Building with Nature

Straw, clay, black locust, and recycled glass make up key components of this Bear Lake home

By Hanna Lee-Kleb | Sept. 21, 2024

On a rural farm near Bear Lake, a distinctive home is under construction, challenging conventional building practices with its shape and its use of natural materials.

Led by builder Thomas Hirsch of Benzonia-based Bungalow Builders and architectural designer Ellis Wills Begley of Bale Craft, the project embraces sustainable methods, incorporating materials like straw-clay insulation, black locust wood, and foamed glass aggregate. This unique structure offers a glimpse into the future of eco-friendly and healthier living spaces.

A Round Design Rooted in Nature

The decision to build the studio in a circular form wasn’t merely aesthetic. According to Begley, round shapes are inherently natural and create a sense of openness, free from the harsh edges of conventional design.

“Circles create comfortable, inclusive spaces that don’t have the hidden corners that collect shadows or dust,” he explains.

For Hirsch, the challenge of constructing a round house was a welcome one. “It poses unique structural requirements that you don’t face with a rectangular house,” he says. “But I enjoy that challenge, and the owner was keen on this design, so we made it work.”

The round design required innovative techniques, including diagonal bracing, which Hirsch likened to creating a basket.

“The diagonal bracing creates a strong, supportive framework,” he says. “This was our first straw-clay round house, and it came with its own set of challenges, but the result is something really beautiful.”

A Low-Carbon Insulation Alternative

One of the standout features of this project is its use of straw-clay insulation. This natural material is a blend of straw, which is a waste product of grain production, and clay. The straw is coated with a clay slip, giving it fire-retardant and thermal mass properties, meaning it can store heat or coolness for extended periods.

“Straw is an amazing material—it’s hollow, so it traps air, making it an excellent insulator,” Hirsch says. “And when you mix it with clay, it becomes resistant to fire and mold.”

While straw-clay is cost-effective in terms of materials, it’s labor-intensive to install, which presents a challenge.

“The materials are dirt cheap—literally,” Hirsch jokes. “But it takes a lot of hands-on work. That’s why we often involve the homeowners in the process. They can contribute to the build, whether it’s mixing straw and clay or applying natural plasters.”

Thomas also notes that the use of straw-clay insulation is now code-approved in Michigan, which has helped reduce the hurdles for builders interested in using this sustainable material.

“It’s been approved since 2015, which makes things a lot easier. But back when we first started using straw-clay, we had to present engineering reports to get it through the building department. Now, it’s recognized as a viable method.”

A Durable (and Invasive) Wood Source

Another key material in the studio is black locust wood, chosen for its natural durability and resistance to rot.

“Black locust is one of the most rot-resistant woods that grows in America,” Hirsch tells us. “It’s super hard and can be a little tricky to work with because of its grain, but once you get the hang of it, it’s fantastic. It’s also an invasive species in some areas, so using it is kind of a win-win—getting rid of an unwanted species while building with a material that will last.”

Unlike chemically treated lumber, which can release toxins, black locust offers a natural, non-toxic alternative that aligns with the project’s broader goal of creating a healthy living space.

Recycling Glass for Insulation
Beneath the studio’s floor is another eco-friendly innovation: foamed glass aggregate. Made from 100 percent recycled post-consumer glass, this material provides a sustainable alternative to Styrofoam insulation, which is commonly used in conventional builds.

“Foamed glass aggregate is one of my favorite materials,” Begley says. “It’s non-toxic, made from recycled glass, and doesn’t produce harmful dust during installation. Plus, it allows moisture to move freely, which helps prevent mold.”

By using foamed glass aggregate, the builders were able to eliminate the need for plastic vapor barriers, further reducing the project’s environmental impact.

Natural, But Not Simple

Despite the numerous benefits, building with natural materials comes with its own set of challenges. For Hirsch, the most significant hurdle is the work involved.

“It’s labor-intensive,” he says. “If a client wanted to hire out the entire process, it wouldn’t necessarily be cheaper than using conventional materials. That’s why we encourage homeowner involvement. It not only helps reduce costs but also creates a deeper connection to the home.”

Hirsch has seen a growing interest in natural building methods, particularly from clients who are looking for healthier homes.

“People are starting to question the materials we’ve been using for decades,” he explains. “They want homes that don’t off-gas toxic chemicals, homes that are energy-efficient and environmentally friendly.”

Hirsch acknowledges that natural building is still on the fringes in many areas. “Here in northwest Michigan, it’s not as widespread as I’d like it to be,” he admits. “But there’s a growing movement, especially among younger generations who are more mindful of their environmental impact. And that’s exciting.”

Looking to the Future

For Hirsch, the future of natural building lies in education and community involvement.

“One of my dreams is to create a natural building and design institute here in northwest Michigan,” he says. “We need more people trained in these methods, and we need to keep experimenting with new materials and techniques. There’s so much potential—whether it’s using mushrooms as insulation or finding new ways to sequester carbon in the building process.”

And rather than doing all the work individually, there could be benefits to going back to the barn-raising days of yore, where communities and trained experts would work together.

“If we can create a system where people help each other build, like a cooperative labor pool, we can reduce costs and make natural building more feasible for a wider range of people,” Hirsch adds.

As for the round studio home, it stands as a testament to what’s possible when innovation and sustainability come together. “It’s a labor of love,” Hirsch says. “But when you see the finished product, it’s all worth it.”