Papercrete is a building material consisting of re-pulped paper fiber with Portland cement or clay and / or other added soil. First patented in 1928, it was revived during the eighties. Although perceived as an environmentally friendly material due to the significant recycled content, this is compensated by the presence of cement. The material lacks standardization and, therefore, proper use requires care and experience. Eric Patterson and Mike McCain, who have been credited with the independence of "inventing" papercrete (they called it "padobe" and "fibrous cement"), have contributed significantly to research into machinery to manufacture it and ways of using it for construction.
As of 2007, papercrete lacks the approval of the International Code Council. This limits its range of use within the city limits of most of the incorporated cities of the United States where construction codes are applied. It is not used as a loading wall where building codes are applied. However, its strength in the structures of the models has been demonstrated and houses and small commercial buildings are being built. There is little or no evidence of its long-term durability today.
In these small construction projects, papercrete is used as a filler wall in combination with structural steel beams or other carrier elements.
Papercrete gets its name from the fact that most formulas use a mixture of water and cement with cellulose fiber. Fiber is usually purchased from recycled paper, lottery tickets and telephone directories. The mixture has the appearance and texture of the oatmeal and is poured into forms and dried in the sun, just like the process for the manufacture of adobe.
Dry papercrete has a very low strength but fails by slow compression (due to the high air content and therefore the compressibility) instead of being brittle. Concrete and wood (although dry and soft wood can be as high as R-2 per inch, the high moisture content greatly reduces this value) are not known for their insulating qualities; however, papercrete also provides good insulation.
The Papercrete R-value is reported to be within 2.0 and 3.0 per inch (2.54 cm); the papercrete walls are typically 10 to 12 inches thick (about 25-30 cm). Unlike concrete or adobe, papercrete blocks are lightweight, less than a third of the weight of a brick of comparable size. Papercrete is resistant to mold and has utility as acoustic insulation material.
Research papers on papercrete have been conducted by Barry Fuller in Arizona and Zach Rabon in Texas. Fuller directs government-funded research on papercrete through Ira A. Fulton School of Engineering at Arizona State University. He is also the head of a subcommittee for the American Society for Testing and Materials, and his goal is to establish standards that will lead to product acceptance within the architectural community and product marketing, especially for affordable housing.