FABRIC-FORMED UNSTABILIZED POURED EARTH AND METHOD THEREOF

Information

  • Patent Application
  • 20240295121
  • Publication Number
    20240295121
  • Date Filed
    March 04, 2024
    8 months ago
  • Date Published
    September 05, 2024
    2 months ago
Abstract
A method of fabricating an earthen construction formation and of testing the earthen construction formation are presented. The earthen construction formation is prepared by way of a site-derived earthen material mixture. The site-derived earthen material mixture can be free of cement stabilizer additives. A geotextile fabric formwork is filled with the site-derived earthen material mixture. The geotextile fabric formwork is flexible and permeable in nature. The site-derived earthen material mixture is allowed to dry in the geotextile fabric formwork.
Description
TECHNICAL FIELD

This disclosure relates generally to earthen construction building materials and, more particularly, relates to fabricating earthen construction formations with site-derived poured earth material mixtures with fabric.


BACKGROUND

Conventional concrete construction typically includes Portland cement as a stabilizing binder. The conventional materials are usually transported to construction sites from off-site locations, and often utilize framing structural components such as plywood and steel amid their fabrication. According to some estimates, use of Portland cement is responsible for eight percent (8%) of global carbon dioxide emissions. As a more environmentally sustainable alternative, earthen construction building materials have been employed in contemporary constructions. Yet the material is still sometimes brought-in from offsite locations and, while smaller in amount, still sometimes includes Portland cement. Further, past earthen construction building practices typically involve formation via planar impervious formwork. Altogether, challenges remain for greater acceptance and utilization of earthen construction building materials and practices.


SUMMARY

In an embodiment, a method of fabricating an earthen construction formation may include multiple steps. One step may involve preparing a site-derived earthen material mixture. The site-derived earthen material mixture lacks cement stabilizer additives. The site-derived earthen material mixture constitutes a pourable site-derived unstabilized earthen material mixture. Another step may involve filling a geotextile fabric formwork with the pourable site-derived unstabilized earthen material mixture. The geotextile fabric formwork exhibits flexibility and permeability properties. A further step may involve maintaining the geotextile fabric formwork with the pourable site-derived unstabilized earthen material mixture in an upright position. And yet another step may involve allowing the pourable site-derived unstabilized earthen material mixture filled in the geotextile fabric formwork to dry while maintained in the upright position.


In another embodiment, a method of fabricating an earthen construction formation may include multiple steps. One step may involve preparing a site-derived earthen material mixture. The site-derived earthen material mixture constitutes a pourable site-derived earthen material mixture. Another step may involve filling a geotextile fabric formwork with the pourable site-derived earthen material mixture. A further step may involve maintaining the geotextile fabric formwork with the pourable site-derived earthen material mixture in an upright position. The geotextile fabric formwork with the pourable site-derived earthen material mixture is maintained on a local ground. And yet another step may involve allowing the pourable site-derived earthen material mixture filled in the geotextile fabric formwork to dry while maintained in the upright position and while on the local ground.


In another embodiment, a method of testing an earthen construction formation prepared by way of a site-derived earthen material mixture may include multiple steps. One step may involve placing a geotextile fabric formwork in a testing support structure. The geotextile fabric formwork exhibits flexibility and permeability properties. The testing support structure supports the geotextile fabric formwork distanced above a local ground. The testing support structure has a multitude of openings residing at a bottom or at more locations thereof. Another step may involve filling the geotextile fabric formwork with the site-derived earthen material mixture while the geotextile fabric formwork is placed in the testing support structure, and then allowing the site-derived earthen material mixture filled in the geotextile fabric formwork to dry while the geotextile fabric formwork is placed in the testing support structure. A further step may involve performing testing to the earthen construction formation.





BRIEF DESCRIPTION OF THE DRAWINGS

Exemplary embodiments will hereinafter be described in conjunction with the appended drawings, wherein like designations denote like elements, and wherein:



FIG. 1 is a perspective view of an embodiment of a geotextile fabric formwork filled with a pourable site-derived unstabilized earthen material mixture while being maintained in an upright position for drying purposes;



FIG. 2 is a schematic representation of drying states of the pourable site-derived unstabilized earthen material mixture;



FIG. 3A is a side view of a conventional planar impermeable concrete formwork;



FIG. 3B is a side view of an embodiment of the geotextile fabric formwork filled with the pourable site-derived unstabilized earthen material mixture while being maintained in the upright position for drying purposes;



FIG. 4 is an enlarged view of an embodiment of the geotextile fabric formwork;



FIG. 5 is a segmented view of an embodiment of form ties at an interior of the geotextile fabric formwork;



FIG. 6 is an enlarged view depicting water escaping the geotextile fabric formwork;



FIG. 7A shows an embodiment of an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via the geotextile fabric formwork;



FIG. 7B shows an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via a conventional planar impervious formwork;



FIG. 7C shows an earthen construction formation prepared from a pourable site-derived earthen material mixture with Portland cement stabilization via a conventional planar impervious formwork;



FIG. 8 shows an embodiment of an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via the geotextile fabric formwork;



FIG. 9 shows an embodiment of an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via the geotextile fabric formwork and allowed to dry via hanging above a local ground from roof rafters;



FIG. 10 shows an embodiment of the geotextile fabric formwork filled with the pourable site-derived unstabilized earthen material mixture while being maintained in the upright position and supported on a local ground for drying purposes via a multitude of support structures and a multitude of wires at an exterior of the geotextile fabric formwork;



FIG. 11 shows an embodiment of the geotextile fabric formwork filled with the pourable site-derived unstabilized earthen material mixture while being maintained in the upright position and supported on a local ground for drying purposes and systematically lowered via actuation as the earthen material mixture dries and decreases in size;



FIG. 12 is a graph of moisture sensor data taken over twenty-two days of an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via the geotextile fabric formwork, of an earthen construction formation prepared from a pourable site-derived unstabilized earthen material mixture via a conventional planar impervious formwork, and of an earthen construction formation prepared from a pourable site-derived stabilized earthen material mixture, with days plotted on an x-axis and moisture content plotted on a y-axis;



FIG. 13 is a table of embodiments of pourable site-derived unstabilized earthen material mixtures having various soil mix proportions;



FIG. 14A is a side view of an embodiment of a testing support structure for a cylinder compression strength test;



FIG. 14B is a bottom view of the testing support structure of FIG. 14A;



FIG. 15A is a perspective view of an embodiment of a testing support structure for a three-point modulus of rupture test;



FIG. 15B is a side view of the testing support structure of FIG. 15A;



FIG. 15C is an unassembled view of the testing support structure of FIG. 15A; and



FIG. 15D is a view of an embodiment of a geotextile fabric formwork that can be used with the testing support structure of FIG. 15A.





