John B. Carnett, PopSci's staff photographer, is using the latest green technology to build his dream home. Follow his progress in his monthly magazine column (the first of which you're reading now) and on the Green Dream blog.
In the past 20 years, I've lived in some pretty weird places — a leaky loft, a sailboat, an old carriage house that I rehabbed myself. Makeshift bachelor pads were fine until I found myself with a wife and two small boys.
Now I'm building a real home on three acres of land with river views and plenty of room for the kids to explore. And I'm going as green as I can, as cheaply as I can, starting with the prefab panels that I'm using instead of lumber to build the basic frame.


The walls arrive on site pre-cut and ready to install, no special tools or hired help required. With a few buddies, I simply tilted the panels in place and secured them to a steel track on the foundation, building the whole box in less than eight days. A lumber frame would have taken me weeks to measure, cut, fit, and nail everything in place. Other types of insulating panels can require extra labor and a crane to install — in other words, more time and money.
House: 3,500-square-foot, four-bedroom contemporary
Location: Greenwich, N.Y.
Project: Install a prefab panel box
Cost: $7.04 per square foot
Time to install: Approx. 8 days
Materials: Metal frame filled with expanded polystyrene and graphite
Eco advantages: Fully recyclable; no off-gassing, heat loss or mold
Five amazing, clean technologies that will set us free, in this month's energy-focused issue. Also: how to build a better bomb detector, the robotic toys that are raising your children, a human catapult, the world's smallest arcade, and much more.


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Is the cost relative to location? He is in N.Y. and I am in Ga. will it be cheaper for me to build here in the south?
Cant wait to see the video's of the construction . If anyone has any links our further information about designing a project please post.
It should be interesting to see all the tradeoffs. It is easy to see how the costs could be close to stick since it appears to be a simple form with metal exoframing. How does this construction hold up in a high wind situation I wonder. I did see a sheet metal exterior on one picture. Fill it and you have concrete foam construction. And that is high wind tolerant.
This is a great post. However I think it would be a little better with at least some pictures of what was done. Also this seems to pick up after the foundation was poured, was there anything special that needed to be done there. Is there a basement or does this need a slab.
Sorry one more thing..Is that $7.04 per square foot of the house or per square foot of the walls.
Fascinating article. Would like to know more about the walls and how they hold up with longevity/maintenance vs. lumber or steel construction. Also, there is no mention of fire resistance...same as lumber?
I am really looking forward to this project playing out, more details on the foundation and what type of roofing panels are available, pitch, slope, and all the necessary structural info would be great to get one's design cap on to create the new greener homes of the future. Also some contact info for direct contact with the Kama Building Systems Co. would be a real plus! What about local building codes and possible multi family units...more...more ...more!
More information on Kama Building systems can be found at www.lightshipgroup.com. This product is energy efficient and can be used for residential and commercial applications.
is this type of construction approved by most regions and administration authorities? or is it going to be scrutinized for months before permits are issued? i'm very interesed.
I'd like to see more detail on utilites races thru the material: how do you move electrical wiring vertically, how do you install plumbing piping or pex for plumbing fixtures?
Was this supposed to be an article or a teaser?
There was no significant information!
It looks interesting, but 'where is the beef'?
I would expect better from PopSci.
I live in GA am in LV now. Went to kama headquarters here and saw production facility. The guys on the east coast makes panels for new england area. Kama owner was great to visit with. I am a builder and came away with lots of material. Saw panels being made. Worth it if you visit vegas. I think the web site is www.kama-eebs.com. Jon
i agree with caste & uglib MORE! & QUICKLY!! please start from the foundation up for those who would like to follow in the author's footsteps. i would think that if it is too expensive for the print version PopScicould get more details here.
$7.04 a square foot for the panels WOW. I can't afford it now but eventually plan to build my own house on 31/2 acres I will inherit one day. Just think how affordable grren housing might be in five to ten years when I'm ready. This has inspired a new direction in my ideas of what my house would be like. I plan to do all I can to make it self efficient and completely off the grid except for communications of course (gotta have my net)! MORE PLEASE!!
The construction cost for "just the panels" will be related to the trucking distance from fabrication to site and then your local labor rates. The cost of the rest of your house (electrical, roof, etc.) will be regional.
