Mk 1 DIY very low cost lnsulated room dividing / shelter panels (DIGRS Project) to save energy in the winter / reduce heat in summer

 

 I'm still working on the D.I.G.R.S. Project (DIVIDE- rooms with portable insulated panels, fabric or green walls to save energy & aid function) 

 Please note: this is just an experiment & not guidance or instruction. There are many ways of making an insualted panel & I encourage others to experiment as winter approaches. The panels can be used to make small indoor shelters as well as room dividers. 

The first panels are not fire resistant, , though may have certain elements that are ( aluminium tape & foil) as the low budget does not allow it.

When time allows and more funding is available, I will experinment with  a fire resistant panel using drywall light steel framing & fire proof rigid PIR foam or mineral wool.

 I have recently made some prototype panels and worked with local fencing co's to reduce their waste by reusing wood clearance stock & off cuts.

We have approx 4000 x 1.8m long treated wood battems, 10k x bzp metal hinges, 20k  x corner reinforcing brackets / screws for sale at low cost, and are still looking for partner gropups to distribute these to diy makers / users.

Contact cabinznet@gmail.com for further details

Below are Mk1 plastic & Mk1 wood panels with a 1.8m high wood batton frame, other is with  plastic / grp composite door edge strip. A trellis frame is belwo that for outside.

 As the first aim is for low icome groups to make their own panels easily with a minimum of cost & tools, i have experimented with corner joints of metal staples from hand staplers & fibreglass reinforced sticky tape to support the frame  (see pics) .

These hold the frame in place until the corner bracket & hinge are screwed on, which hold the corner joint securely

Thick fabric was sourced for £1 a mtr from a local shop clearing stock (the T Shirt shop open wed to sat , next to Grey & Pink records in Brook st chester who have several thousand mtrs for sale at same price) , which is stapled to the frame. 

Then a sandwich of several layers of used cardboard are used for insualtion. which can be wrapped in domestic or thicker catering aluminium foil for extra insualation / fire resistance ( see pic) 

Thick indoor fabric covered grp / plastic composite door edge strip frame insulated panel mk 1

 Indoor (leather look ) thick fabric covered wood frame insulated panel mk 1

Close up (without corner support bracket or hing/ joint gasket seal)

Close up (without corner support bracket or hing/ joint gasket seal)

Rear view (uninsulated)

Rear view (uninsulated)

Above pic is corner stapled together with hand stapler then with fibreglass reinforcrd sticky tape (fgst) wrapped around to hold it.

Below is cardboard taped with fgst, attempting to stop it gaping, A staple, bolt or stictch may be reqired in middle. 

Belwo is gaffer tape, sealing air into cardboard to aid insualtion, this can be stapled to wood or further gaffer tape can added round frame either side (not shown in pic)  connecting cardboard & frame to hold insualtion in place

Hand stapling of DES before tape added

Wood frame before corners support & fabric added. Note: the corner support wood piece was salvaged from offcuts from the smaller centre horizontal beam, as its smaller than the top & bottom . If a shorter panel is requiredthe bottom beam can be cut to be insided the vertical beams & offcuts used to support 2 corners as well 

plastic frame with tape reinforced corner at bottom. (Note: it would likely be best ot add inside plastic corner support before taping ) 

Metal corner bracket installed with hinge attached and foam draught excluder tape added to seam

aluminium foil & sticky tape covered cardbard panel, attached ot frame by alu tape ( note gaffer tape would be stronger but not fire resisatant )    

 After being filled with insualtion, this panel could be placed to insulate a wall. If a room divider is required, the other side could be covered with fabric stapeld in place (perhaps seam hidden iunder gap sealing gasket / foam )

Other side of hing & corner bracket showing 2 wood & 1 self drilling screw through metal . Hinge can be attached in different ways ie hidden in side gap

For external wall insualtion & greenery, I have been experimenting with trellis from local fence co pallet wood spacers (horizontal wood beams in pic) 

I will be looking at green walls generally, being  encouraged by this article - Green walls can reduce heat lost by buildings by over 30% in temperate climates

Below is Mk 1 trellis prototype. 1.8m h x 1.2m w

More thoughts on reusing plastic bottles, waxed cuboid cartons, metal cans & cardboard, for insulation & shrapnel protection

Following on from Previous experiments by Paul Ridley reusing plastic bottles, waxed cuboid cartons & cardboard over several years, mainly for packaging items & insulation, I have some more ideas.