DETAILED DESCRIPTION

Embodiments of a method of fabricating an earthen construction formation, as well as a method of testing the same, are presented herein. The earthen construction formation can be employed in use as a building construction component in a larger building construction assembly. A site-derived earthen material mixture is prepared in pourable form and filled in a geotextile fabric formwork. Unlike past cement mixtures, no cement stabilizer additives such as Portland cement are combined in the site-derived earthen material mixture, per an embodiment. In other words, the site-derived earthen material mixture can be unstabilized. The geotextile fabric formwork is flexible and permeable, accommodating shrinkage and settling and other changes in shape as the earthen material mixture dries over time. Its permeability has been shown to facilitate a more uniform and even evaporation and drying action over a greater extent of the earthen material mixture filled in the geotextile fabric formwork. Cracking at form ties is also mitigated. Moreover, the site-derived earthen material mixture minimizes or altogether eliminates off-site transportation of outside materials to construction sites, and can minimize or altogether eliminate the use of framing structural components such as plywood and steel amid fabrication. Compared to past construction building materials and practices, the method of fabricating an earthen construction formation set forth herein is more environmentally sustainable. A more effective and efficient fabrication process of earthen construction formations is furnished.


The method of fabricating an earthen construction formation 10 involves multiple steps. The steps can vary according to differing embodiments based upon—among other potential factors—the soil composition of the subject building construction site and location, as well as the design and construction and desired properties of the ultimately-fabricated earthen construction formation. In an embodiment, the method includes the steps of: i) preparing a site-derived earthen material mixture, ii) filling a geotextile fabric formwork 12, iii) maintaining the geotextile fabric formwork 12 in an upright position, and iv) allowing the site-derived earthen material mixture to dry while in the upright position. Still, the method of fabricating the earthen construction formation 10 could include more, less, and/or different steps in other embodiments. Embodiments of the earthen construction formation 10 fabricated by the method described herein are depicted in FIGS. 7A and 8 (in FIG. 8, a fabric pattern and imprint is visible). The earthen construction formation 10 here has a generally rectangular shape. Its shape is dictated in large part by the shape of the accompanying geotextile fabric formwork 12. On its front and rear surfaces, the shape of the earthen construction formation 10 can resemble a grid of soft curves with an overall pattern of tufted upholstery, according to an embodiment. There can be numerous earthen construction formations 10 in a single building construction assembly. The earthen construction formation 10 can be used as non-structural wall panels, per at least some implementations. Further, in some implementations, the earthen construction formation 10 can be utilized as infill.


A multitude of form ties 14 can be disposed in the earthen construction formation 10. The form ties 14 can have varying designs, constructions, configurations, and quantities in differing embodiments. The form ties 14 are disposed in place in the geotextile fabric formwork 12 amid the drying of the site-derived earthen material mixture. The form ties 14 span through an interior of the geotextile fabric formwork 12, as depicted in FIG. 5. The form ties 14 serve to laterally restrain and hold the geotextile fabric formwork 12, and generally keep its shape, when filled with the site-derived earthen material mixture. The geotextile fabric formwork 12 and form ties 14 together temporarily holds the earthen material mixture in a shape and size intended until a dried state is reached. Over-sized washers can be used with the form ties 14 in order to distribute and reduce stresses on the geotextile fabric formwork 12.


In the method, the step of preparing the site-derived earthen material mixture can involve various procedures in differing embodiments. In an embodiment, the preparation includes excavating a portion of earth and soil at the subject building construction site and location. Such excavation is not uncommon for foundations, basements, utilities, and for leveling purposes. The amount excavated depends on the size and quantity of the earthen construction formations 10 sought-after for fabrication. The excavated earth and soil can be augmented with other constituent materials in order to effect desired strength, durability, stability, binding, shrinkage, and pourability—among other potential properties—of the site-derived earthen material mixture. The constituent materials of the site-derived earthen material mixture need not be exclusively obtained on-site and at the subject building construction location, according to some embodiments. The phrase “site-derived” is not intended to mean solely obtained on-site and without the addition of off-site constituent materials. In some embodiments, a majority of the constituent materials of the site-derived earthen material mixture are procured on-site at the subject building construction site and location. Clay can be added to the excavated earth and soil, as well as water. Another addition could be a small amount of fiber, per some embodiments. Still, other augmented constituent materials are possible. The excavated earth and soil and any added constituent materials can be mixed together via hand-mixing or machine-mixing to prepare a pourable mixture. When water is added, according to an embodiment, it can be soaked with the excavated earth and soil and other constituent materials for a length of time. The length of time can vary and, per an embodiment, can be twenty-four (24) hours or longer; still other durations are possible in other embodiments including shorter or longer durations. Yet still, no soaking with the water need occur according to some embodiments. The prepared site-derived earthen material mixture can lack, and hence be free of, Portland cement—that is, the site-derived earthen material mixture can be a site-derived unstabilized earthen material mixture. Rather, according to some embodiments, clay can effectively function as a binder for aggregates in the site-derived earthen material mixture. To remove any air bubbles that may be present in the site-derived earthen material mixture, the mixture can be subject to vibration.


The composition and make-up of the site-derived earthen material mixture can vary according to differing embodiments. Its precise composition can be dictated by composition of the excavated earth and soil at the particular building construction location, as well as any added constituent materials. In an embodiment, the site-derived earthen material mixture can include varying amounts of aggregate, water, and clay. The clay can be illite clay, granite clay, or some other type of clay, per certain embodiments. In an example, the site-derived earthen material mixture includes approximately 52 percent (%) by weight aggregate, 18% water, and 30% clay; the water and clay can be added. Still, many other embodiments with other constituent materials and percentages are possible.


The table provided in FIG. 13 sets forth numerous examples of pourable site-derived unstabilized earthen material mixtures having various soil mix proportions. Tests were performed to determine mixes, pourability, and cracking of poured earth. Three basic material mixes were replicated: A (78% aggregate, 8% clay, 13% water by weight), B (54% aggregate, 30% clay, and 12% water by weight) and C (24% aggregate, 55% clay, 11% water by weight). In the testing, the first forms were one foot×one foot×six inches thick rectangular prisms made of plywood. The A and B mixes were pourable, relatively speaking. The C mix was rigid once the clay was hydrated and developed air pockets and voids as it was packed into the mold. It was determined that experiments would continue with mixes between A and B, as the A mix was easily friable on the surface, due to the greater amount of exposed aggregate and the B mix was stiffer than the pourable mix sought for the larger mockup. These explorations were all done with the illite clay: Hawthorne fire clay from pottery-style clay.


