encourage the use of packaging waste as a building material.
  2. The government can promote innovation so that packaging waste can be encouraged to be used more in buildings by supporting initiatives that introduce this innovation to the community at large.
  3. There needs to be enforcement of government policies around waste management. This includes punishing offenders at illegal dumpsites and promoting the sorting of waste at waste management plants.

Government should track waste management activities as one platform by using a set of matrices making it easy to share and report information with stakeholders about the amount of waste available.

9. Appendices

Appendix A: List of Key Respondents

Respondent NoName of Company/ ProfessionNumber of years of ExperienceProfession
Respondent 1Plastic Brick Producer3 yearsIndividual brick contractor/Plastic brick maker
Respondent 2Pheha Plastic5 yearsFounder
Respondent 3Ministry of Environment10 yearsEnvironmental spet
Respondent 4Maseru City Council10 YearsWaste manager  at  MCC
Respondent 5Nebulart Company9  yearsDesigners of Plastic Brick making machine
Respondent 6Organo-Pharma Ltd5 yearsPlastic brick constructor
Respondent 7Boloka Bohloeki16 years Owns the company that in charge of the waste site Associations of Waste
Respondent 8 Solar lights  15 yearsArchitect who built using metal for
Respondent 9Upscaling low-income houses ( Community architect 18 yearsArchitect in South Africa who works on upscaling
Respondent 10Nomsa Plastic brick1yearPlastic brick producer
Respondent 11KHY Plastic ( plastic recycling company)18 yearsOwner of the recycling plastic company in Lesotho
Respondent 12UNDP7 yearsEnvironmental Spet
Respondent 13Cape Insulation11 yearsProfessional Cellulose installer and marketing personal for the companyl
Respondent 14Mookoli scrap yard ( collect paper3 yearsEntrepreneur and Founder of a recycling company
Respondent 15Carton6 yearsEmployee of Carton


 

10. Bibliography

Amosu, A. 2002. Lesotho: Recycling Tin Cans into Houses. https://allafrica.com/stories/200209170001.html 

Hospodarova,  V . Stevulova, N &  Sicakova, A. 2015. Possibilities of Using Cellulose Fibres in Building Materials https://iopscience.iop.org/article/10.1088/1757-899X/96/1/012025

Hurtado, L. Antoine, R. Virginie, V. & Christine, D. 2015. A Review on the Properties of Cellulose Fiber Insulation. https://www.researchgate.net/publication/284232857_A_review_on_the_properties_of_cellulose_fibre_insulation

Attainable Home, 2022. Cellulose Insulation Pros and Cons  (loose -Fill and Sprayed) https://www.attainablehome.com/cellulose-insulation-pros-and-cons/

Fatima, S. 2017. Study of Material Flow Analysis of Paper Waste in Municipal Solid Waste of Lahore Cantonment. https://neptjournal.com/upload-images/NL-53-20-(18)D-224.pdf

Lesotho Vision, 2020/ UNEP Law and Environment https://leap.unep.org/countries/ls/national-legislation/lesotho-vision-2020

Khanlari, A. Tuncer, D. Faraz, A. & Socen, G. 2023. Utilization of Recyclable Aluminum Cans as Fins in Vertical Solar Air Heating System: An Experimental and Study. https://www.sciencedirect.com/science/article/pii/S2352710222014528

Kumar, A. Biswas, M. & Debarashi, N. 2020. A Study of Manufacturing Bricks Using Plastic Waste. https://www.jetir.org/papers/JETIR2008243.pdf

Lamba,P. Kaur,D. & Raj, S. 2022. Recycling/ reuse of Plastic waste as construction material for sustainable development: a review. https://link.springer.com/article/10.1007/s11356-021-16980-y

Mojtaba,V. & Masoud, V. 2022. Investigating  the Application of Plastic Bottles as a Sustainable Material in Building Construction. https://www.researchgate.net/publication/320988328_Investigating_the_Application_of_Plastic_Bottle_as_a_Sustainable_Material_in_the_Building_Construjtabaction

 Mdrezaur, R. & Muhammad,K. 2022. Extraction Types and Classification of Cellulose. https://www.sciencedirect.com/science/article/abs/pii/B9780323857710000038

Sharma, K. & Chandel, M. 2017. Life Cycle Assessment of Potential Municipal Solid Waste Management Strategies for Mumbai, India. https://journals.sagepub.com/doi/abs/10.1177/0734242X16675683

Sandanayake, M. Yanni, B. & Vrcelj, Z. 2022. Current Sustainable Trends of Using   Waste Materials in Concrete-A Decade Review. https://www.semanticscholar.org/paper/Current-Sustainable-Trends-of-Using-Waste-Materials-Sandanayake-Bouras/7fea5f0303321116db1ce88b9ef8db61972827de

UNDP, 2021. Lesotho Annual Country Report 2020 Country Strategic Plan. https://lesotho.un.org/en/145108-lesotho-annual-country-report-2020

 Viola, H. & Nadezda, S.  2015. Cellulose Fibers Used in Building Materials. https://www.researchgate.net/publication/300400574_Cellulose_Fibres_Used_in_Building_Materials

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Information Library

Building with Hempcrete Blocks

Desk Research & Primary Findings

Issued on:30th August 2023

1. Background

1.1 Overview of Hemp

Hemp is widely regarded as one of the most versatile plants on the planet, with a wealth of potential applications that make it a highly valuable resource. The hemp plant stem has numerous applications, with a long history of use as a building material. Its history in the construction of homes and bridges dates over 2,000 years (Assaf 2023; Roberts 2021). Historic structures made from hemp, such as the house in Nagano shown in Figure 1.1. and Figure 1.2 displays hemp stalks.

