CEB Press: Difference between revisions

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{{Hint|Last updated Jan 2018}}


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[http://opensourceecology.org/wiki/CEB_Press_6_-_Overall_Machine_-_Development_Board Link to CEB Press Build June 2015]


=Introduction=
{{OrigLang}}


This page is an introduction to the collaborative development of a high performance Compressed Earth Block (CEB) press,'' The Liberator.'' We aim to provide a low-cost, ecological, ergonomical, and economically-significant press.     The design process and final plans will be "Open Source"-- part of the public domain, with free access to anyone. The press is designed through voluntary efforts. Funding for parts, labor, testing, and development are procured via donations from interested parties (ie. builders, buyers, producers of CEB presses; community developers; general supporters of our work).  If you are interested in helping the development process in any way, please feel free to contact us.
<html><iframe src="https://player.vimeo.com/video/49864277" width="500" height="281" frameborder="0" webkitAllowFullScreen mozallowfullscreen allowFullScreen></iframe> <p><a href="http://vimeo.com/49864277">The CEB Story 2012.</a> from <a href="http://vimeo.com/opensourceecology">Open Source Ecology</a> on <a href="http://vimeo.com">Vimeo</a>.</p></html>


As detailed in the outline above, below is an overview of the CEB, our work on "The Liberator" including timeline and budget goals, and resources.  For more details, please also see our weblog which we update with CEB information frequently.  [http://openfarmtech.org/weblog/?cat=13# This link] will send you directly to CEB-relevant posts.
{{GVCS Header}}


=OSE Product Development Cycle - CEB Overview=  
=Overview=


The key to a low cost product is to utilize open source development and co-funding. The essence of the fundraising mechanism is that a large pool of stakeholders are invited to make small, voluntary contributions by using an online funding basket with PayPal (currently under development by collaborator Sam Rose). When a designated sum is collected, the project moves forward. When the sum is not collected, then none of the PayPal commitments are charged.
[[File:Machine.jpg|right|400px|thumb|CEB Press (aka "The Liberator"). See [[CEB_Press_6#Instructional_Files]] for detailed pictures of the latest machine build (v6), and for an exact picture of v6. Version shown is v3.]]
[[File:Liberator_bricks.JPG|right|400px|thumb|Bricks pressed on [[The Liberator]]]]


Potential stakeholders for "The Liberator" include those interested in:
The Liberator is OSE's automatic, high throughput Compressed Earth Brick Press. It is named The Liberator because it is intended to free people from the single highest cost of living - housing. See [[Cost of Living]].


#Buying a CEB press at a predicted cost of under $5k, for a machine that produces 3-5 bricks per minute (ie. contractors, owner-builders, brick-producing enterpriser, natural builders, community developers)
The CEB is at product release status and is being actively manufactured at Factor e Farm. The presses was used heavily as a part of the [[Factor e Farm Infrastructure Buildout 2011]]. Builds using the OSE CEB ress continued with the [[Microhouse 1]], [[Microhouse 2]], [[Microhouse 3]], and [[MicroHouse 4]] built in 2014 - [http://www.prweb.com/releases/2015/01/prweb12440135.htm]. We have also built a utility room brick floor and an 8' wall section out of CEBs in the 2016 build of the [[Seed Eco-Home]].
#Building a CEB press (DIY or low-budget individuals, organizations, and companies)
#Starting an enterprise for producing CEB presses (distributed production reduces shipping costs and increases local control)
#Our overall goals at Open Source Ecology (appropriate technology development; sustainable and just living and livelihoods; localized production)


Our general strategy and organizational process for developing products, including the CEB is described [http://openfarmtech.org/index.php?title=Main_Page#Deployment here].  
In 2020, we did a [[CEB Microhouse Build in Belize]].


On this page, we go through the actual process, from concepts (see 2.2 eco-review) to design (2.4) to prototype to fabrication facility (2.4.3) to production for market. The timeline for 2008 is:
The bill of materials cost of the current, fully-automated machine is about $5000 US. See [[CEB Press#BOM]].


[[Image:CEB_timelin.jpg]]
The machine can also be made as a manually-controlled version with hydraulic valves. Other options are:
*small or large hopper
*with or without hopper shaker
*automatic controller at 6-10 bricks per minute, depending on power unit


This timeline shows the ''development cycles'' on top, along with the corresponding ''funding cycles'' and ''deliverables'' in green and red. For each development cycle, we adapt a 10-step procedure, whose steps are shown at the bottom of the diagram.  
'''We are currently selling the full machine without power unit for $10k FOB Kansas City, lead time 2 months. Email info at opensourceecology dot org.'''
*Price is FOB Kansas City, Missouri, USA, for a fully assembled machine, with quick couplers, ready to be plugged in to a power source. Price for other packing/crating options is extra.
*Delivery time: machines are produced during scheduled production runs, with 8 weeks lead time from submission of payment.
*Buyer is encouaraged to attend the build event - to learn how the machine is designed, built, and therefore, to learn about repair and modification. Basic instruction on using FreeCAD will be provided for viewing the CAD file. An operating and maintenance manual will be provided to the client. The buyer is encouraged to brind additional people to the build event to learn about the machine.


