Tag Archives: Timelapse

XPS gunite formwork for the south wall

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Posted on July 14, 2018 by

In this segment, we formed the south wall for gunite.  The video, details and pictures can be found below.

The Video

Details

Order of the layers

We had formed previous shotcrete walls with steel studs and lath and steel studs with XPS insulation.  We liked the idea of combining the insulation in the form because it saved us the step of attaching it, however, the steel studs caused “void shadows” in the shotcrete and water could travel thru those voids, etc.

For this south wall, we decided to use the steel studs to form the XPS, but we would put the shotcrete outside the insulation, on the opposite side from the steel studs.  We could then use just a single layer of XPS and then backfill between the Studs later to increase our R value.

If this were a load bearing wall that needed to incorporate rebar in the shotcrete, we may have come up with a different idea.

Curved Bucks

To make the curved bucks, I used CAD software to figure out the size and angles of the little wood blocks, making sure that the longest side was something easily measurable on a straight edge.  In this case, I used a 5 inch length (4.999 is close enough to 5) and an angle.  I setup the miter saw with a stop block so I wouldn’t have to measure each one.  Then I would just need to flip the wood board for each cut so the blocks came out with the right trapezoid shape to assemble into the circle.

Gallery

A picture is often the best way to tell a story, so here are a bunch of them.

Erecting the steel for the radial vaults

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Posted on July 6, 2018 by

 

This post is all about erecting the steel arches and rebar for the radial roof vaults.  This process took us a few weeks to get done and really looked great.  I’ll put details and a lot of pictures down below, but first, the time lapse videos…

The Video(s)

Yes, I had to break this one into two videos.

Here is the first 6 vaults going in…


And here are the remaining 4 and a final walk thru.

The Gallery

A picture is worth a thousand words, so lets talk about things in the context of a gallery…

Stucco For the Bedrooms

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Posted on January 20, 2018 by

This post has two videos (because I had too much footage) and a lot of good pics in the gallery.

The videos

The first video is about applying the scratch coat.  This actually took most of the time because we spent a lot of time trying to make everything nice and smooth over the rough shotcrete and lath walls.  After getting the wall the right shape, we would use a special tool to “scratch” the stucco so that the next layer would have nice ridges to grip on to.  Here is that video.

The second video is for the brown coat.  This is a smoother coat that we applied over the scratch coat.  It was easier because most of the work to get the right shape was done with the previous layer, but it did have the challenge of getting a nice smooth finish, which was particularly tricky because we were not out there for enough hours at a time…  Here is the video to explain.

The lessons learned

We really learned a lot of useful stuff while doing this project and it certainly can’t fit into the videos, but I’ll try to put some of it here….

I’ll come back and fill this in later (promises promises)

The Gallery

This is the part most of you wanted to see anyway…  I try to tell a story with the captions.