Moreover, over the last few years in South Africa, Afrimat played a vital role in the development of Africa’s initial hemp dwelling in 2011 (refer to Fig 2.1), which was chosen as a World Design Capital 2014 initiative. Subsequently, they erected an additional five structures made of hemp, including the world’s tallest building constructed with hempcrete and boasting 12 floors (refer to Fig. 2.2).

The utilization of hempcrete as a building material is not well-known among the general public and policymakers in Lesotho. Yet there is widespread growth of hemp ranging from medical cannabis cultivated legally. But, more prominently, illegally grown for traditional medicinal purposes and as a recreational drug. The literature review does not indicate any local exploration in the construction field. Because there is a local and world reassessment of the regulation of hemp plants, we need research ahead of any deregulation to prepare the industry. We have researched information on the accessibility, legal guidelines, durability, carbon footprint, resource cost, and the necessary knowledge and techniques for hemp application as it has proven to be a successful building material in South Africa (Duvall, 2019).

1.2. Characteristics of Hempcrete

Hempcrete is a type of biocomposite made from a mixture of hemp shiv, lime binder, and water. Compared to concrete, it is lightweight, weighing only around one-eighth of the concrete’s weight. According to Isaacs and Bedliva (2014), hempcrete can be sprayed to construct walls, floors, and roofs. Additionally, the lime component contains air lime, which accelerates the setting process. The coarse parts of hemp that stick to the fiber after it is split can be sourced from hemp stalks, as suggested by Tradical (2022). As a result, the combination of lime and hemp produces a natural concrete material that is lightweight, with the possibility of ultra-lightweight under specific applications.

1.3. Uses of Hemp as a Building Material

Hempcrete has limitations in load-bearing applications or as a foundation material due to its lower compressive strength compared to concrete. Roberts (2021) reported that hempcrete has a compressive strength of 1 MPa,[1]  which is 1/20th that of concrete. However, according to Hempitecture (2021), hemp can also be utilized in the form of fiberboard and bricks. Hemp panels are suitable for insulation purposes, while hemp bricks can be used as non-load-bearing infill in partitions and exterior walls for both new construction and renovation projects.

Hempitecture (2021) outlines two main methods for constructing buildings with Hemp Lime composites: Cast-in-place and Hemp Blocks. For Cast in Place, hempcrete walls can be built on-site using two techniques: pouring the mixture into temporary formwork and manually tamping it (as shown in Figure 3.1), or spraying the material onto the target area using the projection method (as depicted in Figure 3.2) (Lupu et al 2022).

2. Advantages of Hempcrete Blocks

Tradical (2022) states that the combination of lime and hemp creates a natural lightweight or ultra-lightweight concrete. The material is known to regulate indoor temperatures and remove fungi, fine dust, and bacteria from the air, creating a pleasant odor due to its ionizing effect (Hahmed, Mahmud, Sarker & Islam, 2022). 

The environmental benefits of using hempcrete in the building industry are observed in every stage of the production and use of the material (Tradical, 2022). Since it is made from the stalks of the hemp plant, hempcrete carries the inherent advantage of promoting the farming of plants that have a restorative effect on the environment. Secondly, hempcrete is produced in a simple, low-resource process that promotes reuse and recycling of waste materials which can be used to further the interests of companies in the waste management space. Lastly, the excellent thermal properties of hempcrete benefit homeowners and the environment by lowering the need for temperature control. Additionally, hempcrete is a sturdy material that does not require the use of harmful chemicals for pest and parasite control (Tradical, 2022).

Hempcrete is also carbon-negative and sequesters carbon dioxide from the atmosphere throughout its life cycle. It is resistant to mold, pesticides, and pests, and has a two-hour burn rating. The material filters particulates and provides a thermal mass barrier to regulate interior temperatures, making it disaster-resistant and an ideal option for earthquake-prone areas (Roberts, 2021). Hempcrete has high thermal capacity and vapor permeability properties, resulting in high-performance buildings that meet current and future thermal regulations (Tradical, 2022). Additionally, it is grown without the use of harmful chemicals, requires minimal irrigation, and contributes to soil regeneration (Tradical, 2022).

3. Disadvantages of Hempcrete Blocks

Although hempcrete is a promising and innovative building material, it currently remains relatively expensive compared to more conventional options, according to Lynch (2020). Estimates suggest that it may cost at least three times as much as regular concrete. Additionally, hempcrete can be difficult to obtain, as the production of hemp can be seasonal, and the material needs to be dried for eight weeks, which is affected by changes in weather conditions.

Furthermore, according to Lynch (2020), the maximum compressive strength of hempcrete is 3.5 megapascals (MPa), which is significantly lower than the lowest compressive strength of regular concrete at around 17 MPa.

4. Primary Explorative Research  Findings

4.1. Research Methodology

To collect primary data, the stratified and snowballing sampling techniques were convenient for this study, because it was imperative to select respondents based on their qualifications and expertise, ensuring they have the necessary background to provide valuable insights. This chapter presents the findings from the one face-to-face, three calls, and six Zoom interviews that each lasted between 45 minutes to an hour held in January and February 2023, with professionals and experts who have worked or are working with Hempcrete. A set of questions (see Annex 3 questionnaires for hemp), which included open-ended questions, had been prepared with the aim of gathering information about some specific topics such as availability and accessibility, cost, durability, knowledge, and techniques around hempcrete.