In short, the development process cycles through two prototypes of the CEB machine itself, and two prototypes of an XYZ, computer controlled torch table (see [http://www.torchmate.com/industrial/index.htm professional version] and [http://openfarmtech.org/index.php?title=Torch_Table open source version]). The torch table will be used to automate the fabrication of the CEB machine, reducing fabrication time by an estimated 20 hours.  
A tractor loader is used to provide approximately 2 cubic yards of soil per hour at at 6 block per minute pressing rate. A tractor loader is needed to keep up with the machine throughput. Approximately 3 people are required to keep up with the machine for stacking the block upon pallets. Approximately 30 people would be required to load the machine manually with shovels and buckets if no tractor loader were available. At the minimum, 4 people (1 tractor operator, 3 stackers) are required to produce palletized block on an all-day basis.


The development process also includes building actual structures to test the quality of the blocks and durability and ease of use of the press. Moreover, we will be build a production facility for the CEB machines, and developing an open source business model to disseminate production of these machines to other areas of the world.
==Specifications of the Standard Model==
*Block is plain block, not interlocking. Please see discussion on [[Interlocking_bricks]]
*Version 17.08 is our most current model. See [[CEB Press Genealogy]] for past versions.
*Open source hardware, controller, and software ([[CC-BY-SA 4.0]], [[GPLv3]])
*Controller is fully automated for hands-off operation
*Does NOT come with a power source - it is powered by a hydraulic power source, such as by our [[Power Cube]] or a tractor hydraulic take-off.
*Full size bricks are 4"x6"x12", plain flat-faced bricks
*Brick height is adjustable from 2"-4"
*Brick dimensional variations: +/- 1/16". This assumes uniform soil. Soil uniformity will determine height uniformity of brick.
*The standard model guarantees 6 full-sized bricks per minute at 12.5 gallon per minute hydraulic flow. See [[Brick Pressing Calculations]]. Brick pressing rate will increase with a higher hydraulic flow, up to the maximum rated flow of the hydraulic solenoid. Hydraulic solenoid valve is rated for a maximum of 10 gpm fluid flow at 3000PSI.
*Cost of production for actual block ranges from 5 cents to 40 cents per block - depending on amount of cement used for stabilization (0-10%) and cost of labor (free to $25/hr). See [[Cost_of_CEB_Block]]
*Fuel consumption with [[Power Cube]] running at 12.5 gpm fluid flow - about 1 gallon per hour
*System hydraulic pressure - 2400 psi
*Comes with hydraulic quick couplers ready to be connected to a power source
*Weight - 1700 lb
*Moving: brick press is moved with forks. Footprint (with legs in the inner position) allows machine to be placed in the bed of a 3/4 ton pickup. It has adjustable legs for uneven terrain. Machine can be moved around on a trailer (not included)
*Material cost: $3000-$6500 depending on suppliers; manual machine (without  hydraulic solenoid, machine costs $1000 less in materials. Production cost for a full kit: US$5000 above the bill of materials/supplies/consumables cost, paid by the buyer. Production currently occurs in [[Extreme Manufacturing]] Workshops - where the buyer is invited to the build so they understand how the machine is built - and is part of the buyer's Lifetime DIY Warranty. This warranty means that the user can maintain the machine for decades because they know how the machine is built, how it works, and how to source parts for the machine from local and online sources. This means that this is not a consumer machine, but a prosumer machine.
*3'x6' grate for loading the machine with a tractor. Includes soil deflectors


==[http://openfarmtech.org/index.php?title=Main_Page#OSE_Product_Cycle '''Step 1. Core Team''']==
=Additional Power=
The machine can be used to produce up to 10 blocks per minute with a larger power source. A larger secondary hydraulic cylinder must be used in that case. See [[CEB Press Log]] for developments.


Presently, we are recruiting the Core Team for this effort. We presently have the [http://openfarmtech.org/weblog/ Factor e Team] on technical development and [http://openfarmtech.org/index.php?title=Sam_Rose Sam Rose] on the social enterprise development. We are looking for peer reviewers and strategic developers, and are assembling a fundraising team.
=BOM=
See build BOM from 2017 at [[CEB_Press_v17.08#BOM]]
=Versions=


==[http://openfarmtech.org/index.php?title=Main_Page#OSE_Product_Cycle '''Step 2. Ecological Review''']==
{{Hint|'''For full project version history, see [[CEB Press Genealogy]] and [[CEB Press Controller Genealogy]]'''}}


We ask a basic question at the outset: is the CEB press worth developing? [http://en.wikipedia.org/wiki/Compressed_earth_block Wikipedia] provides a neutral overview of the CEB construction method. From a U.S. perspective, we do not have a neutral evaluation of this building technique because we conclude that no other building method comes close when an integrated evaluation is considered.  
=Details=
The CEB Press takes earth/dirt/soil and compresses it tightly to make solid blocks useful for building. Compressed earth blocks have many advantages as a building material: by making the building materials from the readily available dirt on the building site, they eliminate the need to transport bricks from elsewhere, reducing financial cost and environmental impact. Compressed earth blocks are very strong and insulate well against both heat and sound, making for very energy-efficient building (especially combined with the energy savings from not needing to transport them from offsite). Best of all, the material they use is already on-site and does not need to be purchased -- quite literally, dirt-cheap!  See the wiki page on [[Compressed Earth Blocks]] and the [[:Category:CEB|CEB category]] for more details on building using CEBs.