Other testing was conducted at the Rio Grande Valley in Albuquerque, New Mexico, U.S.A. An eighteen inch×eighteen inch×six inch thick void in the ground was excavated. The excavated material was piled onto a tarp and then field sieves were used to separate the pile into its constituent parts (see Table 1). The sieves produced a range of particle size from Agg. >0.2″, Sand 0.05-0.2″, Silt 0.002-0.05″, Clay <0.002. Those piles were weighed and classified by size.









TABLE 1







Proportions of components of found site-soil.










Initial Sifting

Soaked Sifting














Aggregate 4000
19 lbs 8 oz
Aggregate
5
oz


Microns+


Sand 500-4000
27 lbs 9 oz
Sand
40
lbs










Microns+





Silt 63-500
7 lbs 11 oz
Silt
12 lbs 5 oz


Microns











Clay <63 Microns
6.3
oz
Clay
2 lbs 3 oz












Organic Materials
<2
oz
Organic Materials
6-8
oz









In the testing, as it seemed likely that some of the particle sizes classified as aggregate were clay material adhering to some larger size object, it was decided to pursue a traditional Pueblo pottery method of gathering clay to separate clay from other materials. The materials were soaked for 24 hours and allowed to pass through a fine cloth sieve in a traditional clay harvesting manner to separate silt from clay. Each pile of sieved particle sizes was soaked separately and then poured through fine cloth. The fabric created a bowl-shaped form that filled with the materials that did not filter through. In most cases, those materials separated into a fine layer of clay on the top of the sandy silty materials. As they did not filter through, the forms dried in place. Each of those forms held its own texture, due to the different particle sizes of sands and silts. The clay at the top of the forms showed small organic pieces that floated to the top of the material as it was in liquid form and the inherent shrinking and cracking in the clay. The fabric print on the bottom of the forms was the surface texture of the fabric formwork used. This process required several days for each hydrated form to dry completely. Further, the material was heavy in organic matter and in silts, as befits a river deposited soil. Much more clay was harvested from the soil by soaking it. The results from initial sieving and from the soaking process are shown in Table 1. The clay was harvested from below the fine cloth and on top of the dried forms that did not drip through the cloth. The secondary processing resulted in roughly five times as much clay from the material in contrast to the original sieving process. To create an optimal mix, according to an embodiment, once the site soil proportions were defined, off-site clay was added (see Table 2 below) to create a mix of 30% clay.









TABLE 2







Proportions of components of found site-soil.












All Site
Weight
Site Soil +
Weight



Soil Mix
(Lbs.)
Off-Site Clay
(Lbs.)
















Site Silt and Clay
7
Hawthorne Fire
11



Particles

Clay 35 mesh



Site Sand
5
Site Sand
6



Site Aggregate
15
Site Aggregate
18



Water
5
Water
8




32 Total

43 Total










In further testing, soil was excavated in an eighteen inch×eighteen inch×eight inch hole. A jar sedimentation test informed that the material was 5% organic, 12% silt/clay, 33% sands, and 50% of it was aggregates. The soils were then sieved into particle sizes to determine their classification. Soil constituent materials can be identified by their particle size: Agg. >0.2″, Sand 0.05-0.2″, Silt 0.002-0.05″, Clay <0.002. Our sieves approximated these categories. By sieve, 6% was silt clay, 36% was sands, and 57% was aggregate with some organic included. The testing, sorting, and mixing method developed for site soils can take place on-site in order to minimize the carbon impact of building and to fully understand the terroir of the building materials. For this testing, a graded sieve set was used to identify soil types in the field. Particles were screened with 5 mesh (4,000 microns), 10 mesh (2,000 microns), 35 mesh (500 microns), 60 mesh (250 microns), 120 mesh (125 microns), and 230 mesh (63 microns) screens. This resulted in a silty clay rather than a completely pure clay. By weight, 9 lbs. of the excavated material was determined to be in the range of clay and silt particles, 50 lbs. of material was determined to be in the range of sands, and the final 78 lbs. was in an aggregate scale and above. A significant portion of the large aggregate was urban detritus, concrete, brick, and glass. The particles were then mixed by dry weight with one mix created completely from site excavated materials and the second mix adding 27 lbs. of Hawthorne clay to create the optimal mix, per an embodiment. Both mixes had agave fibers added to form a binder from a native, non-irrigated plant. The Hawthorne clay was excavated off-site and transported to the testing site, but all aggregates and sands came from the testing site.


In this further testing, Table 3 below shows the amounts of particle size sorted material from the site, as well as the mix used, which was determined by the earlier testing to be optimal, per an embodiment (30% clay, 18% water, 52% aggregates—divided into 25% sand and 75% aggregates above ¼″ in size). The first column shows the site soil mix with no added clay. Two considerations emerged in the process of mixing and hydrating site materials for pouring. First, after a week of soaking, the site soil mix had a gaseous smell indicating organic materials in the mix. The second mix, with Hawthorne clay added, did not have any odor after the week of soaking. Second, soil dampness, despite the dry climate of New Mexico, added to the difficulty of sieving clay out of a raw material. Clay may also be present in larger aggregate sizes, clinging together and creating a pebble-like form.









TABLE 3







All site soil mix vs. site soil + off-site clay.










All Site
Weight

Weight


Soil Mix
(lbs.)
Site Soil
(lbs.)













Silt and Clay
09.0
Hawthorne Fire
27.0


Particle Sizes

Clay 35 Mesh


Site Sand
03.9
Site Sand
12.0


Site Aggregate
11.7
Site Aggregate
35.0


Water
05.4
Water
16.0



30 lbs. Total

90 lbs. Total









Furthermore, when water activates clay, it swells as its microscopic platelets are surrounded with a thin film of water during the hydration phase. The distance between the platelets reduces as the water evaporates and leaves the material after pouring and drying. The platelets rearrange in a different pattern because of the electrical attraction between the platelets. This attraction becomes the binding force that holds the fine and coarse aggregates together. According to some estimates, water evaporation can cause linear shrinkage ratio in the ranges between 3% and 12% with wet mixtures. Due to such shrinkage, the methods used to form poured earth make shrinkage a not insignificant characteristic of the material. This was observed firsthand when a crack formed through a test block just beneath a static form tie when testing poured earth in conventionally rigid formwork early in the research. It was noted that as the material shrank and fell due to gravity within the planar surfaces, the material above the form ties was held up and created a crack that separated the material above and below both form ties.