4.1.1. Availability of Hempcrete Blocks

The aim was to ascertain whether hemp is locally grown and its intended applications. Additionally, to grasp the impact of regulations and laws on hemp production feasibility in Lesotho. As a result, One respondent (from the Ministry of Health) showed that a few hemp plants are already available in the country. The Respondent mentioned that hemp grows well and is primarily cultivated for medicinal purposes, following guiding laws to ensure legal compliance. Additionally, the Respondent noted that hemp has potential applications like creating hempcrete blocks. However, the policy lacks clarity as it primarily concentrates on medical uses.

Nine Respondents explained that Lesotho doesn’t cultivate hemp mainly because the policy focuses on medicinal cannabis production and doesn’t adequately cover hemp’s various uses.

4.1.2. Cost of Hempcrete Blocks

Another aspect evaluated included the cost of obtaining a cannabis cultivation license in the country, along with establishing the purchase price and production cost of hempcrete blocks from South Africa. Eight Respondents revealed that the license fee is substantial, amounting to M500,000 (EUR 25,000) for the operation of a cannabis plant in Lesotho. Additionally, companies must adhere to international guidelines, including GACP (Good Agricultural and Collection Practices), which increases licensing costs to M600,000 (EUR 30,000). However, a Ministry of Health representative mentioned that if companies only require the hemp plant’s stalks, an operator’s license is not necessary. The official also pointed out that the Ministry of Health can request hemp-cultivating companies to supply stalks. This way, the Ministry could provide these stalks to entrepreneurs for free.

Regarding the purchasing cost of the material, two Respondents mentioned that buying hempcrete blocks can be expensive compared to conventional bricks. Furthermore, the Respondents pointed out that the requirement for skilled foreign manufacturers to educate entrepreneurs in hempcrete production and construction contributes to increased labor expenses. Nonetheless, Hempcrete blocks offer long-term thermal advantages resulting in cost savings towards heating costs.

4.1.3. Durability of Hempcrete Blocks

Additionally, the study aimed to evaluate the durability of hempcrete blocks compared to traditional bricks. Four Respondents highlighted that the lime and silicone binding agents gain strength over time, enhancing the resilience of hempcrete blocks in contrast to concrete blocks.

4.1.4. Environmental Impact of Hempcrete Blocks

Understanding the carbon emissions linked to hempcrete’s usage emerged as a crucial aspect. The analysis acknowledges that hempcrete, primarily a biological byproduct, has a lower embodied carbon than conventional bricks. Throughout its lifespan, it absorbs carbon dioxide from the atmosphere. Furthermore, two respondents emphasized that hempcrete blocks can also sequester carbon, helping reduce greenhouse gas emissions

5. Feasibility of Hempcrete blocks

Lesotho, as the pioneering African nation to legalize and permit the cultivation of medicinal cannabis for international export, boasts favorable conditions for cannabis cultivation. The country benefits from ample available land on the outskirts of its towns, attracting significant attention from international enterprises interested in investing in medicinal cannabis production. However, the high costs associated with operating licenses present a significant barrier for Basotho farmers seeking to cultivate hemp. Hemp is currently categorized alongside the highly profitable medicinal cannabis plant, amplifying these challenges. To fully leverage the potential of cannabis, it’s imperative to integrate its diverse applications into the national policy framework. Presently, existing cannabis companies face limitations in utilizing byproducts like stalks, which are often discarded, due to stringent regulatory constraints. These companies are constrained from selling or even donating these byproducts due to the stringent legal protocols they must adhere to.

Avans University Masters research

In partnership with Rise International (2022), a team of Master’s students from Avans University in the Netherlands conducted a study to assess the practicality of employing hemp as a construction material in Lesotho. Their findings emphasize that crafting hempcrete is a straightforward procedure achievable with standard farming equipment or even by manual means. Furthermore, they highlight its efficiency, noting that a single acre of hemp yields four times more fibers than a forest, with a rapid 100-day harvesting cycle. The researchers affirm that hemp thrives in Lesotho’s soil conditions, and its three-month growth cycle positions it as a swiftly renewable resource (Houtbouwbeurs, S. D, as cited in Avans University 2022). This dynamic suggests a consistent and substantial output from hemp farms. The researchers concluded that affecting this transformation necessitates a reclassification of the Cannabis sativa plant, which contains higher CBD and minimal THC—constituents that give rise to hemp—distinct from the Cannabis sativa plant employed in medicinal cannabis production, characterized by elevated THC levels. Such differentiation would exempt hemp production from the currently prohibitive licensing costs. For more insight, refer to the Avans student’s accompanying video here

6. Distribution

Currently, there are limited instances of hempcrete structures in Lesotho, except for a private residence underway in Morija, approximately 40 minutes from the capital city, Maseru. However, the expenses involved are substantial due to the importation of hempcrete blocks from South Africa. This is further compounded by increased logistical and labor-related expenditures. The scarcity of expertise in hempcrete construction is also a notable challenge, as only a small number of individuals have received training in this specialized technique.

7. Unmet needs of Hempcrete

Lack of public knowledge about the opportunities for the production of hemp is the greatest hindrance to development. It would be an advantage for Lesotho to use hemp as a building material as it can be produced quickly and efficiently on a small and large scale. Ultimately, a local hempcrete industry would also stimulate the economy and reduce the reliance of Lesotho on South Africa’s construction material industry. The emergence of a new industry would also introduce new job opportunities for Basotho.

8. Conclusion

Hemp can be used as a building material, and it has also been confirmed by experts (Director of Pharmaceutical, and Afrimat Managing Director), and it has a massive potential market in Lesotho. This is because not only does Lesotho have a favourable climate and vast lands to start the industrial production of hemp, it already has a policy directing the production of cannabis. However, the Drug Abuse Policy fails to incorporate and advocate for other uses of other types of cannabis such as hemp as it only shows support for the production of medicinal cannabis. Additional factors that hinder the use of hemp in construction are high licensing costs and the necessity of imports for creating hempcrete. These imports include lime and skilled labour for the production and construction of hempcrete blocks.