Consider these main building options for North America. You have a choice of wood: stick-frame, timber frame, post and beam; structural masonry: brick, concrete block, rock, CEB (note that CEB falls into the class of structural masonry); earth-mix: adobe, rammed earth, stabilized earth blocks, cob, earthbag; and other natural building methods: strawbale, cordwood, papercrete, earthships and variations of all types. Here are some considerations.
The Liberator has been fully designed and tested by the [[Open Source Ecology]] team.  Because the Liberator is an open source technology, you can freely download instructions to build your own from materials you can obtain yourself, or contact ''opensourceecology[at]gmail[dot]com'' to buy a kit or a finished machine.
   
#'''Suitability of building technique for economic localization''' - CEB walls can be made with 100% insite soil, and even with the soil that is removed for a basement or foundation. Machine production can also be completely local. Only lumber houses can come close to localization potential when lumber is harvested locally and sustainably.  Other earth or natural building techniques can use local material, but they don't contribute too much to mainstreamable localization economics because they are too expensive due to the building time requirements.
#'''Ecological qualities''' - 100% local, natural, onsite material, even for the 'mortar' - see [http://en.wikipedia.org/wiki/Compressed_earth_block Wikipedia]. Non-stabilized earth and other natural building methods also score well on local, ecological use of materials.
#'''Strength''' - CEB is second only to [http://www.coldspringgranite.com/comparing_granite_to_other_build.htm rock] and steel. Strength of CEBs is up to 2000 psi according to Wikipedia. Walls are tornado- and bullet-proof.
#'''Cost''' - if one has access to a $3-5k machine of the type being developed here and onsite soils, then CEB wins hands down. A tractor with loader and rototiller are required to prepare the soil for massive building projects.
#'''Building ergonomics''' - 3-5 bricks per minute (bricks are 6x12x4 inches) means a 6 foot high wall for a 300 square foot round building can be erected in one workday. This is possible because the mortar used is a slurry of the same material as the bricks, with added water. This is as fast or faster than walls with stick framing in the context of a 2-person team with tractor and rototiller. On this account, other natural building methods do not even come close. We have first hand experience with cordwood and earthbag, in that they take about 10 times more time than engineered methods. The natural building methods are not by any stretch easily replicable, unless one feels good about committing the large amounts of time
#'''Durability''' - Unsurpassed except for stone. 100-500 year lifetime is expected.
#'''Thermal properties''' - unsurpassed. Significant thermal flywheel.
#'''Aesthetics''' - see [[CEB house examples]]


Stick frame construction is the main building method in North America. It is a weak but fast building method, which makes money for developers but returns little value to the homeowner, if one considers lifecycle cost of buildings. Procuring lumber drains money out of local economies. This is not to mention clear-cutting and vast lumber monocultures that supply the lumber. We are interested in raising the standard of building, away from stick frame. We believe that with all these considerations, the CEB is the only building technique that even remotely has a chance of substituting for stick frame constuction, and that with our machine, priced $3-5k and designed for fabrication replication, will fill in a great need. CEB construction has the potential for mainstreamability in home construction.
Building a machine yourself might seem intimidating, but every step of the process is fully documented and the OSE community is available on our [http://forum.opensourceecology.org/ discussion forums] if you need help, advice, or a little hand-holding.


We have heard one recurring critique of CEB construction. [http://radio.weblogs.com/0119080/stories/2003/04/09/theMythAndPromiseOfDirtChe.html It has been said ] that CEB building is either for the idle rich, who can afford the high cost of construction, or the idle poor, who can afford to take the time to build the house. Both cases imply outrageous time requirements, and this appears inconsistent with claim 5 above. Based on our experience we find that to be untrue. We believe that the truth is that poor people do not have access to high performance machines, and rich people are charged a lot because the quality of the finished product is high, regardless of how many hours went into construction. The answer to this seeming inconsistency is the availability of a high-performance, low-cost Liberator.  
Using the CEB Press, two people can build a 6 foot high (1.83m) round wall, 20 feet (6.1m) in diameter, 1 foot (30cm) thick, in one 8 hour day, though construction time will vary somewhat depending on preparation time, what equipment is available (tractor to prepare the ground and move the blocks where they need to go), the quality of the soil, and other factors. The bigger the block size, the faster a wall can be erected, but at the cost of heavier blocks that are more of a strain to work with.  Blocks from ''The Liberator'' average 25 pounds (11.3kg).