A more urgent case for plastic reuse can be made with recent articles highlighting recycling problems, like The Big Plastic Count: Survey shows 'recycling doesn't work' 

  3 years ago, I experimented Making an Insulated Eco Brick by Filling Empty Plastic Bottles with Rolled Cardboard or Plastic & Evacuating Air (VIB))   

As the world has changed with major inflation, material shortages & european war. I believe it's time to revisit some of these ideas. Perhaps such ideas could be used in Ukraine to help protect from sharpnel while also insulating structures internally or externally from harsh winters.

I mentioned protection from projectiles on the blog post: Design method to reuse existing refugee camp tents and further insulate them from temperature / fire / projectiles at low cost

It has occurred to me that using water inside a can / bottle for thermal mass & projectile protection that has a squirt of expanding foam inside at either end to strengthen the structure & seal the water in.

Crumpled or shredded plastic /polysterene / cardboard  (see UBUNTU BLOX ) could also be used instead of water for impact 

 Fabric could be reused at either end & glued in place with the expanding foam for additional strength. I will update this blog with photos & progress shortly & welcome comments / related experiments 

update: 20-7-22 - Relevant full reseach paper on metal drink can insulation in concrete slabs

Evaluation of Aluminum Cans As A Thermal Insulator in Reinforced Concrete Slabs      March 2009  

"

The cost of any insulation material has the controlling rule for selection, the higher the cost,

the better the insulation and the higher the construction cost. In this study, AC was found to

meet the minimum cost requirements, since AC could be collected from Aluminum

Recycling Agencies, beside the minimal construction cost. AC may also be bought directly

from the factory for insulation use. The cost of AC is much lower than the cost of TB and the

PB

4. Conclusions:

The tested insulation materials were evaluated through models, AC showed a significant

results. Experiments also showed that the cans are a good thermal insulation material and can

withstand a considerable live and dead loads, in addition to the low construction cost and low

dead weight. From practical side of view, these cans could be packed using nylon sheets with

suitable dimensions (100x100cm or 50x50cm) for easy installation process beneath the

floor’s or ceiling’s tiles. As it was stated before that the AC recycling rate is decreasing, the

use of these cans is certainly will contribute in solving part of the environmental problems."

 

Edit: 22-7-21

 

(PR Idea) - How about making a living fence or wall insulating panel into a bug hotel by using wood or plastic frame, containing plastic bottles or tins stuffed with cut twigs/ hay etc into, 

Guide here - Build a bug hotel for spiders, woodlice, beetles, bees

Using cans info here

6 Large Rubble Bags of New Tanalised & Used Timber donated to Ellesmere Port Mens Sheds by Cabinz CIC / SAHBN

 6 Large Rubble Bags of New Tanalised & Used Timber donated to Ellesmere Port Mens Sheds by Cabinz CIC / SAHBN  on 8-7-22

Woodwork to Wellness in Saltney was offered some as well, but they have no storage, so we are storing some wood until they have the room

 

Low Cost 2 Metre Long Composite Plastic & Fibreglass Off Cut Beams supplied to Connahs Quay Allotment for Raised Beds. Many available for £6 each in 7 colours- rot free & don't need painting.

Many available for £6 each from Saltney, contact cabinznet@gmail.com 

These are to replace rotting scaffolding boards. We can deliver locally at low cost or post larger quantites of 20+ on a pallet nationwide . 

We can supply screws and metal angle brackets to join corners at low cost

Cabinz have previously made  these panels into Green Houses  Cloche & Polytunnel Frames (Heavy duty grp fibreglass sheets available at £5 a metre)  Organic Chicken Coops  Rot Proof Shed Base & Frame

2 metre x 48mm Door edge strip (DES) Original off cut from a composite door factory, when a door blank is cut to size. Available with a colour on one side of red, dark blue, mid brown, dark brown, black, green, white.

They are similar to hardwood in weight, take screws / nails fine & do not split. They have a wood grain effect fibreglass strip either side, and moss will grow on them in time

 These beams are nailed together from smaller strips (2 are shown in the front of the picture and are available for £1 each (min. 6) ) and were part of our long term test & have already been outside for 3 years in the weather without any damage and moss grew on the outside edges.

contact cabinznet@gmail.com to order or for more info.