9. Recommendations

The first consideration is the economic implications of using hemp as a building material. Hempcrete, made from hemp plant stalks, not only extends the plant’s lifespan and value but also multiplies its benefits. We recommend further research to support policy changes promoting hemp farming in Lesotho. Hemp is a global billion-dollar economic sector, covering medical, recreational, and various other applications. Lesotho’s inherent advantage in hemp growth offers a significant economic opportunity. This holds implications for construction development, including skills advancement, job generation, business prospects, and exports. However, the high licensing costs must be reevaluated for a more inclusive industry.

This paper identifies diverse sociopolitical implications for the hempcrete industry, primarily linked to the Drug Abuse Policy. The recommendation put forth in this paper suggests a revision of this policy to encompass the advantages of hempcrete production and usage. Firstly, the policy’s blanket classification of all hemp plants is criticized, stemming from the negative associations with a few strains used for recreational drug abuse. Secondly, neighboring South Africa’s legalization framework stands as a viable model for adoption in Lesotho. Given that multiple African nations are currently moving towards hemp deregulation, creating regional competition, prompt action is essential. If current and future hemp producers, primarily focused on oil extraction, find hemp cultivation financially unviable, it could result in the loss of a cost-effective and dependable material for our construction industry.

10. Appendices

Appendix A: Key Respondent List

Respondents #CompanyYears of ExperienceProfession/ Qualifying Criteria
Respondent 1Afrimat14 yearsSales Manager & Managing Director Hemp constructor
Respondent 2Owner of the first hemp building in Lesotho 50 years Customer perspective First Hemp Homeowner in Lesotho
Respondent 3 Individual Entrepreneur4 yearsBuilder of the first hemp builder in Lesotho
Respondent 4Ministry of Health24 yearsDirector Pharmaceutical
Respondent 5Medi grow8 yearsEnvironmental Spet
Respondent 6WeGrow5 yearsAgricultural spet
Respondent 7Hemp Africa6 yearsAgricultural Spet Africa
Respondent 8Ignited Unlimited21 yearsAgronomist (knowledge of Cannabis)
Respondent 9Constructed the first Hemp building17 yearsConstruction manager on the first building of hemp in Lesotho
Respondent 10Organica13 yearsEnvironmental Spet


 

11. Bibliography

Adams Popescu (2018). Centuries old, hemp grew in popularity for home building. https://www.seattletimes.com/nation-world/centuries-old-hemp-grows-in-popularity-for-home-building/ . (Accessed: 12/05/2023)

Ahmed, A. Islam, M. Mahmud, S. Sarker, E. & Islam, R. 2022.  Hemp as a Potential raw Material toward a Sust

Assaf, J. (2023). Hemp 101: The difference between Cannabis, Hemp, and marijuana explained. https://feel.prima.co/magazine/what-s-what-hemp-cannabis-and-marijuana. (Accessed: 12/05/2023)

Avans University Masters Students (2022). Using hemp to protect Lesotho. https://drive.google.com/drive/folders/1o5o6YUjmRw1IzG4UjoaG-3q8Dxp4t57R.(Accessed: 01/05/2023)

Clarke, R.  (2006). Journal of Industrial Hemp: Hemp Museum Tour of Nagano Prefecture (PDF) Hemp Museum Tour of Nagano Prefecture. (Accessed: 02/05/2023)

Downing, S. (2022). AG Daily. Hemp as sustainable building blocks: This ‘ancient green building’ tech is making a comeback. https://www.agdaily.com/crops/hemp-building-blocks-sustainable-technology-is-making-comeback/ . (Accessed: 12/05/2023)

 Duvall, C. S. (2019). A brief agricultural history of cannabis in Africa, from prehistory to canna-colony. https://doi.org/10.4000/echogeo.17599. (Accessed: 02/05/2023)

Isaacs, N. & Bedliva, H. (2014). Hempcrete- An Environmentally Friendly Material? https://www.researchgate.net/publication/286736682_Hempcrete_-_An_Environmentally_Friendly_Material. (Accessed: 12/05/2023)

Hempitecture (2021). Hemp Lime Building Systems. https://www.hempitecture.com/hempcrete. (Accessed: 12/05/2023)

Lupu, M. ( 2022).Hempcrete – modern solutions for green buildings https://ui.adsabs.harvard.edu/abs/2022MS&E.1242a2021L/abstract

Lynch, P. (2020). Way of leaf: Biggest disadvantages of hempcrete as a building material. https://wayofleaf.com/hemp/disadvantages-of-hempcrete-as-a-building-material. (Accessed: 12/05/2023)

Moraes, C. (2022). South Africa: Cape Town is home to the world’s tallest hemp building. https://www.constructafrica.com/news/south-africa-cape-town-home-worlds-tallest-hemp-building#:~:text=A%2012%2Dstorey%20building%20at,Hemp%20and%20Wolf%20%26Wolf%20Architects.(Accessed: 12/05/2023)

Roberts, T. (2021). Building with hempcrete. https://www.buildwithrise.com/stories/building-with-hempcrete. (Accessed: 12/05/2023)

Tarun Jami, Sumit Kumar (2017). Assessment of Carbon Sequestration of Hemp Concrete.https://www.researchgate.net/publication/320058537_Assessment_of_Carbon_Sequestration_of_Hemp_Concrete. (Accessed: 12/05/2023)

