The house calls for steel beams for both design and function. These beams will hold the upper floor joists. Both the architect and structural engineer worked together to create the ideal placement and size requirements for the beams.  

These steel beams are extremely heavy and therefore a crane assisted in the placement. This was an exciting day! These beams will be exposed in the home and create the industrial look the owners are hoping to create.
 

Framing

05/17/2015

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Framing has begun and four Glulam beams are placed.
Glulam is a superior glued laminated beam and header. It has been chosen for its design, reliability, ecofriendly, and qualities for the home. These beams will be exposed and seen in the finished product of the home. 
 
 
The architect wanted a unique design element seen front of the house. A concrete wall was selected to keep in line with the rustic/modern look that is desired. Here we show you the step-by-step process of creating this beautiful and unique element. 


Rebar was used as the main form to create a solid structure. Each square is welded together for added reinforcement. 
The reclaimed wood that was previously sanded and prepped, is placed atop OSB and nailed in place to create forms. These forms will be used to both hold the concrete in place for the wall and to create the textured look on the concrete. 
Here, the forms are complete and ready for use.
Next, the forms are added. The reclaimed wood (used from the caboose) is placed so that the wood slats are facing inward. This is what creates the textured look on the finished piece.  
Here you can see an inside view of the project pieced together. Rigid insulation board (UPS) is added to help create a higher R-value in the home. This will help the energy efficiency in the concrete and ultimately in the home. 
Concrete ties are added for stability. This prevents the forms from bowing when the concrete is poured and helps hold the structure together.
Once the concrete had been poured it needed to be tented and kept warm since the nights were below freezing. After three or so days, the forms were removed and the result is a beautiful textured wall. 
The ties will be cut off and the finished wall will be sealed.
The process was repeated for the top half with added structure and stability to prevent leaking onto the bottom half. A backhoe was used to help lift the forms onto the top half. 
The concrete was then poured in by buckets. By adding the concrete bit-by-bit this allowed the heavy mixture to fill the forms, preventing 'honeycombs' and voids.