Staff Photographer
Popular Science Magazine
"uglib" ASKED about the foundation?
I am building into a bit of a hill so I used typical footings and then an ICF foundation and first floor wall that went to the first 10'. I did not have to bring the ICF to 10' but wanted to experiment with the material. I installed radiant heating in the first floor slab.
Staff Photographer
Popular Science Magazine
"Stephen Fields" Asked about pex/electrical runs in the material...
The material comes from the factory with a pre cut horiz run on the interior of the material- You would typically not be running plumbing on an exterior wall so the pre cut area is perfect for wire-but you could run so Pex- The factory supplies you with a heated cutter to go vert- or make a last minute drop in the field.
Staff Photographer
Popular Science Magazine
"caste" asks for MORE...
The project is early in it's construction- Every system and subsystem is under review every day-please follow the blog as I find my way thru the options...
Staff Photographer
Popular Science Magazine
What keeps the walls from biodegrading in place? My first home was a 236 year old pier and beam in Mystic Conn. No bidegrading goin on round there
I'm glad to see more and more people looking at energy efficient construction. I would like to introduce you to a green building product that has been around since the 70's called ThermaSteel. (www.thermasteelcorp.com) We have buildings in all 50 states and 27 countries with national and iternational building code approvals. The more companies entering the green buildng market will allow more people to become aware of alternative building systems, which is great for the enviroment. I am very interested in seeing how this project progresses, please include additional photos in your next article.
Hey JC, hope you're pleased with the updated construction schedule. All of us here at The Lightship Group http://lightshipgoesgreen.blogspot.com are thrilled to have aided with the homes design and engineering. Thanks for choosing our firm as you Construction Mangers as well. Together we are really creating something special, thanks in large part to your vision. See you onsite.
when can i move in? www.youtube.com/watch?v=hEUWrj7SyPk
Thank you John, incredibly inspiring. Most educated people understand the possibilities of living "greener," in every aspect of life yet are unaware of the steps needed to take in order to make it a reality. Great to see some articles and facts with steps and progress in turning a home no-less into an eco-friendly entity. Will be following all your posts. . .Keep them coming and keep the masses updated and educated.
-Verblist
-Verblist.net
Wow, this is seriously cool. My goal in life is to have a house made out of 100% recycled material.
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JC - In the '80s, I used a Nascor SIP 1st floor and raised the existing building (now 2nd floor). Fastfoot has an interesting, continuous pour, footing and ICF wall. Legalett has a pad foundation and radiant floor heating (air) system (one 'piece'). Warmboard has a simpler subfloor, radiant heat (water) system. I am looking for ideas, to build a 24' x40' heated work shed, in a water access location. My thinking now, is to use Fastfoot footings; PT wood foundation; SIP floors, walls and ceiling; black, perforated steel panel skin (for passive solar heat); oriented, 60^ sun facing (at 45^ latitude) steel roof panel (for future, cheaper, membrane, solar heat and power) - and all of the efficient doors, windows, etc. I also want a glass, patio/garage door, with at least a 9' wide opening - to store a trailered boat in winter; and ??hard?? floor covering - to handle snowmobile studs and carbides. The water access is a limiting factor for weight and machinery.
I never have much to add to these blogs, but thought I would concur with those who would like to see more pictures of the actual project.
Mr. Carnett- Put the Earth to Work- great article. I am in the GEO Thermal energy field. I did some quick calculations for your 3500 SF home and with a total of 1300 LF of loop pipe will provide about 39000 BTU's of energy source or 3.25 tons. This amount
Mr. Carnett- Put the Earth to Work- great article. I am in the GEO Thermal energy field. I did some quick calculations for your 3500 SF home and with a total of 1300 LF of loop pipe will provide about 39000 BTU's of energy source or 3.25 tons. This amount of loop piping seems a little short for the size of the house, unless the building envelope has a high R factor. The standard for loop piping is 30 BTU's per LF Example a 200'verticle well with a soil conductivity of .85 equates to approximately 12,000 BTU's.
bemethompson: www.kama-eebs.com. Also info@kama-eebs.com. 702-451-7155. I am going in for training on their product this week in Las Vegas. KAMA has a new eco system for existing structures which I am very interested in. Wraps the building without any deconstruction to the existing structure at all.