Our experience has shown $30/square foot costs for the cordwood house, and similar rates for the earthbag house, if $10/hour labor is considered. We estimate time requirements to be at least 5 times shorter for CEB construction, we are expecting $5/sq ft total building costs including $10/hour labor. That is dirt cheap for top quality housing. Direct data, gathered from our building program beginning in April, will prove or disprove our claims.
See [[CEB Design]] for more information.


For these reasons, we conclude that anyone who is interested in building a new house, or making a house addition, should consider the CEB press seriously because of its ecological, economic, durability, replicability, and localization merits. While other building techniques may be superior on one of these qualities, CEB construction is the only technique that scores well on all these criteria.
=Product Ecology=


==[http://openfarmtech.org/index.php?title=Main_Page#OSE_Product_Cycle '''Step 3. Product Definition''']==
[[Image:4b-Constructioneco.png|thumb|600px|center|Construction [[Product Ecology]]]]


===Deliverable===
'''From'''
Here are the specifications for the OSE CEB machine: '''''The Liberator'''''. Lifetime specifications will be verified in field testing.
*{{Furnace}}
*{{Welder}}
*{{Torch Table}}
*{{Ironworker}}


#Bricks per minute output: 3-5
'''Uses'''
#Brick size: 12x6x6 inches (30.5x15.3x10.2 cm)
*{{PowerCube}}
#People operating machine: 1-2
*{{Rototiller}}
#Machine power source: tractor hydraulics or any hydraulic power source with 6 gallon per minute capacity
*{{Tractor}}
#Machine mounting: tractor 3 point hitch or stand-alone foot
*[[Earth]]
#Hydraulic pressure: 2000psi
#Hydraulic cylinder: 5 inch diameter, 19.6 inch area; 2.5 inch rod
#Pressing cylinder pressure:  39,250 lb pushing force (~18 tons)
#Controls: 2 spool, manual, hydraulic valve; automatic version forthcoming.
#Compressive strength of bricks: to be measured
#Structural cold rolled steel construction throughout
#Design-for disassembly: full bolt-together construction for frame, compression chamber, table, tractor mount, and feet; welded hopper assembly and press plate; cylinders readily removable with pins
#Wearable components: 1/8" Nylon 6/6 liner on compression chamber and table surface, each piece held by 2 bolts
#Machine lifetime goals: 1 million bricks before repairs; liner may be replaced every 100,000 bricks
#Material costs: $1000-1350
#Fabrication time requirement for optimized production: 3-5 days, about 20 hours of direct fabrication
#Manual fabrication tooling requirements: drill press, welder, acetylene torch
#Optimal fabrication tooling: XYZ table with torch, MIG welder, hoist
#Cost for machine: $3-5k


Future phases for CEB evolution that we are considering beyond the present funding cycle are:
'''Creates'''
#Fully automated CEB machine, like The Liberator, where manual controls are replaced with automoatic valves and a control circuit. The only control required is turning the machine on, and from that point one simply loads soil and unloads bricks. Added material costs in this version are approximately $500.
*[[CEB Bricks]]
#More powerful machines. More speed may be achieved by
##A dual machine, which features 2 compression chambers operating in parallel
##Faster machine by virtue of redesign to allow faster cycling through the steps


The automated machine is a clear and desirable upgrade, which essentially frees up one person to load soil, unload bricks, and build with the bricks right after they are produced. The other machines, such as dual or faster versions, will be reevaluated after significant  experience has been reached by the Factor e Team and collaborators.
'''Enables'''
*[[Workshop]]
*[[Greenhouse]]
*[[HabLab]]


We would like to emphasize our approach and cost predictions: we're open source, lean, mean, and optimal. This effort is funded by voluntary contributions, so our development costs are zero. We have low overhead costs of $107 per person per month because we have donated facilities and lifetime tenure. We are working on a thorough process for a quality product. Indeed, we aim to create a new model for the way products are developed. We aim for full transparency in our development process, so you can see how your money is being spent. And, we are giving the business model away for others to replicate. No strings attached. You can read details of our 3-year plan [http://openfarmtech.org/OSE_Proposal.doc here].
=See Also=
*[[CEB Press Genealogy]]
*[[Brick Pressing Calculations]].
*[http://collections.infocollections.org/ukedu/uk/d/Jh2380e/4.3.1.html Soil Testing]
*[http://collections.infocollections.org/ukedu/uk/d/Jh2380e/4.3.2.html more Soil Testing]
*[[CEB Design]]
*[[Compressed Earth Blocks]]
*[[Cinva Ram]]
*[[CEB_FAQ]]
*[[CEB Press/Rollers]]
*[[CEB Press/ModularRollers]]
*[[Hablab]]
*[[Metric CEB Press]]
*[[CEB Press/Field Testing 2011|Field Testing 2011]]
*[[CEB Press/Videos]]


Our pricing policy is to cover labor and fabrication costs, and to capture value from optimized fabrication. This means that both sides win: we are able to fund further developments by putting all proceeds back into the operation, and you get a low-cost product. We are able to consider special payment arrangements for collaborators or others interested in development for the common good. We do not want cost to stand in the way of access to liberatory technology.
{{GVCS Footer}}
 
[[Category:CEB Press]] [[Category:GVCS]]
 
===Budget===
====Bill of Materials====
Here we present an economic analysis for the CEB machine to explain costs involved.
 