Dozens of material tests were performed focusing on the component percentages of 52 percent (%) by weight aggregate, 18% water, and 30% clay, according to this embodiment. Four prototype sculptural walls were constructed, two at six feet and four feet tall and two at block scale, as in-field proof of concept. In each project, two-thirds of the aggregate used was coarse decomposed granite, and one-third was sand for a mix of particle sizes. The standard mixtures were sieved at a sample ten pounds (lb.) mix amount to determine particle size distribution in the combined aggregate material where 40% of the aggregate is larger than 4000 microns (5 mesh), 14% is larger than 2000 microns (10 mesh), and 20% is more significant than 500 microns (35 mesh). The remaining 25% of the mix is finer particles: 10% at 60 mesh, 9% at 120 mesh, and 2.5% at 230 mesh. The clay used was Hawthorne Fire clay purchased at a 350-mesh specification. The components were incrementally combined in five-gallon buckets according to the mix ratio and mechanically mixed with a mud mixer attachment in a hand-held electric drill. Thorough mechanical mixing benefits the material since the clay becomes a dispersing agent, evenly distributes particles, and mitigates unwanted clumping or settling. The buckets were covered with tarps, and the material was allowed to hydrate for 48 hours before pouring. The hydration enables the water to soak evenly into the different material components, including the clay platelets.


As a control to the unstabilized poured earth mix in these material tests, a stabilized poured earth (SPE) mix was prepared. The SPE mix was identical, except 4% of the clay was removed and Portland cement was added as a stabilizer just before pouring. The components were mixed and left to hydrate for 48 hours. Four percent Portland cement by dry weight was added and thoroughly mixed into the material. The Portland cement was mixed in just before the pour so that it would not force the material to solidify during the hydration period. The 4% Portland cement proportion was derived from a known formulation. Two types of test formwork were constructed—fabric and planar impervious melamine—each twelve inches×eighteen inches×four inches thick. The fabric form was poured with the unstabilized poured earth mix, and the planar impervious melamine was filled with the SPE mix. Each formwork had an identical form tie grid composed of ⅜″ PEX tubing (cross-linked polyethylene) and ¼″ threaded rod with nuts and bolts, spaced 5″ apart and arranged in a diamond pattern. The formwork was attached to a nominal 2″×8″ wooden base. The fabric formwork was made from a woven geotextile and sewn into a tube at the desired dimensions. The fabric was stapled to the wooden base and covered with plywood to help further pinch the fabric to the base. The top of the geotextile bag was folded, sewed to create a hemmed spline along the long sides, and a piece of #3 (⅜″ diameter) rebar was inserted into each spline, protruding approximately 1½″. The protruding bars were hung from a 2″×4″ wooden frame with two loosely tensioned bungee cords. Form ties controlled the reusable geotextile bag on the long sides. The planar forms were two four-sided boxes constructed of ⅝″ thick white melamine at the desired dimensions to test drying time and cracking. The flat planes of melamine were screwed together at the corners and then fastened them to the 2″×8″ wooden base. Form ties controlled the long sides of the boxes.


A replicable three-week test was performed of the two formwork conditions with VH-400 moisture sensors and an eight-channel data logger, both obtained from Vegetronix®, Inc. of Riverton, Utah, U.S.A. The sensors were cast horizontally in each of the three blocks between the top two form ties and the top to form ties to chart the internal drying of the material at different elevations. The three conditions included a fabric formed unstabilized poured earth mix in a geotextile bag with form ties spaced on a diagonal grid at 5″ centers and hung from elastics (e.g., FIG. 3B), and a conventional planar impervious formwork built of planar waterproof melamine panels with form ties spaced on a diagonal grid at 5″ centers poured with unstabilized poured earth mix (e.g., FIG. 3A). A second conventional planar impervious formwork made of melamine panels with form ties spaced on a diagonal grid at 5″ centers poured with the SPE (i.e., poured earth with 4% Portland cement stabilizer). To record the distance, the fabric formed unstabilized poured earth mix bag moved from its original distension with the wet material to shrinking away from a surface of the bag and dimensions of the final block, an LEO Artec 3D scanner was employed. These scans allowed us to make comparative three-dimensional mesh models at various points in the drying and shrinking process (e.g., FIGS. 1 and 2; UsFFPE in FIG. 2 stands for unstabilized fabric formed poured earth).


The moisture sensor data shows a pattern of moisture being removed by the breathable formwork from the poured earth and retained in the earthen material by the melamine panels. The graph of FIG. 12 shows the conventionally-formed blocks losing moisture from a top sensor but largely remaining wet on the bottom. The fabric formwork has a smooth and steady curve towards less moisture throughout the block. Upon removal of the formwork after twenty-two days of drying (FIGS. 7A, 7B, 7C), it was found that the unstabilized poured earth in the conventional planar impervious formwork (i.e., FIG. 7B) had material at the bottom which was still malleable. The block of FIG. 7B did not allow the entire formwork to be removed as it was too wet to stand. There was also a distinct line L between dry material in the top three inches of the form, which had hardened, and the malleable, still damp material in the bottom fifteen inches. The poured earth stabilized with Portland cement block test in conventional planar impervious formwork (i.e., FIG. 7C) had a smooth surface and a slightly damp cloth at the bottom. Still, it remained a rigid self-supporting block once the formwork was removed. The moisture sensor data shows that the Portland cement allowed the material to retain rigidity while the clay was still drying. After twenty-two days, the fabric formed unstabilized poured earth block (i.e., FIG. 7A) was completely rigid, and the fabric was removed to display no visible moisture or through cracking. The unstabilized poured earth poured in conventional planar impervious formwork of FIG. 7B showed cracks throughout the material and sheering that separates roughly a third of the volume of the pour from the pour itself. These lines occurred in relationship to form ties.


