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1) Site Prep. & Footing Placement
Trenches are dug for the future stem wall and footing. Rebar is put in place and the footing is poured. Trenches must be dug wide enough to allow for GFRC spraying once the stems are put in place.
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2) Stem Placement
Stems are placed on the footing and leveled using a thin layer of grout. Once the stems are set in place and leveled, they are coated with GFRC.
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3) Slab Placement
ABC is put down where needed and slabs are poured. S.A.B.S. can be used as a floor if desired. In this case EPS panels are laid flat and coated with GFRC.
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4) Walls Placed
EPS panels are put into place. These panels can either show up to the site cut-to-fit or cut and fit into place on site. These EPS panels are joined using various types of S.A.B.S. approved EPS adhesives. Once the EPS panels are set in place they are coated with GFRC.
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5) Roof / Intermediate Floor
Roof panels must be pre-coated to prevent the EPS from sagging over long spans. These pre-coated panels can be various shapes and sizes depending on the job. These panels can be placed by hand or by crane to speed up the construction process. Once these panels are set in place they are joined at the seam using GFRC.
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6) Utilities installation
Wires and piping are installed by trenching the EPS. Using a hotwire you remove EPS right where the item will go. These items are now glued in place using expanding foam adhesives. Once these are glued in place the wall is coated with GFRC.
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7) Window and Door Placement
Windows and doors are shimmed in place using conventional means and then adhered to the structure using expanding foam adhesive. Waterproofing is necessary for any installation that is exposed to the outside. This is achieved by a bead of sealant around the exterior of the installation.
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8) Finish
Finishes are applied directly to the GFRC coating of the structure. Stucco can be applied without the use of foam, paper or chicken wire. Siding, half brick, and stone can be applied using conventional means also. The interior can be finished with basic texturing or any other finish desired. The GFRC shell can be left unfinished, if desired.
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