I just toured Bonded Logic's Chandler, Arizona plant, 20 minutes outside of Phoenix, where each month the company converts 300 tons of post-industrial recycled denim and other cotton fabric into the UltraTouch line of cotton insulation, sound-proofing materials, duct insulation, and related products. I never knew there was so much I didn't know about cotton insulation!

Liz Obloy, the publisher of Sustainable Facility magazine, and I saw the manufacturing process first hand, from the bales of incoming raw materials to the packaging of finished product. This plant gets the cotton after it's already been fiberized — broken down into the constituent fibers. Bales of polyester and polyolefin "binder" fibers that give the material loft also come into the plant.

The fiberized cotton is treated with a borate solution to make it resistant to fire, mold, mildew, and pests.

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Robotics at the Trane factory In the Trane factory

I took the last train into Clarksville, Tennessee this week (that will mean something to those with enough gray hair) to visit Trane's commercial HVAC equipment manufacturing plant. I was invited, along with a half-dozen other editors, to report on Trane's transition to an ozone-safe refrigerant in its commercial HVAC equipment.

Trane used the opportunity to show off the state-of-the-art mechanical systems at the new 270-bed Clarksville Gateway Medical Center, and give us a wonderful tour of their massive, 1.2-million-square-foot Clarksville factory (one of Trane's largest). This was followed with a presentation by the Ingersoll Rand president and other company managers to the assembled 1,300 employees in celebration of the company's 18-month conversion from R-22 to R-410A — an effort that cost the company more than $100 million. (Ingersoll Rand acquired Trane in June 2008.) That was followed by a great barbeque under tents outdoors, and an exhibit of the company's 17 newly introduced, redesigned, ozone-safe products.

I've got to admit that I love touring industrial facilities. Seeing massive pieces of machinery turning raw materials into complex functioning equipment somehow gives me faith that we have the skills and technical know-how to solve the really big problems we're facing, such as climate change.

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I received an email from a Design student at Kingston University (London) writing a dissertation on "why people are drawn to design inspired by nature." Three questions were sent; I went overboard answering the first one, and basically wussed out on the second two. I'd be interested in your takes on this highly subjective stuff, and will be sure to let our dissertation author in on the discussion.

1. Why in your opinion are people so drawn to design inspired by nature?

2. What in your opinion is the finest example of design inspired by nature in the field of product and furniture design (my course)?

3. Do you think there are psychological benefits to design inspired by nature, and what do you think they are?

1. Why in your opinion are people so drawn to design inspired by nature?

I don't think everyone is drawn to design inspired by nature. Some like Le Corbusier's buildings at their boxiest, and contemporary glass and aluminum offices and homes, and Danish Modern furniture, while others like nature-inspired design... simply because they do. There's no accounting for taste. I know that speaks to the shallowest part of peoples' immediate and visceral reactions to aesthetics, but I think that most of the time — especially in this day and age — that's all there is to it. It's certainly not true of everyone, but most people in these harried times never have any need or desire to consider why some fashion appeals to them while some other fashion doesn't. It is what it is, and there are ten thousand other urgent things to attend to. If pressed, they'll tend to latch onto any available notions that support their position without actually considering them. Look to politics as an independent example of that. Trying to detangle rationalizations from pure impulse is a tricky business. (But it would probably be a much better world if more people tried.)

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Over at The Last Straw blog, Jeff Ruppert has posted a review of Making Lime Mortars, the first of a four-disc tutorial offered by St. Astier Natural Limes. Perhaps the thing I like best about the review is that it doesn't get into the whole "Why use lime" conversation... it respectfully assumes that you already know.

But in case you don't know, here's most of the product description for St. Astier's natural hydraulic lime from GreenSpec:

St. Astier Natural Hydraulic Lime, or NHL, is a 100% natural product that has been in production since 1851. St. Astier NHL Mortar is widely used in the restoration of old buildings. This natural hydraulic lime mortar imported from France allows stone to "breathe" naturally. Used in construction as plaster, stucco, mortar, and paint, its high level of vapor exchange and mineral composition can help reduce the risk of mold development and dry rot. NHL products are highly permeable, elastic, low shrinking, zero VOC, self-healing, and recyclable.

Architectural testing concern HTL will be at GlassBuild America shooting missiles at windows again. The demonstration/demolition follows the Miami-Dade large missile protocol by shooting 2x4s at impact-resistant and non-impact-resistant windows. A press release from HTL quotes NGA Industry Events Director Susan Jacob: "There is nothing quite like the drama of a 2x4 missile shot from an air cannon at glass windows." Wish I was going!

I checked HTL's website for some footage, but was left wanting. There's a link for client videos (and there's some top name clients in there), but they all seem to be password-protected. So it was off to YouTube to find this:

Another interesting short video — less than two minutes — was shot at last year's Glassbuild conference; a reporter from e-Glass Weekly played word-association with a few exhibitors. If this small sampling is any indication, the fenestration industry does not like the NFRC at all; was optimistic (as of last year) about commercial construction; and thinks green building and LEED are the future.