In the test blocks, moisture sensor data showed that while all the material started at a similar dampness, after four days, the fabric-formed block showed much lower moisture levels that continued to drop much faster than in the conventional planar impervious formwork, which indicated little to no change throughout the experiment. Visual inspection also showed water beading (WB) on the geotextile surface in the first hours after pouring and moisture accumulating outside of the bottom of the fabric form (see FIG. 6). Therefore, according to this example testing, fabric formwork allowed for the drying of poured earth faster than conventional planar impervious formwork. Planar impervious formwork creates an internal ecosystem constraining drying, as the unmolding of wet material after twenty-two days of drying showed. Furthermore, temperature can affect dryness, as is visible in the moisture sensor data. Thus, while overall lines trend over the weeks, each line reflects the diurnal 30-40 F-degree shift in the desert temperatures in Albuquerque, New Mexico, where the tests took place. Also relevant is the ambient average humidity of May and June, between 3-30%. Poured earth was well adapted to such humidity levels.


Further, with reference again to FIG. 2, compiled section slices taken at the exact location through the 3D mesh models show the reduction in volume and the shifts in form as the material moves over time, thus creating a four-dimensional system. The first scan shows the fabric bag filled with the material at the time of the pour, indicating the maximum stretch of the geotextile. The thickness of the form is constrained by the length of the form ties, which subsequently dries and shrinks away from the surface of the geotextile and the initial height of the block in the following scan two weeks later. After initial shrinkage, the external form of the material moved little during the interior drying period. Scans of the surface of the bag demonstrated both the distended surface form and the gathering of the fabric as the earth shrinks from it, compared to the final scan when the fabric has been removed. As demonstrated by the last scan, the block had a smooth surface; it had retained the initial form but was retracted from the distended bag due to shrinkage. In terms of overall shrinkage, the mesh models allowed for a comparative calculation of the volume upon casting and the final block, further quantifying the shift in form with the shrinkage of the material. The last block was 7.6% smaller than the original pour. The scans also showed that the flexible system allows the form ties to drop down with the shrinking material, preventing cracks at the form ties. The scan provided information about the need for a responsive hanging system that can accommodate the shrinkage of the poured earth in larger forms without Portland cement stabilization.


Conclusions of this testing, according to certain embodiments, may include i) in non-porous planar impervious formwork, poured earth cracks and does not dry within three weeks, ii) without the use of Portland cement, but iii) shrinking is accommodated and drying time is accelerated if poured earth is cast into fabric formwork hung from expandable elastics. The data gathered by the moisture sensors corroborate physical observations. Additionally, this testing proved, at least according to an embodiment, that fabric forms hung from elastic are an alternative to Portland cement stabilization for poured earth casting with formwork qualities that complement the intrinsic material properties of poured earth. Furthermore, the fabric formed unstabilized poured earth forming system tested created a responsive forming system for the less-predictable material. Similarly, the fabric formed unstabilized poured earth forming system did not statically hold the fabric. Still, it let the mix move as it shrinks and settles to avoid cracking over time, thus creating a four-dimensional wall system. The floating form ties acted as a temporary structure by limiting the expansion of the material. Alternatively, fabric formwork hung with elastics accommodated uniform drying and shrinkage of unstabilized poured earth. The woven geotextile responded to the latent material properties of the soil by allowing it to evacuate water during the drying process. The fabric allowed the poured material to expand into the gaps between the form ties, permanently capturing the liquid state of the earth to create a curved surface. Following the intrinsic properties of the shrinking material, the testing diverted from conventional planar and rectilinear forming methods.


In the method, the step of filling the geotextile fabric formwork 12 with the site-derived earthen material mixture can involve various procedures in differing embodiments. The site-derived earthen material mixture, when sufficiently hydrated, can be a liquid and flexible material that is pourable. The filling can be carried out in different ways in differing embodiments. In one embodiment, the filling is carried out manually with buckets of site-derived earthen material mixture; and in another embodiment, the filling can be carried out more automatically and machine-based, such as via front-loader equipment or other types of filling equipment. The geotextile fabric formwork 12 can be flexible and malleable in nature, and can be permeable to moisture. The geotextile fabric formwork 12 can have an open top 16 for filling purposes, and can be closed at its remaining sides. The geotextile fabric formwork 12 constitutes a breathable formwork that, according to an embodiment, can permit water to move out of clay-based materials uniformly from all areas of the poured site-derived earthen material mixture. In this way, shrink and/or swell effects of the clay can be mitigated, and cracking can hence be minimized. The geotextile fabric formwork 12 can allow for time-based shifts of material, swell, shrink, settling, dewatering, and compression, per some embodiments. In certain cases, the geotextile fabric formwork 12 has been found to be able to accommodate material shrinkage of as much as 8% in size, or 4% in size; still, other quantities of shrinkage accommodation are possible in other embodiments. In an embodiment, the geotextile fabric formwork 12 can be reused in a multitude of fabrication processes after fully drying and removal from a fabricated earthen construction formation.


In an example embodiment, the geotextile fabric formwork 12 was produced via sewing. The geotextile fabric formwork 12 can have a front face of 39″ and a back face of 41″ widths respectively. The front and back faces can be connected with sewn panels to create a width of 5″, with slip pockets for two battens to constrain the material and create a key in the edge of the pour. The bottom edge of the bag can be left open with a 6″ margin at the bottom to attach to the base of the pour. The top edge of the bag can be hemmed to create a slot for two ⅜″ curved rebar rods. The bag can be measured prior to sewing with a diagonal grid at 5″ on center on the 39″ width side and then an expanded grid out from a centerline on the 41″ width side. These markings can then be drilled through and an assembly of a threaded rod, a PEX sheath, and nut and washers at each end can be inserted to create a grid of form-ties. In another example embodiment, a woven geotextile fabric was sewn with a panel of 20″×18″ tall on the back side and 15″×18″ tall on the front side for producing the geotextile fabric formwork 12. The side panels were kept at 5″ continuously and the tubing that maintains a rigid edge at the top of the fabric form was bent to a radius that allowed for a roughly 18″ center. All seams were sewn three times with a roughly 3/16″ zigzag stitch and poly thread. Form ties made of ⅜″ PEX tubing with ¼″ threaded rod inserts at 5″ on center were laid out in a grid, with one center tie and four diagonally symmetrical ties. Still, other designs, constructions, and dimensions of the geotextile fabric formwork 12 are possible in other embodiments.