Here is the Bill of Materials (BOM) for the CEB prototype:
 
[[Image:CEB_BOM.jpg]]
 
References:
#http://surpluscenter.com/item.asp?UID=2008010512293756&item=9-1143-08&catname=hydraulic
#Gotten from surplus.
#http://surpluscenter.com/item.asp?UID=2008010512293756&item=9-7156&catname=hydraulic
#http://surpluscenter.com/item.asp?UID=2008010512293756&item=9-6702&catname=hydraulic for $156
#Gotten from surplus.
#Item # 905-12120 and 905-1236 at http://surpluscenter.com/
#Item 8609K13 at http://www.mcmaster.com/
 
The main cylinder and control valve used were from surplus, so this price may rise by about $250 for the cylinder and $100 for the valve, for a total of about $1350 in readily-accessible parts. The total number of hours spent building this protoptype was about 140 hours. The time expected for fabricating the second prototype is 40 hours. Production runs are expected to take about 20 hours per machine, using an XYZ torch table for fabrication assist.
 
====Fabrication Facility====
Here are the capitalization requirements for fabrication capacity. The ''Cost'' column reflects the price structure if off-the-shelf tools and materials - and proprietary development procedures - are utilized. This cost is conservative, as intellectual property costs are probably higher than the $10k that was specified. The alternative route, or the ''Open Source Cost'', is that which utilizes open source know-how and is built on a land-based facility. The open source option means that certain equipment may be fabricated readily from available components when a design and bill of materials is available.
 
[[Image:CEB Fab Facility.jpg]]
 
References:
9. www.torchmate.com ;
10. Does not include the control computer;
11. Torchmate 3, http://www.torchmate.com/overview/index2.htm ;
12. http://bluumax.com/ ;
13. http://www.harborfreight.com/cpi/ctaf/displayitem.taf?Itemnumber=43550 ;
14. http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_200306001_200306001 ;
15. http://www.northerntool.com/webapp/wcs/stores/servlet/product_6970_18544_18544 ;
16. Not including land costs;
17. Cheapest barn kit: http://diypolebarns.com/pb_kits.php , more expensive: http://www.shelter-kit.com/b_prices.html ;
18. Using CEB construction with on-site soils, plus site-milled lumber leaves only doors, windows, foundation, and electrical costs of building;
19. This is difficult to estimate, but here we will include 200 hours of development work at $50 per hour- for producing 2 prototypes and testing prior to production runs.
 
In particular, the great cost reducer in the open source route is the availability of: (1) a low-cost XYZ table, (2), low cost workshop building, and (3), absence of intellectual property costs. In total, the price of putting together a fabrication facility is only $3700 if one has access to land, some kind of tractor or skid loader for material handling, and utilizes onsite building materials (CEBs and milled lumber) to construct the workshop space. It should be added that more labor will go into building an XYZ table than buying one, but not much more, if a transparent bill of materials and fabrication procedure is available. Workshop building time may also increase over the off-shelf option.
 
The XY table is a pricey solution if obtained off-the-shelf. New kits cost $8k at the low end for an industrial duty, 4x8 foot table. We should note that, as expected from the open source development method, ridiculously low costs are feasible for the CNC table. For example, a [http://www.instructables.com/id/Easy-to-Build-Desk-Top-3-Axis-CNC-Milling-Machine/ small CNC mill] is under $200. The electronics of a CNC XY table are inexpensive. Three stepper motors plus controller and power supply cost $45. (http://bluumax.com/ - Note - these stepper motors are half the required size, so we expect the real price to scale accordingly.)  Rails may be the expensive part, and other than that, it’s mostly a structure that can be fabricated via xyz bolt-together design. The CNC table should be accessible at <$500 plus structural steel at approximately [http://torchmate.com/overview/index2.htm $400].  That is a Factor 10 reduction over the competition.
The cost structure for building a physical production facility for the CEB will be documented fully with forthcoming experience in 2008. We will be building this facility at Factor E Farm. Part of the development will be deploying an open source XYZ table, which we expect to cost <$900 in parts. There may be additional costs involved in finalizing a simple design for the XYZ table. The goal is a facility that can produce 1 CEB machine every 3 days with 1 fabricator working full time.
 