Tradical (2022). Hempcrete Insulating Lining. https://www.weber-tradical.com/en/hempcrete/what-is-hempcrete-2/#:~:text=Hemp%20is%20a%20plant%20that,%2C%20or%20ultra%2Dlightweight%20even.(Accessed: 12/05/2023)

William, S. and Alex, S. 2014. The Hempcrete Book: Designing and Building with Hemp-Lime (Sustainable Building)

Jami, T., & Kumar, S. (2017). 185-191[1] [2] 


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Building with Sandstone

Desk Research & Primary Findings

Issued on: 30th August 2023

1. Background on Sandstone

1.1. Overview of Sandstone

Sandstone is a type of sedimentary rock that can be found in abundant quantities on the Earth’s surface (Hall, 2010). It has been used as a building material since ancient times and continues to be a popular choice for traditional Lesotho houses, as noted by Piotr (2021). The use of sandstone as a construction material dates back to approximately 1825 circa the founding of Lesotho and the reign of the country’s first King Moshoeshoe I. Traditionally, small round houses called ‘rondavels’, were built from sandstone by the Basotho people as shown in Figure 1.

Fig. 1: King Moshoeshoe I House (by Jessica Macdonald, 2021)

In recent years sandstone has become popular in Lesotho as a building material for prestigious hotels, lodges, as well as institutional and government buildings themed along vernacular designs. Despite the popularity of the building material, various factors have led to a decline in the usage of sandstone in the present architectural and construction era. These include financial, technological, and logistics-related challenges. The primary challenge remains the procurement and sale of the material for homeowners. The perception among Basotho is that dressed and cut sandstone is prohibitively expensive and is only affordable to wealthy households, due to the misconception that its mineral-like qualities make it expensive. Furthermore, despite the emergence of more advanced construction techniques in Southern Africa, the potentially lucrative natural building material in Lesotho has remained untapped at an industrial level (Bourne, 1982). These can still be seen in various parts of the country, but architectural development has produced modern buildings that take advantage of the materials’ various properties and abundance.

The literature reviewed about sandstone did not explore the possibility of utilising it on an industrial scale in Lesotho. There are socioeconomic, political, and environmental factors associated with the usage of sandstone in widespread construction. These take into consideration its availability, accessibility, durability, carbon emissions, and environmental impact. This research will specifically address these issues.

1.2. Geomorphology of Sandstone in Lesotho

Hanco (2004) states that the Karoo Supergroup rock underlies Lesotho, consisting of sediments and basaltic lavas. The sandstone sediments in this region are classified into three types: Clarens, Elliot, and Molteno (refer to Fig 2). As a result, there is a consistent underlying geology in Lesotho, and each geomorphological unit contains a distinct sandstone type (Davide, Katrin, & Julie, 2020). The various formations have resulted in diverse sandstone types being distributed throughout the region, each with its unique characteristics. Moreover, the local climate and environment significantly impact the sandstone types found in different areas, which means that different types of sandstone can be present in one location.

Fig 2: Formations under the Karoo subgroup; which play a role in the formation of different sandstone (Michiel Olivier de Kock, 2009)

1.3. Sandstone Formations

The Clarens Formation is spread across a vast area in the central highlands of all provinces in the Republic of South Africa and in different regions of Lesotho, both in the lowlands and highlands. Various sandstone deposits from the Clarens Formation can be found in Lesotho, but the largest mining area that has been utilised is in the Berea District, specifically in an area called Lekokoaneng, which is regarded as the largest quarry in Southern Africa (Eriksson, 1981). (see Figure 3.1 & 3.2)

The unit is situated stratigraphically between the red beds of the Elliot Formation. The thickness of the Clarens Formation is usually between 115 m and 195 m, and it consists of light-colored, fine-grained sandstones, sandy siltstones, and mudstones, as well as subordinate coarser-grained components (Eriksson, 1981). The rock’s surface is white when first extracted from boreholes and quarries, but when exposed to the elements, it weathers to a characteristic tan or golden hue. Due to its very low permeability, the rock is an ideal building material. ( see Figure 4.1 & 4.2)

The Elliot Formation is present in multiple locations in Lesotho, including Qacha’s Nek, Quthing, and near the capital city of Maseru, particularly in Nazareth. This formation varies in thickness, ranging from 28 metres to over 150 metres, and consists of red-coloured, clayey sandstone with a grain size that varies from fine to coarse and gritty at the base (Eriksson, 1985).

The thickness of the Molteno Formation varies between less than 10 m and more than 100 m, making them less permeable and it is composed of grey mudstone, shale, and sporadic coal seams. The sandstones in the Molteno Formation may range from fine to very coarse and are primarily composed of quartz-rich feldspathic wackes. They have high interstitial content and may exhibit subordinate argillaceous structures, according to Eriksson (1984). The sandstone from Clarens and Elliot is not permeable and has a low chance of aquifers, but Molteno is more permeable and is regarded with a high chance of aquifers occurring.


2. Advantages of Sandstone

Sandstone is an essential and sustainable building material that boasts remarkable longevity and durability (Kristensen, 2016). It also has a significantly lower carbon footprint compared to other widely used building materials. The carbon emissions associated with mining and processing are minimal as it does not require high energy consumption to extract. The amount of waste generated is also minimal in contrast to the production processes involved in creating prominent materials like concrete bricks (Kristensen, 2016).

According to Kristensen (2016), building with sandstone offers significant long-term cost savings that outweigh the initial higher material costs. This is due to the fact that sandstone buildings can be easily redeveloped, adapted for change in use, or remodelled internally without having to buy replacement materials. Sandstone buildings also have a longer serviceable life than their design life, and at the end of their useful life, they can be recycled in various ways.