In the method, the step of maintaining the geotextile fabric formwork 12 with the site-derived earthen material mixture therein in an upright position can involve various procedures in differing embodiments. The site-derived earthen material mixture is not self-supporting and self-stabilizing when initially filled in the geotextile fabric formwork 12 and without at least some duration of drying. This step can be performed at a temporary staging location on the subject construction building site and location, for instance. The upright position is demonstrated when a longitude or lengthwise extent of the geotextile fabric formwork 12 with the site-derived earthen material mixture therein is generally arranged orthogonally with respect to a local ground LG. The geotextile fabric formwork 12 stands tall on the local ground LG when in the upright position. The upright position is depicted in FIGS. 1, 3B, 9, 10, and 11. Maintaining the geotextile fabric formwork 12 with the filled site-derived earthen material mixture in the upright position when drying is taking place has proven beneficial according to at least some embodiments. It has been found to facilitate fabrication of the earthen construction formation—more uniform and even drying can be enhanced, material shrinkage can be more readily accommodated, crack development in the earthen construction formation can be more readily mitigated, and overall integrity of the intended size and shape can be facilitated, among other potential enhancements. The upright position can be maintained in various ways according to differing embodiments.


In an embodiment, the geotextile fabric formwork 12 with the site-derived earthen material mixture therein is maintained in the upright position for drying purposes via hanging slightly above or directly upon and in abutment with the local ground LG. Supports 18 can be employed for such hanging. The geotextile fabric formwork 12 with the site-derived earthen material mixture therein can be suspended above or upon the local ground LG via the supports 18. A wooden base can be provided at the bottom of the geotextile fabric formwork 12 for support and for attachment to the geotextile fabric formwork 12. The supports 18 can be secured to the geotextile fabric formwork 12 adjacent the open top 16 thereof. One or more rigid bars can be inserted or otherwise installed with the geotextile fabric formwork 12 to more readily brace such securement. When hung, a bottom of the geotextile fabric formwork 12 can rest upon the local ground LG. The supports 18 can have varying designs, constructions, and components in differing embodiments to effect its holding functionality. In the embodiment of FIGS. 1 and 3B, the supports 18 are in the form of elastic supports 20. The elastic supports 20 can be bungee chords, as an example. The elastic supports 20 can extend from a rigid post or beam 22 located above the geotextile fabric formwork 12, as depicted. The elastic supports 20 can be wrapped around or otherwise anchored to the rigid post 22. With reference to FIG. 9, in other embodiments a permanent building structural member 24 of the larger building construction assembly can be utilized as a temporary holding and anchoring structure for the supports 18 during hanging. In the example embodiment of FIG. 9, the permanent building structural member 24 is a multitude of roof rafters 26; still, in other embodiments other types of permanent building structural members are possible. While not depicted in FIG. 9, the roof rafters 26 can be designed and constructed to be rotated downward for placement against the local ground LG for such hanging. Furthermore, in other embodiments, the supports 18 could be inelastic straps.


It has been found that, per at least some embodiments, material shrinkage of the site-derived earthen material mixture due to drying and amid being held in the upright position can have an adverse effect on the ultimately-fabricated earthen construction formation. In one example, it was observed that material shrinkage caused a reduction in overall height and longitudinal extent from an initial 48 inches to a final 45.5 inches—a loss of approximately 2.5 inches in height. The geotextile fabric formwork 12 and the site-derived earthen material mixture could be deformed and distorted in unwanted ways due to material shrinkage when held in the upright position. Increased compression and pulling of the geotextile fabric formwork 12 on the site-derived earthen material mixture, as well as increased crack development at the form ties 14, have been observed as a consequence of shrinkage in the upright position and the gravitational forces exerted thereupon. Accordingly, physical lowering of the geotextile fabric formwork 12 with the site-derived earthen material mixture therein from its hung position at certain stages of drying and accompanying material shrinkage has been determined to partly resolve or altogether preclude such unwanted deformations. The lowering accommodates and accounts for any material shrinkage that may occur. The lowering distance and direction occurs vertically and toward the local ground LG. The elastic supports 20 described above furnish such lowering of the geotextile fabric formwork 12 with the site-derived earthen material mixture. The elastic supports 20 stretch as shrinkage occurs and can keep the geotextile fabric formwork 12 with the site-derived earthen material mixture therein in abutment with the local ground LG. This, in a sense, provides a passive lowering system.


With reference to FIG. 10, another embodiment of the step of maintaining the geotextile fabric formwork 12 with the site-derived earthen material mixture therein is presented. This embodiment has been shown to minimize or altogether eliminate any lifting pressure on the geotextile fabric formwork 12 and material mixture that could otherwise cause unwanted deformations and distortions in the material mixture. Support is furnished at front and rear faces of the geotextile fabric formwork 12 at the exterior thereof. The design, construction, and components of such support can vary according to differing embodiments. In FIG. 10, a multitude of support structures 28 and a multitude of wires 30 are provided; still, other components could be provided in other embodiments. The support structures 28 and wires 30 work together to maintain the upright position of the geotextile fabric formwork 12 with the site-derived earthen material mixture therein without the exertion of substantial lifting pressure. In installation, as shown, the support structures 28 and wires 30 are located at the exterior of the geotextile fabric formwork 12. The support structures 28 can extend from the form ties 14 and can be connected thereto. The support structures 28 can be in the form of spacers manufactured via a three-dimensional (3D) printing process or manufactured via some other way. Pass-throughs residing in the support structures 28 accommodate reception and insertion of the wires 30 in assembly. The wires 30 can extend vertically between the local ground LG and an upper post or beam positioned above the geotextile fabric formwork 12. The wires 30 span through the pass-throughs of the support structures 28. A single wire 30 spans through a pair of vertically-spaced support structures 28, per this embodiment. The wires 30 can be in the form of tension wires. The support structures 28 are braced by the wires 30, furnishing support of the geotextile fabric formwork 12 with the site-derived earthen material mixture therein. As material shrinkage occurs, the support structures 28 and accompanying form ties 14 are able to slide down the wires 30, thereby accommodating such shrinkage.