Neopor? Steel? If you truly want to build an eco-friendly, efficient and sustainable structure, why not use earth bag construction. Earth is free (once you purchase the land) and nothing is more efficient than 3 foot thick earth insulated walls. Google it.
I have been reading PoPSci since I was a child and enjoyed many long discussions with my dad. In fact I thought I’d become an inventor one day but took the path that lead me to write today. While obviously well intentioned, like much of the green movement, this "dream house" is an embarrassment. The desire for a house to be energy efficient does not mean it has to be designed by amateurs and look like a human storage unit. Architects spend 6 years in college learning how to understand design then another decade before some of us become good at it and others give it up for a less tortuous pursuits. Homes are where American families bring babies to grow into children and healthy adolescents, do homework and one day introduce their future husbands or wives. Where people fall in love and live their dreams as they grow old together. This looks like a little chemical plant that tests fertilizers on it’s roof. I don't disagree that it's our fault. The American Institute of Architects is famously bad at communicating with the public. One reason for that is that it's mostly run by those with time on their hands - which is rarely the best us. ..and the public has little interaction architects. Unless you're wealthy or a high level executive, you may never meet an architect your entire life, let alone know what we do. But I can tell you with great confidence that what we spend all that time learning cannot be cranked out by Joe 12 pack who just spent $49.95 on do it yourself house maker software any more then a taxi driver can design a race car. Whether Pop Science or anyone else, I urge you to spend a little time learning about how important architecture is to our daily lives and where it really comes from. Look for your local AIA chapter and search for 'design awards' to find firms near you that would be happy to help. If you're serious about wanting to see what the next generation of American home could become, don’t be so cheap. Hire a talented architectural firm to design and engineer one that fits your goals and vision. Have him include mechanical, electrical and plumbing engineering consultants who will design those systems around the latest technology available for the goals while he focuses on designing the house for people who will actually want to raise a family there. I am confident that you will be very pleasantly surprised by the talent and knowledge that resides within even modest size architectural firms in your city.
Fantastic. Nothing inspires me more than individuals actually make a stance for themselves and doing it there way. I have seen many creative methods of sound proofing, managing elements and also just simply aesthetic appeal. This ticks all the boxes. Well done and thank you.
www.eurocell.co.uk
With so much discussion on the technical aspects of your home building, I am going to just state that you are an inspiration to those who dream of building the dream for their family, and you are doing it in style with consideration for the impact you may have on the landscape. Your two children will be proud that is for sure. Good luck!
www.northchicago.floorcoveringsinternational.com
As well as the energy saving and efficiency that has to be gained from these new building materials I feel when they become more widely available and the prices for procurement of these materials comes down and technology more accesible we can maybe use this technology to provide housing to third world countries who have not yet the expertise and skills to produce this quality of building.
This magazine is leading the way and I hope people from poorer countries are accessing it and gaining the valuable insights that my company certainly has.
www.fasciasoffitsuk.com
The end game is to build a solid structure that will perform at an unusually strong energy-saving level. kama and Green-Source Products, Cleveland, OH. are both making a similar wall and roof panel. Both of these companies use tubular steel studs which when installed into the solid EPS insulation, will create a terrific thermal break. Other manufacturers make a wall type with a thru-stud design that transfers the heat or cold more and as such performs at a lesser R-value theoretically. In all these cases, these new wall type designs using a solid insulation material far exceed the performance of the standard wood or steel stud wall type + fiberglass batt insulation, offering a substantial on-going ROI for the homeowner. Building with the traditional wall and roof types is simply black & White TV technology ! Who would logically invest 21st century $$$ on a 20-30 yr. investment developed during WW 1; it's another case of suppressed innovation whose time has come !! Energy usage typically runs $1.25-1.50/sq.ft./yr. and with good planning and execution it can be affordably reduced to $.45-.65/sq.ft/yr. ROI should be 2-3 yrs. max. to pay for these technologies, so unless you are moving out right away you win bigtime !! Now can we get the architects to design with these innovative designs PLEASE !!
J.W.