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The finished product shown here with minimal facade looks, at first glance, like most any other loft-style building. But that stucco box
contains plenty of sophisticated thought, planning and engineering. In this sequence, we'll show you the building process and the
technical components that make up a Gulf Cost Loft.
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This building starts about eight feet below grade with a dozen over-sized piers resting on a stable layer of clay. Here we see the steel reinforcement for
one such pier before the concrete is poured in place.
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Next comes a reinforced concrete footing. This evenly distributes the weight of the entire building across the piers. The re-bar sticking up provides
continuous reinforcment into the wall, which will be added next. Note the stack of ECO-Blocks awaiting installation in the background.
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Here we're placing the first row of ECO-Blocks to check alignment and fit. In actual practice, all of the re-bar for the walls, both vertical and
horizonatl sticks, are placed and tied before the blocks are stacked up for a given floor. This turns out to be a huge advantage, because the building
inspectors can verify the size, quantity and placement of all reinforcment before it gets covered by the ICF blocks. To the best of our
knowledge, this is only possible with ECO-block ICF components. |
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Here the re-bar and blocks are all in place for the first floor on the back of the building.
Notice again that vertical re-bar is protruding up for a strong connection to the next story.
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As we finish the other walls, it's time to take delivery of the Insul-Deck components which will be used to form the second, third and forth floors.
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Even though the Insul-Deck components are huge blocks of reinforced styrofoam, they are easily lifted into place by two men. Here we see the ICF beams in place
on the bottom side of the second floor.
The scaffolding provides support for the concrete that will make up the beams and deck of the second floor while it hardens.
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Atop the Insul-Deck components we place a re-bar matrix for the second floor, as you would use for any concrete slab.
We use a proprietary method of integrating the re-bar for walls and floor to provide super-strong integrated structure.
Each floor thus serves as what structural engineers call a 'membrane'; this kind of structure can withstand earthquakes.
Other multi-story ICF building that we're aware of use conventional wooden joists for the floors. Our approach is vastly stronger and provides much better thermal insulation.
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Here we're taking delivery of the concreate for the first story walls and the second floor. Using a boom truck like this allows us to carefully meter
the concrete and ensure precision placement. |
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Here our team is monitoring flow and placing concrete to be smoothed. Notice the bottom of the boom tube in the background. |
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This floor is done, and gets a final inspection by the foreman.
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And now we start the process over again for the second story. |
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And now most of the ICF blocks for the second story walls are in place. That framed aperture will be a set of double doors leading to the balcony. |
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As the third story is getting completed, it's time to start installing the utilities.
This two by three foot aperture in the floor is for a vertical utility chase that runs the full height of the building.
We put a mechanical room on the roof at the top of this chase; that's where the AC, fans and water heater will go a bit later.
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Here we see the fully loaded mechanical chase, with HVAC ducts, electrical conduit and water lines. Our utility sub-contractors loved this feature,
as it made installation fast and easy.
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Well, the building shell is done. Now it's time to put a durable stucco finish on the outside. |
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Simultaneously, we frame in the interior walls.
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"Lookin' good", says Dan, a few days later. |
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And here's a finished room with a beautifully stained floor. Pretty cool, huh?
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