Still further, an active and automatic lowering system can be implemented in certain embodiments. With reference now to FIG. 11, an embodiment of such an automatic lowering system is presented. The automatic lowering system can have various designs, constructions, and components in differing embodiments. In the embodiment of FIG. 11, a sensor-based and pulley lowering system is depicted. Here, the system includes actuators 32, connections 34, sensors 36, and a controller 38; still, more, less, and/or different components could be provided in other embodiments. The actuators 32 can be linear actuators that release and lower the connections 34 and hence cause lowering of the geotextile fabric formwork 12 with the site-derived earthen material mixture therein upon commands from the controller 38. There can be two actuators 32 or another quantity of actuators provided. The actuators 32 are supported on an upper post or beam that is positioned above the geotextile fabric formwork 12 in this embodiment. Movement of the actuators 32 back and forth raises and lowers the geotextile fabric formwork 12 with the site-derived earthen material mixture therein relative to the local ground LG. The connections 34 extend from the actuators 32 and to the geotextile fabric formwork 12. The connections 34 can be part of the supports 18, previously described. The connections 34 are in the form of wires in the embodiment of FIG. 11. The wires each traverse over a pulley and extend to the geotextile fabric formwork 12. The wires can be clamped or otherwise attached to the geotextile fabric formwork 12 with the site-derived earthen material mixture therein. The sensors 36 are installed at the geotextile fabric formwork 12 to sense a parameter thereof for initiating lowering. The sensors 36 are electrically coupled to the controller 38 and send signals indicative of the sensed parameter for receipt by the controller 38. In the embodiment of FIG. 11, the sensors 36 are in the form of moisture sensors provided by Vegetronix®, Inc. of Riverton, Utah, U.S.A. The moisture sensors are embedded at various positions within the site-derived earthen material mixture in order to detect a moisture content and value thereat. There can be a multitude of moisture sensors at a multitude of locations. For example, a first moisture sensor can be disposed at an upper region of the site-derived earthen material mixture, a second moisture sensor can be disposed at a middle region of the site-derived earthen material mixture, and a third moisture sensor can be disposed at a lower region of the site-derived earthen material mixture; still, other quantities and other locations are possible in other embodiments. Further, the controller 38 can manage actuation of the actuators 32 based on the received data from the sensors 36. The controller 38 can be a micro-controller that is programmed to actuate the actuators 32 for lowering in response to drying of the site-derived earthen material mixture as determined by the sensed moisture, according to this embodiment.


Furthermore, a manual lower system can be implemented in certain embodiments. One example is ratcheted straps in connection with the geotextile fabric formwork 12 with the site-derived earthen material mixture therein. The manual lowering can be employed according to a predetermined lowering schedule. For example, a first lowering by a first amount and distance can be carried out at a first time, a second lowering by a second amount and distance can be carried out at a second time, and a third lowering by a third amount and distance can be carried out at a third time, etc. In one particular example, the lowering can be carried out at a rate of one-half an inch per day for the first five days of drying; still, other lowering distances and timings are possible in other examples.


In the method, the step of allowing the site-derived earthen material mixture to dry while in the upright position can involve various procedures in differing embodiments. The geotextile fabric formwork 12 with the site-derived earthen material mixture therein can be maintained in the upright position according to the various embodiments described herein while drying occurs. The precise duration of complete and final drying can vary according to the composition of the site-derived earthen material mixture and the climate conditions of the drying environment, among other potential factors. In an example, the drying duration can be several weeks.


With reference now to FIGS. 14A-15D, embodiments of a testing support structure 40 are presented for a method of testing the earthen construction formation 10. The method involves multiple steps. The steps can vary according to differing embodiments based upon the particular testing executed and the building code standards involved, among other potential factors. In an embodiment, the method includes the steps of: i) placing the geotextile fabric formwork 12 in the testing support structure 40, ii) filling the geotextile fabric formwork 12 with the site-derived earthen material mixture, and iii) performing testing to the earthen construction formation 10. Still, the method of testing the earthen construction formation 10 could include more, less, and/or different steps in other embodiments.


The testing support structure 40 is designed and constructed based on the particular testing to be executed. In the embodiment of FIGS. 14A and 14B, the testing involved is a cylinder compression strength test. The cylinder compression strength testing can be according to the standards of the 2015 New Mexico Earthen Materials Building Code, or can be according to other standards in other embodiments. In the embodiment here, the testing support structure 40 is designed and constructed to form an appropriately shaped and sized earthen construction formation 10 for testing purposes, and to allow the earthen construction formation 10 to be fabricated based at least partly upon the method of fabricating an earthen construction formation 10 set forth above. The testing support structure 40 includes a bottom wall 44 and numerous legs 46 extending therefrom. The bottom wall 44 supports the geotextile fabric formwork 12 above the local ground LG. A multitude of openings 42 reside in the bottom wall 44 to allow moisture from the geotextile fabric formwork 12 and from the site-derived earthen material mixture to escape the testing support structure 40. The legs 46 serve as side walls in the testing support structure 40. The geotextile fabric formwork 12 is placed in the testing support structure 40. The geotextile fabric formwork 12 is set in place on the bottom wall 44 and among the legs 46 at its sides. The open top 16 of the geotextile fabric formwork 12 is exposed for filling of the site-derived earthen material mixture while the geotextile fabric formwork 12 remains placed in the testing support structure 40. After filling, the site-derived earthen material mixture is allowed to dry while the geotextile fabric formwork 12 remains placed in the testing support structure 40. Once drying is complete, the earthen construction formation 10 can be removed from the geotextile fabric formwork 12 for subsequent testing purposes.


In the embodiment of FIGS. 15A through 15D, the testing involved is three-point modulus of rupture test. The three-point modulus of rupture testing can be according to the standards of the 2015 New Mexico Earthen Materials Building Code, or can be according to other standards in other embodiments. In the embodiment here, the testing support structure 40 is designed and constructed to form an appropriately shaped and sized earthen construction formation 10 for testing purposes, and to allow the earthen construction formation 10 to be fabricated based at least partly upon the method of fabricating an earthen construction formation 10 set forth above. As before, the testing support structure 40 includes the bottom wall 44 and legs 46 extending therefrom. The bottom wall 44 supports the geotextile fabric formwork 12 above the local ground LG. The openings 42 reside in the bottom wall 44 to allow moisture from the geotextile fabric formwork 12 and from the site-derived earthen material mixture to escape the testing support structure 40. Unlike the previous embodiment, a main body 48 of the testing support structure 40 is rectangular in shape and allows the geotextile fabric formwork 12 to be placed on its side rather than upright for filling and drying purposes. Plates 50 are further included in this embodiment for holding the geotextile fabric formwork 12 open at least during filling of the site-derived earthen material mixture.


As used herein, the terms “general,” “generally,” and “approximately” are intended to account for the inherent degree of variance and imprecision that is often attributed to, and often accompanies, any design and manufacturing process, including engineering tolerances—and without deviation from the relevant functionality and outcome—such that mathematical precision and exactitude is not implied and, in some instances, is not possible. In other instances, the terms “general,” “generally,” and “approximately” are intended to represent the inherent degree of uncertainty that is often attributed to any quantitative comparison, value, and measurement calculation, or other representation.