We will set up a social enterprise website to raise between $3700-5000 for deploying CEB machine fabrication. This site will designed to motivate the minimal funding of the facility, by directing as many potential stakeholders to the site as possible. Stakeholders include owner-builders interested in natural building, building organizations such as Habitat for Humanity, disaster relief organizations, building contractors, and a wide range of others. We are asking for collaboration in directing potential stakeholders to the funding website.
 
In summary, this is our first experiment of co-funding a significant production facility. Deployment funds will be used to build the facility, procure some tools, and build an open source version of the XYZ table. Utilizing existing collaboration, we will use up to $3k from the budget to design, build, and deploy the XYZ table. Together with Factor e Farm contribution of facility space, a fabricator who has already been recruited, and utilization of onsite materials for facility construction – we believe that we have an attractive package that can be funded. Costs and risk are distributed, and low overhead makes the entire project dirt cheap for the significance of the promised deliverable. It is a pressing issue (no pun intended) for us to deploy CEB machine production with 3-5 day delivery time – for proving a novel, state-of-art peer production mechanism.
 
====Heavy Equipment====
The balance of the budget for the open source CEB development is in materials handling and testing: a tractor with front end loader and rototiller. The tractor is required for soil preparation: digging soil and rototilling the soil to prepare it for use in the CEB machine. The tractor is also used to power the CEB machine for testing, and for material handling of raw steel that is used in the CEB machine. Moreover, we are presently utilizing a tractor to generate 20 kW of electricity by using a power take-off (PTO) generator. This powers the welder and other equipment, but we aim to replace this with a renewable power system as soon as we can. We currently run smaller electrical tools with a 3 kW inverter and a battery bank. These costs summarized are:
 
[[Image:heavey_equipment.jpg]]
 
Notes: 1. We are considering an Allis Chalmers D17 Series IV Diesel tractor as a robust, all purpose tractor with good hydraulics
 
===Timeline===
The goals are to produce a hydraulically-driven, manually operated CEB press ready for sale by October, 2008. By November, we aim to produce a fully automated hydraulic machine. By December, we aim to develop a training program for builders of the CEB machine.
 
Given the budget explanations above, here are the funding cycles that we are proposing for this project. Delivery date for optimized production is November 1, 2008, when we will begin filling orders.
 
The funding cycle overview is:
 
[[Image:Funding_cycle_CEB.jpg]]
 
The table above shows the deployment costs with 7% overhead for fiduciary duties of funding collection management. The cycles in detail are:
 
The first funding cycle starts Feb 1, and continues for 4 weeks. We hope to collect the necessary funding via a concerted 2 week effort with our volunteer fundraising team. The funding cycle carries on for 4 weeks, but the actual developments with the proceeds collected  last longer.
# '''Cycle 1: Feb. 1 – Feb. 28 Collection Cycle, $5190''' - XYZ table, and 2nd Prototype
 
##Recruiting core team
##Recruiting reviewers
##Documenting all past design and fabrication work
##Distributing present effort out for review
##Designing XYZ table by Feb. 1
##Reviewing XYZ table by Feb. 7
##Procuring fabrication bids for table by Feb. 14
##Fabricating XYZ table, by Mar. 8
##Procuring MIG welder by Mar. 8
##Producing prototype 2 by Mar. 31
 
#'''Cycle 2: March 1-March 31 Collection Cycle, $5350''' - Demo Buildings
 
##Procure tractor with front-end loader by April 7
##We will build our first significant demonstration structures with the 2 CEB prototypes. Construction will continue for 1 month to document experience with the ergonomics and economics of this method, and to verify field performance of the 2 CEB prototypes.
 
#'''Cycle 3: April 1-April 30 Collection Cycle, $2675''' - Fabrication Facility
##NOte: this covers the foundation, doors, water, and electrical hookup, as well as extra battery power to run the facility.
##Procure battery bank
##Build facility for fabricating CEB machines
 
#'''Cycle 4: May 1-May 30 Collection Cycle, $3210''' - Optimize Production for Replicability
##Production facility optimization
##Produce replicable design for XYZ table
##Build second XYZ table prototype to prove the economics of fabrication of the XYZ table
##Make any rearrangements in fabrication facility to facilitate workfow
##Build additional accommodations for additional fabricators. We are planning on 4 new fabricator positions.
 
==[http://openfarmtech.org/index.php?title=Main_Page#OSE_Product_Cycle '''Step 4. Design Phase''']==
===Design===
We have already built a prototype, which can be seen [http://openfarmtech.org/index.php?title=Main_Page#Deployment here].
 
Design has 5 major components:
#Documentation of Prototype 1
#XYZ table for automating fabrication
#Documentation of Prototype 2
#Facility Design
#Final CEB design
 
Go here to see the designs of CEB Prototype 1.
Click [http://openfarmtech.org/index.php?title=CEB_Prototype_1_Fab here] to see the 50 step procedure for fabricating Prototype 1.
 
