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.

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