It is to be understood that the foregoing description is of one or more preferred exemplary embodiments of the invention. The invention is not limited to the particular embodiment(s) disclosed herein, but rather is defined solely by the claims below. Furthermore, the statements contained in the foregoing description relate to particular embodiments and are not to be construed as limitations on the scope of the invention or on the definition of terms used in the claims, except where a term or phrase is expressly defined above. Various other embodiments and various changes and modifications to the disclosed embodiment(s) will become apparent to those skilled in the art. All such other embodiments, changes, and modifications are intended to come within the scope of the appended claims.


As used in this specification and claims, the terms “for example,” “e.g.,” “for instance,” and “such as,” and the verbs “comprising,” “having,” “including,” and their other verb forms, when used in conjunction with a listing of one or more components or other items, are each to be construed as open-ended, meaning that the listing is not to be considered as excluding other, additional components or items. Other terms are to be construed using their broadest reasonable meaning unless they are used in a context that requires a different interpretation.

Claims
  • 1. A method of fabricating an earthen construction formation, the method comprising: preparing a site-derived earthen material mixture, wherein the site-derived earthen material mixture lacks cement stabilizer additives, the site-derived earthen material mixture constituting a pourable site-derived unstabilized earthen material mixture;filling a geotextile fabric formwork with the pourable site-derived unstabilized earthen material mixture, the geotextile fabric formwork exhibiting flexibility and permeability;maintaining the geotextile fabric formwork with the pourable site-derived unstabilized earthen material mixture in an upright position; andallowing the pourable site-derived unstabilized earthen material mixture filled in the geotextile fabric formwork to dry while maintained in the upright position.
  • 2. The method as set forth in claim 1, wherein preparing the site-derived earthen material mixture comprises adding water to the site-derived earthen material mixture.
  • 3. The method as set forth in claim 1, wherein maintaining the geotextile fabric formwork in the upright position comprises hanging the geotextile fabric formwork adjacent a local ground.
  • 4. The method as set forth in claim 3, wherein the geotextile fabric formwork filled with the pourable site-derived unstabilized earthen material mixture is hung via at least one elastic support.
  • 5. The method as set forth in claim 3, wherein the geotextile fabric formwork filled with the pourable site-derived unstabilized earthen material mixture is hung adjacent the local ground from at least one permanent building structural member.
  • 6. The method as set forth in claim 5, wherein the at least one permanent building structural member is at least one roof rafter.
  • 7. The method as set forth in claim 1, wherein maintaining the geotextile fabric formwork in the upright position comprises providing a plurality of support structures extending from form ties of the geotextile fabric formwork at an exterior of the geotextile fabric formwork, the geotextile fabric formwork being supported on a local ground.
  • 8. The method as set forth in claim 7, wherein maintaining the geotextile fabric formwork in the upright position further comprises providing a plurality of wires at the exterior of the geotextile fabric formwork, the plurality of support structures braced by the plurality of wires.
  • 9. The method as set forth in claim 1, wherein maintaining the geotextile fabric formwork in the upright position comprises supporting the geotextile fabric formwork on a local ground and systematically lowering the geotextile fabric formwork on the local ground to maintain support of the geotextile fabric formwork on the local ground as the earthen material mixture dries and as the earthen material mixture decreases in size in the geotextile fabric formwork.
  • 10. The method as set forth in claim 9, wherein systematically lowering the geotextile fabric formwork on the local ground comprises actuation of at least one actuator in connection with the geotextile fabric formwork based on at least one sensed parameter.
  • 11. The method as set forth in claim 1, further comprising, once fully dried, removing the earthen construction formation from the geotextile fabric formwork and reusing the geotextile fabric formwork.
  • 12. An earthen construction formation made by the method of claim 1.
  • 13. A method of fabricating an earthen construction formation, the method comprising: preparing a site-derived earthen material mixture, the site-derived earthen material mixture constituting a pourable site-derived earthen material mixture;filling a geotextile fabric formwork with the pourable site-derived earthen material mixture;maintaining the geotextile fabric formwork with the pourable site-derived earthen material mixture in an upright position and on a local ground; andallowing the pourable site-derived earthen material mixture filled in the geotextile fabric formwork to dry while maintained in the upright position and while on the local ground.
  • 14. The method as set forth in claim 13, wherein the site-derived earthen material mixture is free of cement stabilizer additives.
  • 15. The method as set forth in claim 13, wherein maintaining the geotextile fabric formwork in the upright position and on the local ground comprises providing a plurality of support structures extending from form ties of the geotextile fabric formwork at an exterior of the geotextile fabric formwork, and providing a plurality of wires at the exterior of the geotextile fabric formwork, the plurality of support structures braced by the plurality of wires.
  • 16. The method as set forth in claim 13, wherein maintaining the geotextile fabric formwork in the upright position and on the local ground comprises lowering the geotextile fabric formwork on the local ground upon to maintain support of the geotextile fabric formwork on the local ground as the earthen material mixture dries and as the earthen material mixture decreases in size in the geotextile fabric formwork, the lowering effected via actuation of at least one actuator.
  • 17. The method as set forth in claim 16, wherein actuation of the at least one actuator is based on a sensed parameter indicating a drying state of the earthen material mixture.
  • 18. A method of testing an earthen construction formation prepared via a site-derived earthen material mixture, the method comprising: placing a geotextile fabric formwork in a testing support structure, the geotextile fabric formwork exhibiting flexibility and permeability, the testing support structure supporting the geotextile fabric formwork above a local ground and having a plurality of openings at least at a bottom thereof;filling the geotextile fabric formwork with the site-derived earthen material mixture while the geotextile fabric formwork is placed in the testing support structure, and allowing the site-derived earthen material mixture filled in the geotextile fabric formwork to dry while the geotextile fabric formwork is placed in the testing support structure; andperforming testing to the earthen construction formation.
  • 19. The method as set forth in claim 18, wherein the site-derived earthen material mixture is free of cement stabilizer additives.
  • 20. The method as set forth in claim 18, wherein the testing structure provides shaping and sizing of the earthen construction formation according to the testing being performed, and wherein the testing performed comprises at least one of a cylinder compression strength test or a three-point modulus of rupture test.
Provisional Applications (1)
Number Date Country
63449981 Mar 2023 US