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Compressed Waste Straw Fibre Panels For Low Cost Housing and Schools

Country: Canada

Organization: ABT Insulpanel Limited

2) Sector of activity: Housing

From this . . .

3) Description of your products or services: We have developed a technology using waste fibres from wheat straw, Elephant Grass and Typha Australis (cat tails) as well as other indigenous grasses to make compressed fibre panels for housing, schools, field hospitals, community centres and etc. for low-income peoples.

This system uses renewable as well as biodegradable materials. This sustainable, biodiverse system is unique as it uses local materials versus importing at a much greater cost.

The houses are very low cost, can be built by locals in a very short time, vermin reistant, weather and sound proof, earthquake and high wind resistant, healthy, easy to maintain, long lasting, modular (expand as family expands) functional and attractive. The local farmers/population will be the gatherers and harvestors of the fibres rather than burning the fields after wheat harvest or burning back or slash burning the wild grasses. Using local fibres creates income for locals and has a direct impact on the local as well as the global environment. No burning of fields or depleting the forests.

4) Description of the operational model: The Mill, a continuous extrusion machine in which five processes take place.1 Raw material preparation during which the fibres are loosened and spread along a conveyor belt leading to the compression ram. 2 Compression process, during which the fibres (without any additives) are forced into the extrusion tunnel by the rapid strokes of the. 3 Heating process, during which the compressed fibres are heated by the high temperature (400˚F) of the top and bottom plates of the extrusion tunnel.4 Wrapping process, during which the compressed fibre material is covered on all sides with heavy Kraft paper adhered with a thin film of thermosetting resin adhesive. This wrapping process takes place while the panel is passing through the heated extrusion tunnel.5 Cooling/cutting process,the continuous Insulpanel panelling strip travels along a conveyor line to allow cooling. At the end of the line the strip is cut to the various desired lengths of panels.The Insulpanel panelling consists of a highly compressed fibre core, all surfaces of which are wrapped with heavy Kraft paper. Several agricultural waste fibres can be used as the core material, all of which are available in abundance at low cost. The Insulpanel panelling cross-section dimensions are set at 2 inches thick (5.08 cm) and 47.25inches wide (120 cm). It is then rough-cut to several selected standard lengths from the continuous strip. The factories are built were the grasses are and low income peoples live. Grass = House

With this . . .

5) Description of the financial model: Since the houses are modular and kit packages the majority Low-income peoples will be able to afford either a complete kit or panel by panel. The kits are easily erected by the buyer with a minimum of supervision. Many of the buyers will be either farmers or local gatherers of the grass fibres and will be paid for the raw material or credited with housing panels. The initiative is very self sustaibale and is expected to earn profits after the first year of production. The strategy is high volumes,low costs and low mark ups.

      Client fees represent this approximate percentage of operational budget: 0%

6) Key operational partnership: The main partners are local farm communities,private business entrepreneurs and Regional Governmnts. The major opportunities is to turn waste material into a cash crop. Wheat farmers in developing countries typically burn or turn the straw under after harvest. Burning is a disaster to the environment and turning under depletes the health of the soil. In regards to Elephat Grass, every year a mass burning takes place to push back the encroacment of wild grasses on arable lands.

By locals . . .

7) Current outreach:

  • We are at the Start Up stage. The first(Turkey)plant will be in production this fall and will supply panels to Nigeria and coffins to Kenya. The machinery for Nigeria will be shipped this coming January and will be in production late summer of 2006.

  • How many clients have benefited from your product/service in total? Over the last year? Start Up

  • What percentage of your clients is below the poverty line ($2 per day)? 50%

  • What is the order of magnitude of the potential demand for your products or services? Which
        other low-income groups, countries or regions could benefit from it? Try to quantify (number
        of clients, market size in currency):

    The numbers are beyond calculation and are limited to production capacity. Each Mill can produce 4000 low income homes per year and the Government of Nigeria ahs indicated it requires over 100,000 homes per year. We are also going to produce 100 Prmary Scholls for Northern Nigeria per year during start up. Each factory site can support 3 production lines = 12,000 low income homes per year.

    To this . . .

    8) Scale-up strategy:

  • How many low-income individuals do you plan to benefit in three years from now? How are you planning to scale up or replicate your solution? What are the major constraints to scale up?
    In general the outcome will promote livelihood and lifestyle. Initially the project will require no less than 40 square kilometers (15 square miles) of fibre production (3885 hectares or 9600 acres) to produce approximately 4000 low cost 90 square meter homes. This amount can triple in three years.

    Scaling Up and Replicability potentials are realistic. Eastern, Western and Southern Africa are all potentials. The company is also working in Turkey, Romania, Ukraine for low cost housing projects using the local waste wheat straw. The main constraint is financing. A minor one is getting local building approvals also solved with financing.

  • Which specific areas - and why - in your field would benefit most from investment by corporations, foundations, and other investors:
    The project is structured as a profitable enterprise guaranteeing its sustainability over medium/long term. High volumes/low mark-ups. Large targeted beneficiary base.The Scaling Up and Replicability potentials are realistic. Eastern, Western and Southern Africa are all potentials. The company is also working in Turkey, Romania, Ukraine for low cost housing projects using the local waste wheat straw.

    9) The organization: How does the initiative fit with your overall organization's strategic goals and priorities? How did the initiative start?
    ABT Insulpanels main objective is to supply low income housing in large volumes with minimal mark-up to developing and third world countries that are agriculturally dependent or have access the grass fibres similar in structure to wheat straw.Our company and staff have been involved directly in affordable housing solutions in Eastern and Central Europe since 1989. The company specialized in Light Steel Framing for residential construction and received building approvals in Ukraine, Croatia and built model house in Zapresic, Croatia in cooperation with the Canadian International Development Agency, an addition and renovation to an apartment complex in Lviv, Ukraine with a local bank and Export Development Canada. The company strongly believes in transferring technology, know how, manufacturing equipment and processes. Since 1998 the company focused on a lower cost building systems.

    10) On the mosaic diagram, which of these factors is the primary focus of your work?
    Factor: High volume business based on small (even tiny) in
    Principle: Leverage the power of communities as both consumer

    Contact Information:
    Name: Mr. John Daniels - President
    Organization: ABT Insulpanel Limited
    Mailing address: 814-8501 Bayview Avenue, Richmond Hill, Ontario L4B 3J7
    Country: Canada
    Email: danielsabt@sympatico.ca
    Tel: (905) 882-2499
    Fax: (905) 882-5168
    Website: http://hometown.aol.com/danielsabt/myhomepage/business.html

    Organization's legal status: Province of Ontario, Canada Incorporation
    Number of Employees: 65



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