According to Kristensen (2016), using sandstone in construction can significantly decrease energy consumption compared to lightweight concrete blocks. This is because sandstone can absorb heat during the day and release it at night, helping to maintain ambient local temperatures. Sandstone’s chromatic variation enables it to be used for various purposes. The material is often used in the restoration of historical buildings and monuments due to its availability and compatibility with traditional building materials. Since sandstone doesn’t require any speed cleaning techniques, it is relatively easy to maintain. It can also be coated with anti-graffiti and self-cleaning materials. It is often utilised outdoors and typically has high resistance to moisture and harsh weather conditions, as stated by Grab (2010).

3. Disadvantages of Sandstone

The main disadvantage exhibited by sandstone is the presence of different types of matrix that can affect the various properties. A small amount of carbonate in the matrix, for example, can dramatically decrease resistance to rain effects. Many sandstones contain small amounts of clay minerals, which are often inert but can sometimes swell, leading to damage under persistent wetting and drying cycles. In some instances, clay-rich inclusions or zones weather rapidly. Frost attacks will be a major factor in Lesotho. Cycles of heating and cooling will also gradually flake the stone surface (Hunt,2019).

In addition, the drawbacks of sandstone are a consequence of the material it’s made from, particularly from the Clarens formation called Lesehloa. For example, sandstone is known for being porous and therefore has a high absorption rate which makes it vulnerable to damage with time. In extreme cases, liquid, moulds, and bacteria can cause permanent stains deep into the stone. Having said that, certain types of sandstone may not be aesthetically pleasing (Grab, 2010).

Due to the relatively hard nature of the rock, the blade of the machine used for extraction wears out quickly after 3 days, necessitating frequent replacement. Additionally, a significant amount of water is required to wet the rock for the blade to pass through.However these advantages are minimal and surmountable, and there are enough advantages that outweigh the disadvantages to make sandstone a viable building material to research further.

4. Desk Analysis

There are economic factors related to the use of alternatives to sandstone in regards to the development of the mining and construction industries in Lesotho. These include human resources lost to neighbouring South Africa in search of employment. Additionally, there are costs related to the transportation and production of alternative building materials. There is an opportunity cost due to the lack of development of the sandstone industry from a mining, logistics, marketing, sales, and construction perspective. Lastly, at a fiscal level, there is a balance sheet imbalance due to the importation of building materials that are not found in Lesotho.

Additionally, there are environmental considerations as to why sandstone may be preferred to alternatives in the building industry. Often with these, time becomes a significant factor because of the inherent climate change, ecosystem, and sociopolitical impacts that may occur later. Local production of sandstone has the significant advantage of imposing a lower embodied and operational carbon footprint. Lastly, the deconstruction of sandstone buildings yields little-to-no additional waste due to it being a naturally occurring and eroding material. However, quarrying has a permanent impact on the geography and ecosystems around the mines. The silt formed also travels via wind and water causing adverse weather and ecological changes.

There are sociopolitical issues to be thought of when considering sandstone. For every mining plan, there should be proper vetting of the social impact on the existing and surrounding communities due to the industrial set-up. Community redeployment, pollution, and other public health concerns related to the geological and social changes must be rigorously assessed.

5. Primary Explorative Research Findings

5.1 Data Collection

To collect primary data, stratified and snowball sampling were convenient techniques for this study. It was imperative to undertake interviews with professionals and experts with over 10 years of experience, knowledge, and skills working with sandstone. This chapter presents a total of 10 interviews conducted from January to June 2023, the researchers conducted face-to-face interviews that lasted between 45 minutes to 1 hour each. Qualitative surveys (see here for the Research Questionnaire) were used to gain in-depth information, experiences, and narratives about some specific topics such as availability, accessibility, cost, durability, and environmental impact of extraction.

5.2. Availability of Sandstone in Lesotho

The responses on the availability of sandstone allowed for a more generalised understanding of the geomorphology of Lesotho, potential areas for sandstone to be explored, quality, and existing quarries. Eight of the Respondents indicated that Lesotho is rich in sandstone and has the potential for large-scale mining. However, the Respondents stated that so far Berea district is the only area in the country that is mined with about five quarries, and one of the mines in that area is said to be the largest sandstone quarry in Southern Africa. The Respondents outlined that it is the only district being mined because of the belief that it has the best sandstone in the country that comes from the Clarens formation. Also, the Respondents further claimed that due to financial constraints, the Ministry of Mining has not mapped out areas of sandstone deposits. Instead, it offers individual maps that only highlight the geomorphology of Lesotho and do not pinpoint the exact areas where the deposits is found  making  it hard for individuals to venture out into the unknown without proper guidance and knowledge from the Ministry, showing the exact areas to mine in a particular district, hence certain areas like Quthing, Mafeteng, Letseng, and Mohale’s Hoek have not been explored. Nonetheless, the Respondents claimed that the 5 mines all have the potential to be mined at a vast proportion, which indicates that sandstone is available in abundance in Lesotho and more deposits of the material are yet to be explored.

In spite of that, two of the Respondents claimed that government policies and the environmental impact of mining of the material and encroachment of settlement play a big role in the availability of sandstone in the country. The Respondents stated that due to the extensive sandstone quarrying in Lekokoaneng over the years, it is possible that the mines in that district may not be able to sustain large-scale production in the future or may be forced to halt operations to prevent environmental issues. Having said that, different approaches can be taken for the availability of the material such as resettlement of households and exploration of other areas with sandstone deposits.