===Bill of Materials and Sourcing===
===Fabrication===
 
 
#'''Review'''
#'''Bids'''
#'''Fundraiser Recruitment'''
#'''Fundraising'''
#'''Product Delivery'''
#'''Produce Testing'''
#'''Prototype Optimization'''
#'''Fabrication Development'''
#'''Fabricator Recruiting'''
#'''Fabrication Optimization'''
#'''Production'''
 
=Further Resources=
 
Our program is unique in that we are producing both an open source product, and also developing an open source model for the enterprise itself. You may read a review of this novel organizational model at the P2P Foundation website by clicking [http://blog.p2pfoundation.net/marcin-jakubowskis-open-farm-the-most-important-social-experiment-in-the-world/2008/01/22 here].
 
A good article on the CEB may be found at Wikipedia,  [http://en.wikipedia.org/wiki/Compressed_earth_block Compresssed Earth Block]. There are several good online books: click Earth at the left hand bar [http://80.237.211.43/basin/publications/index.asp?A=1 on this website].

Latest revision as of 01:46, 30 April 2021


HintLightbulb.png Hint: Last updated Jan 2018

Link to CEB Press Build June 2015

The CEB Story 2012. from Open Source Ecology on Vimeo.


CEB Press
   Home  |  Research & Development  |  Bill of Materials  |  Manufacturing Instructions  |  User's Manual  |  User Reviews    CEB Press.png

Overview

CEB Press (aka "The Liberator"). See CEB_Press_6#Instructional_Files for detailed pictures of the latest machine build (v6), and for an exact picture of v6. Version shown is v3.
Bricks pressed on The Liberator

The Liberator is OSE's automatic, high throughput Compressed Earth Brick Press. It is named The Liberator because it is intended to free people from the single highest cost of living - housing. See Cost of Living.

The CEB is at product release status and is being actively manufactured at Factor e Farm. The presses was used heavily as a part of the Factor e Farm Infrastructure Buildout 2011. Builds using the OSE CEB ress continued with the Microhouse 1, Microhouse 2, Microhouse 3, and MicroHouse 4 built in 2014 - [1]. We have also built a utility room brick floor and an 8' wall section out of CEBs in the 2016 build of the Seed Eco-Home.

In 2020, we did a CEB Microhouse Build in Belize.

The bill of materials cost of the current, fully-automated machine is about $5000 US. See CEB Press#BOM.

The machine can also be made as a manually-controlled version with hydraulic valves. Other options are:

  • small or large hopper
  • with or without hopper shaker
  • automatic controller at 6-10 bricks per minute, depending on power unit

We are currently selling the full machine without power unit for $10k FOB Kansas City, lead time 2 months. Email info at opensourceecology dot org.

  • Price is FOB Kansas City, Missouri, USA, for a fully assembled machine, with quick couplers, ready to be plugged in to a power source. Price for other packing/crating options is extra.
  • Delivery time: machines are produced during scheduled production runs, with 8 weeks lead time from submission of payment.
  • Buyer is encouaraged to attend the build event - to learn how the machine is designed, built, and therefore, to learn about repair and modification. Basic instruction on using FreeCAD will be provided for viewing the CAD file. An operating and maintenance manual will be provided to the client. The buyer is encouraged to brind additional people to the build event to learn about the machine.

A tractor loader is used to provide approximately 2 cubic yards of soil per hour at at 6 block per minute pressing rate. A tractor loader is needed to keep up with the machine throughput. Approximately 3 people are required to keep up with the machine for stacking the block upon pallets. Approximately 30 people would be required to load the machine manually with shovels and buckets if no tractor loader were available. At the minimum, 4 people (1 tractor operator, 3 stackers) are required to produce palletized block on an all-day basis.

Specifications of the Standard Model

  • Block is plain block, not interlocking. Please see discussion on Interlocking_bricks
  • Version 17.08 is our most current model. See CEB Press Genealogy for past versions.
  • Open source hardware, controller, and software (CC-BY-SA 4.0, GPLv3)
  • Controller is fully automated for hands-off operation
  • Does NOT come with a power source - it is powered by a hydraulic power source, such as by our Power Cube or a tractor hydraulic take-off.
  • Full size bricks are 4"x6"x12", plain flat-faced bricks
  • Brick height is adjustable from 2"-4"
  • Brick dimensional variations: +/- 1/16". This assumes uniform soil. Soil uniformity will determine height uniformity of brick.
  • The standard model guarantees 6 full-sized bricks per minute at 12.5 gallon per minute hydraulic flow. See Brick Pressing Calculations. Brick pressing rate will increase with a higher hydraulic flow, up to the maximum rated flow of the hydraulic solenoid. Hydraulic solenoid valve is rated for a maximum of 10 gpm fluid flow at 3000PSI.
  • Cost of production for actual block ranges from 5 cents to 40 cents per block - depending on amount of cement used for stabilization (0-10%) and cost of labor (free to $25/hr). See Cost_of_CEB_Block
  • Fuel consumption with Power Cube running at 12.5 gpm fluid flow - about 1 gallon per hour
  • System hydraulic pressure - 2400 psi
  • Comes with hydraulic quick couplers ready to be connected to a power source
  • Weight - 1700 lb
  • Moving: brick press is moved with forks. Footprint (with legs in the inner position) allows machine to be placed in the bed of a 3/4 ton pickup. It has adjustable legs for uneven terrain. Machine can be moved around on a trailer (not included)
  • Material cost: $3000-$6500 depending on suppliers; manual machine (without hydraulic solenoid, machine costs $1000 less in materials. Production cost for a full kit: US$5000 above the bill of materials/supplies/consumables cost, paid by the buyer. Production currently occurs in Extreme Manufacturing Workshops - where the buyer is invited to the build so they understand how the machine is built - and is part of the buyer's Lifetime DIY Warranty. This warranty means that the user can maintain the machine for decades because they know how the machine is built, how it works, and how to source parts for the machine from local and online sources. This means that this is not a consumer machine, but a prosumer machine.
  • 3'x6' grate for loading the machine with a tractor. Includes soil deflectors