 

Cabinz cic in local press - Chester: Expert develops new line of easy to assemble structures

Chester: Expert develops new line of easy to assemble structures

 https://www.chesterstandard.co.uk/news/20163545.chester-expert-develops-new-line-easy-assemble-structures/

Saltney based re-use expert Paul plans to turn scrap into refugee shelters and play dens

   https://www.deeside.com/saltney-based-re-use-expert-paul-plans-to-turn-scrap-into-refugee-shelters-and-play-dens/ 

 

D.I.G.R.S. - DIVIDE- rooms with portable insulated panels, fabric or green walls to save energy & aid function INSULATE -walls, floors & ceilings inside. Outside use green walls of soil / water thermal mass GROW - frruit & veg in pots inside & by outside walls for sustenance & mental / physical health REUSE - materials to do this or use materials with recycled content to save money & resources STORAGE & SECURITY in room dividers by adding insulation panels to back of storage unit book shelves

D.I.G.R.S. (an idea by Paul Ridley to help reduce the current high energy cost and food inflation / supply issues)

 

DIVIDE- rooms with portable insulated panels, fabric or green walls to save energy & aid function 

INSULATE -walls, floors & ceilings inside. Outside use green walls of soil / water thermal mass

GROW - fruit & veg in pots inside & by outside walls for sustenance & mental / physical health

REUSE - materials to do this or use materials with recycled content to save money & resources

STORAGE in room dividers by adding insulation panels to back of  storage unit book shelves, and SECURITY SHUTTERS where insulated panels can be reused with loose pin hinges for windows to insulate and protect from rising crime

I encourage people to source preferably reusable materials locally where possible.

Cabinz cic and the Shelter and the Hardware  Bank Network (SAHBN) can supply low cost , high quality fixings such as screws, loose pin hinges & growing buckets to groups to facilitate this and possibly donate some limited amounts. As mentioned by me previously, I recommend DIY'ers exploring Hexayurt construction methods & designs

By Paul Ridley 

contact - cabinznet@gmail.com

Plan to make a low cost hardware kit to allow low income groups to build locally sourced (preferably reused) panels to make foldable shelters like Hexayurts, or for childrens play dens, animals pens or room dividers to reduce heating costs and noise

 Plan to make a low cost hardware kit to allow low income groups to build locally sourced (preferably reused) panels to make shelters like Hexayurts, or childrens play dens, animal pens or room dividers to reduce heating costs and noise

  Following on from previous Experiments in Prototyping a 6' Hexayurt Shelter from  Metal Sided RIGID PIR Foam Sandwich Panels  this expands the idea to use  Loose Pin Hinges (Bzp 75mm -100mm)

 

on the corners joints instead of roof tek screws, so the hinge pins can be removed, and the shelter can be diassembled for storage / easy portability. Reusing panels for alternative uses such as window shutters for insulation / security could be explored. 

A profile / cover to seal the roof seams will have to be designed.

This panel joining system could also be used inside for other shelters such as childrens play dens, animals pens or room dividers to save heating energy, quickly stored away when unused 

An internal tensioned wire or threaded bar system to tighten structure may be required as loose pin hinge joints may need tightening. Perhaps this could be incorporated into a mezzanine in a hexayurt design 

A similar method has been used for 'removable pin split hinges as baseboard connectors'

Materials to experiment making panels for interior use:

If there is a budget:  

metal sided PIR sandwich panels (as in pic above) sips panels, mgo sips, 

recycled plastic panels (poss made by methods of www.preciousplastic.com

No budget: 

Used cardboard with edges taped to keep air inside for insulation, framed in Pallet wood, then painted using repaint project paint

Dissasemble used Furniture

We have been fortunate in aquiring several thousand of the hinges and brackets detailed below at very low cost, so we can beging to offer these hardware kits

75mm Loose Pin Hinges (100mm hinges also available)

 

 

 

Panel corners can strengthened with these Blooma Steel Fixing Clip 24mm Bracket 

 

or smaller panels can be joined together by using them in pairs fixed back to back 

 Panels from dissasembled furniture could be used like in link below and joined togethere with Blooma Steel Fixing Clip 24mm (pic above)

 Low Cost 1-2.05 M High New Remanufactured Shelving with Wood & Threaded Metal Bar Uprights that is Fully Height Adjustable in Several Sizes For Sale 

 Pic of plywood Hexayurt design which may be able to benefit fron the loose pin hinge idea

 

 related page http://hexayurt.com/index.old.html  

video of a Fold up Hexayurt https://www.youtube.com/watch?v=yzC-T72tnYc