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Featured New GreenSpec Listing
Evergreen Aftermarket Blower Motor for Residential HVAC. Evergreen is an electronically commutated motor (ECM) aftermarket replacement for permanent-split-capacitor (PSC) blower motors in residential HVAC systems (except furnaces). According to the company, Evergreen can add up to 1 SEER point to an existing system and uses 25% less electricity than a PSC motor and 74% less in constant-fan applications. (membership required)

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Regular readers might remember the toilet-flushing video from March that showed ridiculous quantities of carrots, chess pieces, Gummi bears, hot dogs, plastic letters and numbers, grapes, golf balls, and dog food getting flushed. Fun, but it didn't qualify for GreenSpec because it only met the federal minimum standard for water use.

Well, here's one that does. The H2Option Dual-Flush from American Standard offers an industry-first siphonic flush of either 1.6 or 1.0 gallons. And it's fun, too. Be sure to show this to the kids (because they don't already have enough ideas).

• 20 golf balls (full flush)
• 1 lb orange peels (full flush)
• 11 water wigglers (full flush)
• 56 chicken nuggets (full flush)
• 2 lbs flushable cat litter (full flush)
• 5 large hot dogs (full flush)
• 5 large hot dogs (half flush)

Wieners aside, it would have been nice to see how all of these went down — or not — on half-flush.

Men should pee sitting down.

Now before you call me a strident feminist, let me say that I'm backed up on this one by male colleagues and the reasons aren't what you think. I'm not arguing for toilet equality here.

I'm talking about urine-separating toilets, which are much easier to use for men and women when sitting down. The bowl of these toilets takes urine in the front, feces in the back. It's hard enough to aim for the whole bowl (or so the evidence of many bathroom floors tells me), much less the front part of the bowl. One guy put a pee can in the corner, but that seems inefficient: pee in the can, then pour it down the toilet. Why not just pee in the toilet?

Why should you care? Because urine contains up to 90% of the nitrogen and 50% of the phosphorous in domestic wastewater. Those chemicals make for great fertilizer — stuff we have to use a lot of energy to produce artificially. In healthy populations, urine is sterile, and removing it from feces makes composting the solids easier and more effective.

Two models of these toilets are available in the U.S., both from Ecovita. But before you rush out to buy one and change your life, remember that composting solids and using urine to irrigate your tomatoes isn't legal in most places. You might be able to get special dispensation from the building code folks, but like most things involving wastewater treatment alternatives, it won't be easy.

Watch for the coming article in the September issue of EBN.

Update - the article is online (members only, though). Urine Separation: The Next Wave of Ecological Wastewater Treatment

Chart from the feature (requires login): Human Health and Environmental Concerns with Polystyrene Constituents (click image to enlarge)

The August EBN feature article, "Polystyrene Insulation: Does it Belong in a Green Building?" (requires BuildingGreen Suite membership) and an accompanying editorial "Rethinking Polystyrene Insulation" (free content) has led our company to reexamine some of the products we list in the GreenSpec Directory.

As those articles (and the related blog post, "Avoid Polystyrene Insulation") point out, there are some troubling health and environmental concerns with both extruded and expanded polystyrene insulation (XPS and EPS). These concerns relate both to the underlying chemistry of polystyrene (especially the benzene used in its manufacture) and a flame retardant, HBCD, that is used in all building-related XPS and EPS products.

Given these concerns, our editorial staff reached the conclusion that polystyrene insulation made with HBCD is "less green" than most other insulation materials. This doesn't mean that there aren't green products made with EPS or that alternative products are necessarily benign. But when there are alternative insulation products that we consider to be more attractive from a health or environmental standpoint and when they offer comparable energy performance, then we consider those alternative materials to be preferable.

So, what does this mean relative to our GreenSpec listings?

Due to environmental concerns with ozone-depleting HCFC blowing agents (which are to be phased out by the end of this year), we do not, and have never, included XPS products in GreenSpec, so there is no change there.

We did remove several EPS boardstock insulation products, and we are working hard to replace them with what we believe to be greener products, such as additional rigid mineral wool insulation products.

However, there are a lot of EPS-based products that are remaining in GreenSpec because we believe that their energy-saving benefits outweigh the health and environmental concerns. These are mostly structural insulated panels (SIPs) and insulated concrete forms (ICFs) — of which we list dozens of each — as well as some specialized products, such as exterior insulation systems used for insulating existing buildings. These products are being used in many of the lowest-energy buildings being built today. Note that our inclusion of these products may be reconsidered in the future if good, non-EPS alternatives emerge in the marketplace and EPS manufacturers fail to find an alternative to HBCD. While we very much hope to see the HBCD flame retardant removed from these products — and we are confident that manufacturers are working to identify safer replacement chemicals — we recognize that energy performance of buildings is a top environmental priority, and EPS continues to play a vital role with many such products.

We look forward to participating in a dialog about life-cycle concerns with polystyrene insulation and hope that our position begins that discussion.

We welcome any comments you wish to post about this issue — use the comment function below.

You can follow my musings about this and other issues through Twitter.

Polystyrene Molecular Structure

That said, insulation materials are not all created equal. When we consider the health and environmental impacts of products over their life cycle (with life-cycle assessment or LCA), some materials look a lot better than others. That's just as true with insulation as it is with any other product, from flooring to adhesives and paints.

This brings us to the issue of polystyrene insulation. Recent concerns have been raised about the brominated flame retardant HBCD (hexabromocyclododecane for the organic chemists among us)—see our coverage in EBN about this—that is found in all polystyrene insulation, both extruded (XPS) and expanded (EPS). HBCD may not (yet) be a household word like bisphenol-A has become, but it's been raising plenty of concern.

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