Zach Popp builds greenhouse from Hempcrete prototype

WITTENBERG — Ten years ago, Zach Popp’s newborn daughter developed respiratory problems. Eventually, they were linked to black mold caused by an ice dam in her bedroom window. This got him thinking about the need for a better construction product, which led him to the bio-composite material, Hempcrete.

“I found out about Hempcrete and how it dries out and prevents mold from forming and is very breathable,” said Popp. “I started to dive into the research being done in Europe for this kind of product.”

Popp, who lives just east of Wittenberg with his wife and seven children, works full time as the director of recruitment for Northcentral Technical College in Wausau. He admits he doesn’t have any other hobbies to interfere with his pursuit of developing better construction materials.

About three years ago, he started working with materials and came up with a proprietary blend of hydrated lime with a special additive — hemp and water. He experimented with different sized panels and developed two-foot blocks to fit within the traditional framing used in building houses.

Having worked seven summers with his father in the construction business, Popp has the practical background needed to understand industry standards. He’s been perfecting his own green building products in his garage.

In January, he built a prototype in his backyard to prove that construction with the product can be done in winter. The greenhouse he constructed was a manageable size and something his family could use.

“I set up a mini factory in my garage and spent a solid month creating the blocks for the greenhouse,” said Popp.

His next phase is to build an entire house as proof of concept. He would like his test home to be his family home.

“I believe in it, and it’s safe,” he said. “I’ll be open to let other people come in to see it.”

Building with Hempcrete is a fairly new industry in the United States according to Popp, who noted the first home in the United States was built for the mayor of Asheville, North Carolina, in 2010-11. Popp believes there is a growing need for construction products that are sustainable, breathable, mold resistant and cost effective. Popp said that building with Hempcrete can eliminate three of the six materials currently need for traditional building; there is no need for insulation, sheet rock or the vapor barrier.

His vision is to have a manufacturing plant in the area, using hemp grown by local farmers. He notes that even though it’s only the second year that hemp growing has been legal in Wisconsin, the number of permits issued this year over last was huge. According to his website, the hardy crop is simple to grow and doesn’t need pesticides. The part of the plant that is used is the woody part that normally gets thrown away because its totally biodegradable.

Popp has run the numbers and said he would need a 4,000-square-foot manufacturing facility to make 40 blocks a day. That would produce enough blocks for one house every two weeks.

“I have some pretty big steps ahead of me,” said Popp, noting that there is still a lot of independent certification that needs to be done, and a strength test alone can cost up to $10,000.

His business plan estimates about $200,000 would be needed to build a house, which includes all the materials but not the labor. He still needs to find the lot, he said.
Popp’s time frame for this business is to raise funds for the next six months and start construction by this time next year. Ideally, the product will be ready to market within two years with all of the certification testing done.

“I want to make sure I’m ready to deliver when the marketing kicks in,” said Popp. “I need to make people aware of the product.”

He plans to market to construction companies and home builders and knows he needs to get both on board to get his company going.

More information can be found on his website sativabuildingsystems.com.