5.3 Cost of Sandstone in Lesotho

The responses acquired on sandstone permitted for better understanding of the impact of the cost of extraction on the price of the material in comparison to conventional building materials. One Respondent narrated that the machinery, and extraction process have resulted in the material being a bit expensive. The Respondents claimed that the elements that lead to the buying price being expensive start from the acquisition of the machinery which has to be designed by engineers and imported from China. The Respondents outlined that during the extraction process, more labour and transport are required from the extraction phase, cutting, and polishing of the machinery according to the customer requirements. Lastly, disposing of clay, cut-off alongside transporting the final product to the storage warehouse contributes to the overall operational costs.

Additionally,  the Respondents stated that the blade costs M15,000 ( EUR 724.65) and it is replaced after every 3 days and it has to be bought from South Africa. The Respondents further indicated that all these underlying factors have resulted in the buying prices being a bit higher as compared to other conventional materials, in that one block of sandstone that is the same size as concrete block type 6k costs M18.24 (EUR 0.91) making it a bit more expensive than concrete blocks which are M15.00 (EUR 0.75). Also in comparison to the cost of a manufactured clay brick, which in Lesotho is only manufactured by one state-owned factory called Loti, sandstone proves to be a bit more expensive as a clay brick costs M6.00 (EUR 0.30), and the equivalent sandstone size brick costs M7.93 (EUR 0.40). Additionally, due to the fact that the quarries are far from the general market, transport costs are expensive to bring sandstone to market.

Nonetheless, there are savings to be made in the long term. Given the durability of the material it does not require regular maintenance, no plastering is required, and given its thermal properties, savings in heating solutions during the winter are notable. There is a low likelihood of getting damaged due to the fact that it is less permeable than conventional material, reducing the costs of regular maintenance. The Respondents gave a clear cost-benefit analysis for both short and long-term costs of Sandstone, demonstrating that it is clearly a viable and feasible building material in Lesotho.

5.4. Durability of Sandstone in Lesotho

The respondents indicated that the formation of the stone plays a big role in its lifespan as this determines the strength and permeability of the material. All the respondents agreed that the durability of sandstone is determined by the underlying formation indicating that the deeper the extraction process the weaker the stone, because of underground water, which results in it being more permeable, however policies put in place don’t allow extraction of rock to go lower than the surrounding area.

To determine the rock’s permeability, a viscosity test (porosity test) has to be carried out. The tests have shown that Lesehloa is highly permeable and breaks easily due to the fact that it is found underneath the lower Elliot and in the Molteno formation which is highly permeable and has high chances of aquifers. While Moramapholi comes from Clarens and Elliot formation, is highly durable due to its compact particles making it less permeable and the fact that it is found on top of the earth’s surface. All the respondents stated the underlying impact of the formation on the durability proving that Clarens and Elliot are highly durable.

5.5. Environmental Impact of Sandstone in Lesotho

Nine of the respondents pointed out that because the mines do not use blasting there is little environmental impact and pollution. Also after the extraction process, the material does not require treatment leading to low carbon emission. Since the extraction process requires a lot of water the quarries have built dams that allow water to circulate back into the plant reducing the amount of runoff water into rivers, which endangers the animals. Additionally, the licences from the Ministry of Environment and Mining permit 10 years of extraction which helps in evaluating the extent of the impact on the land and surrounding area.

However, one Respondent asserted that sandstone mining has negative impacts on the environment. This is because quarrying of the material changes the landscape, besides that runoff and groundwater from the mine goes into the water system leading to polluted water. Additionally, offcuts are haphazardly disposed of and there are no progressive rehabilitation preservation measures after the extraction is done. The government is failing to monitor the enforcement of regulations required to protect the environment. Nonetheless, with proper monitoring environmental impacts can be avoided.

6. Feasibility of Sandstone in Lesotho

Lesotho has 5 sandstone companies and more deposits to be explored. However, during an interview with the Ministry of Mining and Natural Resource, we were informed that the Ministry does not know how many sandstone deposits there are in Lesotho and there is no strategy put in place concerning the other deposits due to constraints in finances and labour as it is time-consuming.

There is an existing market in and outside of the country particularly in South Africa. The skillset is already available for extracting and polishing. The cost of extraction is expensive, particularly the machinery and the blades which are imported. Therefore, the companies need to be in a position to invest a minimum amount which depends on the type of machinery required. Respondents indicated that required start-up investment costs are about M300 000,000 (EUR 150,000) to be in a position to start up a sandstone mining business. However, the other companies stated that within 1 year they had already broken even and were making profits.

7. Distribution of Sandstone in Lesotho

The 5 sandstone quarries in the country are the primary distributors, selling directly to customers in the country on demand and exporting the majority to wholesalers in SA with assuring access to the productivity of over 2,000,000 square metres of a natural resource from the mines. There is a need for quarries to establish partnerships with wholesalers and distributors in order for sandstone to be commercially available to consumers. It’s not a fragile material hence special transportation, packaging, and care are not needed.

8. Unmet Needs

Lesotho still hasn’t mapped out potential areas where sandstone can be mined, due to the fact that it’s time-consuming and financial resources are not available to map out potential areas other than in Lekokoaneng, hence there is insufficient knowledge of the country’s mineral resources endowment and mineral exploration is inadequate. There is an absence of strategies for developing industrial clusters and general economic diversification through infrastructure development and planned connectivity of the mining sector to other economic sectors such as manufacturing and wholesale companies. To fully leverage these benefits, there is a need for innovation in sandstone construction techniques, such as modular designs and prefabricated building components, to increase efficiency and reduce costs.