Additional Power

The machine can be used to produce up to 10 blocks per minute with a larger power source. A larger secondary hydraulic cylinder must be used in that case. See CEB Press Log for developments.

BOM

See build BOM from 2017 at CEB_Press_v17.08#BOM

Versions

HintLightbulb.png Hint: For full project version history, see CEB Press Genealogy and CEB Press Controller Genealogy

Details

The CEB Press takes earth/dirt/soil and compresses it tightly to make solid blocks useful for building. Compressed earth blocks have many advantages as a building material: by making the building materials from the readily available dirt on the building site, they eliminate the need to transport bricks from elsewhere, reducing financial cost and environmental impact. Compressed earth blocks are very strong and insulate well against both heat and sound, making for very energy-efficient building (especially combined with the energy savings from not needing to transport them from offsite). Best of all, the material they use is already on-site and does not need to be purchased -- quite literally, dirt-cheap! See the wiki page on Compressed Earth Blocks and the CEB category for more details on building using CEBs.

The Liberator has been fully designed and tested by the Open Source Ecology team. Because the Liberator is an open source technology, you can freely download instructions to build your own from materials you can obtain yourself, or contact opensourceecology[at]gmail[dot]com to buy a kit or a finished machine.

Building a machine yourself might seem intimidating, but every step of the process is fully documented and the OSE community is available on our discussion forums if you need help, advice, or a little hand-holding.

Using the CEB Press, two people can build a 6 foot high (1.83m) round wall, 20 feet (6.1m) in diameter, 1 foot (30cm) thick, in one 8 hour day, though construction time will vary somewhat depending on preparation time, what equipment is available (tractor to prepare the ground and move the blocks where they need to go), the quality of the soil, and other factors. The bigger the block size, the faster a wall can be erected, but at the cost of heavier blocks that are more of a strain to work with. Blocks from The Liberator average 25 pounds (11.3kg).

See CEB Design for more information.

Product Ecology

Construction Product Ecology

From

Uses

Creates

Enables

See Also


The Global Village Construction Set
Habitat CEB Press Cement Mixer Sawmill Bulldozer Backhoe
Agriculture Tractor Seeder Hay Rake Well-Drilling Rig
Microtractor Soil Pulverizer Spader Hay Cutter Trencher
Bakery Oven Dairy Milker Microcombine Baler
Industry Multimachine Ironworker Laser Cutter Welder Plasma Cutter
CNC Torch Table Metal Roller Rod and Wire Mill Press Forge Universal Rotor
3D Printer 3D Scanner CNC Circuit Mill Industrial Robot Chipper Hammermill
Drill Press Induction Furnace
Energy Power Cube Gasifier Burner Solar Concentrator Electric Motor Generator Hydraulic Motor
Steam Engine Heat Exchanger Wind Turbine Pelletizer Universal Power Supply
Nickel-Iron Battery
Materials Aluminum Extractor Bioplastic Extruder
Transportation Car Truck

Imprimante 3D Scanner 3D Extracteur d'Aluminum Pelleteuse Four à Pain Presse à balles de paille Extrudeuse à bioplastiques Bulldozer Voiture Presse BTC Betonnière Broyeur à marteaux Imprimante de circuits électroniques Table de découpe numérique Trayeuse Perçeuse à colonne Moteur électrique Gazogène Faucheuse Râteau à foin Moteur hydraulique Fourneau à induction Bras robotisé Poinçonneuse Découpeur Laser Laminoir à plaques Microcombine Microtracteur Multimachine Batterie Ni-Fe Machine à granulés Torche plasma Power Cube Presse hydraulique Laminoir à barres et fils de fer Pulvérisateur de terre Scierie Semoir Concentrateur solaire Roto-bêche Moteur à vapeur Echangeur de chaleur Tracteur Fraiseuse de tranchée Camion Alimentation électrique universelle Rotor universel Poste de soudure à l'arc Plateforme de forage de puits Eolienne

Key Design Planning Prototype Almost done Full Release
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