Introduction: Build Your Own Workshop
Like a lot of tinkerers I've been wanting the "Dream" shop for years. I tried several different shop ideas over the years and was never really happy. So I decided to build what I wanted and I had to figure out how to do it. This project is still in progress as it's being built as I get the money and the time.
This is a real basic overview on my solution
Step 1: Getting the Barebones Up
After the site was selected and leveled, holes were dug for the posts. The first few were dug with a hand post hole digger, than I borrowed an auger for my old tractor.
The wood came from the property and was milled with a WoodMizer bandsaw sawmill. I had always heard that the fastest route to a roof was a post and beam structure...so that's what I did.
Step 2: Going Up
I decided to go with 2 stories because I figured since the roof and the pad were the expensive parts it would just make sense. I also originally laid out a 20x20 area and decided it would be too small so I went 30 x 40. The monster was starting to awaken.
(note: 2 stories are A LOT MORE WORK! and 20x20 probably would have been just fine, but now that the hole was started I just jumped right in.)
Step 3: The Slab
Next up in this abbreviated version of the last 2 years of my life was the slab. Slabs are expensive, but, I saved my sheckles and was able to pull it off. Since I was going to all the trouble of a slab I figured I might as well install a radiant heat system. So I did.
First there was 6 inches of well tamped gravel, then a moisture barrier (plastic sheeting) than insulation, than rebar and reinforcement wire than the pex. Covered in a tasty coating of concrete
Mmmmmmmm
Step 4: Bring on the Insulation
I wanted to wrap the skeleton with straw bales for their amazing insulation factor.
The bales deliver somewhere around an R-40 to 50
Step 5: A Plaster Skin
hydraulic lime plaster is applied to the bales . it acts as a skin for strength and helps the building breath.
Plastering is a lot of work .but, really gives the building a nice surface. I'm still plastering on the interior and this spring I hope to finish the exterior. Part 2 : Working with Hydraulic Lime Plaster is up.
It shows in much more detail how to work with this most excellent material.
Finalist in the
Craftsman Workshop of the Future Contest
80 Comments
10 years ago on Introduction
very nice, would love to have a shop that size for welding, auto repair, woodworking and just tinkering
10 years ago on Step 5
* The extra time you put into a strawbale structure to smooth the walls will pay you back many times over when you plaster.
File under things I would do differently
10 years ago on Step 3
The pex used in the floor is 7/8's ID. It was installed in three 300 foot loops
11 years ago on Introduction
Congratulations â¦
Lucky man who has so much space available : would you like to know that your workshop is at least twice (if not more) the size of house ?
;D
Reply 11 years ago on Introduction
all things are relative
Reply 11 years ago on Introduction
Nonetheless, your project is great !
11 years ago on Introduction
could you get free contre slabs from company's that are extras
Reply 11 years ago on Introduction
Don't know about free labs...
12 years ago on Step 5
Wow Very nice job. Would you say the labor involved is more or about the same as a stick built shop?
How much would you say it cost you to build this building as aposed to a stick built or a pole building?
12 years ago on Introduction
also do you have a theme for your shop
Reply 12 years ago on Introduction
No air conditioner here I use an exhaust fan in the morning to pull in the cool air, but pretty much it's just the thick walls of the straw bales.
Theme?
Never thought of one....hmmmm...
"do it yourself"? or maybe "re-purpose/re-use"?
People who visit the shop think it has an "old" feel. I think it's probably because of the big round walls and post and beam structure
Reply 12 years ago on Introduction
old fashiond theme then ever thought of air conditoing where i live it is a must
12 years ago on Introduction
wow nice is the foundation safe and could i ask how do you power it
Reply 12 years ago on Introduction
Safe? it's a 6 inch slab of concrete sitting on 4 to 5 inches of tamped rock. Yeah seems pretty safe. The shop is currently powered on the grid, but, I made sure the roof was aligned and fortified for the possibility of solar when the financial gods are in agreement. Thanks for your comment.
PS: today it's 95º outside and inside the shop is a cool 69º
13 years ago on Introduction
I think it is great you are showing a straw-bale structure. They don't get enough exposure. Cheap and efficient homes and structures. Fire and pest resistant. They also breathe, so you don't feel stuffy like you can in a modern structure. Awesome. I really look forward to seeing your final product and layout of your workshop!
Reply 12 years ago on Introduction
Straw is fire resistant? I was looking at this and thinking, "Aw man, you're screwed if you drop a hot tool, have a sparks from a grinder or something, or anything like that."
Reply 12 years ago on Introduction
That would be a problem if there were any exposed straw, but, there isn't . All straw is covered by at least 2 inches of plaster.
Reply 12 years ago on Introduction
Thank you, you are correct :) The straw being tightly packed and completely sealed in by plaster or cob, this creates a fire resistant environment. Even if somehow fire were to get to the straw, with it being so dense in the wall, it would get snuffed out before damage would be done.
13 years ago on Introduction
This is amazing. I am so jealous, though. You could have at least invited me for the spray plaster part! Seriously, I love what you've done so far. I look forward to getting the chance to see what fixtures are going inside. Hopefully as useful and efficient as the outside. You have my respect, sir.
14 years ago on Introduction
Nice Job. Always wanted to do something like this. Really liked the radiant heating, it's a nice ecofriendly way of heating. Awesome design concepts. Is it the lack of oxygen that prevents the straw bales from rotting? What kind of shop are you building? If it where my shop I might have included in wall pneumatic lines. Great job your instructions where very clear. Sorry for asking to many questions. As far as fire goes ultimately it comes down to not being stupid and outfitting a space with adequate fire extinguishers. Most buildings will burn but with 2" of plaster on either side it would have to burn for a long time at high temperatures to penetrate the sides.(unless of course it finds another route. I.E Power Outlets or the posts) and by that time all of the stuff inside would be destroyed so theirs no point in making the structure any more fireproof. (sorry for this excessively long comment)