9. Conclusions

Sandstone as a building material has been disregarded mostly due to people’s preconceived idea that it’s expensive to buy sandstone as opposed to clay bricks or concrete blocks and failing to see the long-term economic and environmental benefits of using sandstone. Additionally, the lack of knowledge with regard to areas in which it is available in the country has led to a small exploration of extracting sandstone when it could be done at a large scale. Therefore, this has led to the apparent shift to readily available modern building materials such as concrete blocks. Hence, there is an opportunity to revive this vernacular material and promote its benefits and its ability to be more sustainable and environmentally friendly than modern building materials. Sandstone from its extraction and processing has the lowest carbon emission compared to other conventional materials such as concrete blocks. Additionally, a framework was created in (The Minerals & Mining Policy of 2015) that works towards mitigating the negative impacts that occur during the mining of the sandstone, hence making it more sustainable compared to other building materials. Furthermore, its thermal properties result in lowering the amount of high-carbon fossil fuels used to heat the buildings, offering both economic and environmental long-term benefits.

10. Recommendations

More research needs to be done on the country’s mineral resources endowment. Geological mapping and mineral exploration need to be commissioned by the government. This requires resources and proper planning. This is beyond the scope of our work, however, we will sensitise the Government of Lesotho within their strategy for economic development and trade. Strategies for developing industrial clusters and connectivity of the mining sector to other economic sectors such as manufacturing and wholesale companies. There should be investments in proper advanced machinery. Also, rather than the ministry just renewing licenses every ten years for companies, the ministries must know the number of years that sandstone can be mined in a particular area and make sure that all regulations are followed to avoid environmental damage.

There is also a need to look into the life-cycle cost of mining and processing sandstone for use in the built industry. This will promote a fair assessment of the overall health and environmental benefits of using sandstone over conventional construction material.

11. Appendices

Appendix A: Table of Respondents

Respondent NoName of Company/ProfessionNumber of  years of ExperienceProfession /Qualifying Criteria
Respondent 1Lesotho Leading sandstone15 yearsSite Manager
Respondent 2Ministry of Mining10 yearsGeologist
Respondent 3Ministry of Environment12 yearsEnvironmental spet
Respondent 4Nazareth Company18 yearsCraftsman and sandstone supplier
Respondent 5Mokotatsie17 yearsCraftsman and sandstone supplier
Respondent 6Likhalakhala lia buseletsa15 yearsCraftsman and sandstone supplier
Respondent 7Kou sandstone company21 yearsDirector and owner
Respondent 8Lerotholi Sons and sandstone suppliers13 yearsSandstone supplier
Respondent 9Sandstone mining Lesotho16 yearsSandstone supplier
Respondent 10Majoro Sandstone9 yearsSandstone supplier

12. Bibliography

Academic Accelerator . Elliot Formation. https://academic-accelerator.com/encyclopedia/elliot-formation. (Accessed: 12/01/2023)

Davide, G., Katri, W. &  Desarnaud. J. ( 2020). Integrated Strategy to Assess Conservation Treatments on Sandstone.https://www.tandfonline.com/doi/pdf/10.1080/00393630.2020.1767332. (Accessed: 12/01/2023)

Eriksson, P.G. (1981). A palaeoenvironmental analysis of the Clarens Formation in the Natal Drakensberg. Transactions of the Geological Society of South Africa , 84:7-17.

Grab,S. & Goudie, S. A. (2011). Sandstone geomorphology of the Golden Gate Highlands National Park South Africa in the global context. https://www.researchgate.net/publication/262701314_Sandstone_geomorphology_of_the_Golden_Gate_Highlands_National_Park_South_Africa_in_a_global_context. (Accessed: 12/01/2023)

Hanco, J., Rubidge, B. & Bordy, E. 2004.  A Description of the Sedimentology and Palaeontology of the Late Triassic–Early Jurassic Elliot Formation in Lesotho.
https://www.researchgate.net/publication/239521319_A_description_of_the_sedimentology_and_palaeontoloy_of_the_Late_Triassic-Early_Jurassic_Elliot_Formation_in_Lesotho. (Accessed: 15/01/2023)

Hall, S. & Hughes,D. (2010). Local characterisation of fluid of flow in sandstone with localised deformation features through fast neutron imaging. https://portal.research.lu.se/en/publications/local-characterisation-of-fluid-flow-in-sandstone-with-localised-. (Accessed: 15/01/2023)

Hunt, B. 2019. Building Stones Explained. https://onlinelibrary.wiley.com/doi/epdf/10.1111/j.1365-2451.2008.00649.x. (Accessed: 12/01/2023)

Kristessen,T. & Wogwitka, R. J. (2016). Beaver River Sandstone: A silicified toolstone  from northeast Alberta Canada. https://www.researchgate.net/publication/311824467_Beaver_River_Sandstone_A_silicified_toolstone_from_northeast_Alberta_Canada. (Accessed: 13/01/2023)

National Geographic Society (2022). Sedimentary Rocks. https://education.nationalgeographic.org/resource/sedimentary-rock/. (Accessed: 13/01/2023)

Palaeo Electronica. Geological Background of the Clarens Formation. https://palaeo-electronica.org/2008_3/150/intro.htm. (Accessed: 12/01/2023)

Piotr. M. (2021). Sandstone geomorphology – Recent advances. https://www.sciencedirect.com/science/article/abs/pii/S0169555X20304578. (Accessed: 13/01/2023)

Sphera (2020). What is Life Cycle Assessment? https://sphera.com/glossary/what-is-a-life-cycle-assessment-lca/. (Accessed: 15/01/2023)


 

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