Shotcrete home building
Last Post 12 Sep 2014 04:52 PM by cathsand. 26 Replies.
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mrasmussenUser is Offline
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10 Jul 2014 08:50 AM
Thanks, Alton.

I will email those prices to you when I get them. Do you have an opinion on whether or not exterior concrete needs to be sealed or painted? I ask because color can be added to concrete and that would eliminate the need for coloring it after completion. Good tip on the finish quote.
I am interested in seeing your drawings for window buck concepts. I appreciate all of your information. It is helping quite a bit.
AltonUser is Offline
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10 Jul 2014 12:19 PM

Concrete walls with PSI higher than 4200 may not require sealing.  High pressure sprayed concrete (gunite, shotcrete, mortar) often times will test out higher than anticipated based upon the mix.  I think this is so because of the low water-to-cement ratio and the compaction resulting from the high air pressure.

Just to be safe, even with a high PSI, I would seal the roof.  Various products for sealing.  Some are penetrating and some just seal the surface.  Look at Foundation Armor S2000 for penetrating the concrete.  If shrinkage cracks develop, then you may need a surface product that has good elongation properties.

The roof should cost less if the concrete is cast-in-place instead of sprayed.  A steep roof will usually require that the concrete be sprayed.  Including color in the mix will add to the cost but will probably be much less over the years than painting.  I guess you are aware that gray cement will limit the range of colors.  White cement will offer brighter colors but will really add to the cost.

Quikrete makes a bag mix with gray cement.  I think it is made in Birmingham, AL.  There may be a plant near you that could reduce freight charges.

I think that adding color to the mix will lend itself more so to pressure washing than painted concrete.  Even if the concrete is not painted, concrete finish can be damaged if the pressure washer uses too much pressure.

You may want to get a quote for pre-stressed roof panels.  If so, then be sure to add cost for the topping slab and insulation.  There must be work space around the building for precast to be considered since a large crane may be required.

E-mail me if you want a copy of the design for Permanent Anchors/Temporary Bucks for SCIP walls.

Residential Designer &
Construction Technology Consultant -- E-mail: Alton at Auburn dot Edu Use email format with @ and period .
334 826-3979
mrasmussenUser is Offline
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16 Jul 2014 04:07 PM
Update: Well, I'm striking out trying to find a builder for shotcrete/gunite homes. I found one, but they only build domes. I'm somewhat ok with that, but they leave the lining used to build the dome roof exposed. They do not cover it, protecting it from the elements. Seems if-y to me. Plenty of builders that do poured in place concrete homes. But, my labor costs will be much higher than with gunite. Budget is a major consideration. I found one builder a few months ago that claimed he could build a 1500 sf house with gunite for 45K, and even saw some of his work. But his health failed quickly and he has shut down the business. I'll continue looking, but have begun exploring conventional builders.
Richard SimsUser is Offline
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30 Jul 2014 01:00 AM
Hmm I am not aware of a panel that doesn't need shoring of some sort prior to applying mortar.
As for shoring walls it is to keep a straight line or form rather than a strength issues.
For floors and roofs the mortar is part of the integral strength. I know personally a guy who shoots 6" at a pass and up to 2'thick a day on tunnels walls and ceilings with his accelerator. It is shot at a considerably higher cost.
I do not know everything about anything and I am learning all the time.
I was fortunate to see the New Zealand representatives that came to Colorado to have that same person tweak their mix of bendable concrete, so it could be sprayed and stick. I heard later from a engineer in NZ its now in use.
Bendable concrete that flexes during an earthquake and not crack.
I had issues with the mostly flat roof leaking. I tried three different products the claimed, even guaranteed water and vapor solutions.

I finally found one that worked and by chance I met with the owner today to see how the roof was faring with the rain we have been experiencing. A very happy owner is a good thing.

A few months ago I toured several homes along the Gulf Coast that survived Ike or Katrina . One is a combination of a balloon dome and GCT panels. 1st phase dome , 2nd phase GCT panels.
I believe the panels for the beach home were made in Texas and Ron Bell Sierra Insul-Panel.
http://www.pinterest.com/richardsims/disaster-resistant-homes-structural-concrete-insul/pins/
http://www.houzz.com/ideabooks/7986105/list/Highland-SCIP-Home
8th houzz picture is me making my first panel. Probably will not do it again.
To the person (s) who emailed me about making your own panel press leave me contact information. Just because I do not want to make more panels I will pass on what I learned.
jonrUser is Offline
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30 Jul 2014 09:47 AM
I have a question about the construction of SCIPs as shown above. Clearly there are horizontal diagonal wires, but are there any diagonals in the vertical direction? Without them, I would expect the strength to be non-symmetrical (perhaps important in a wall).
rudischubertUser is Offline
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12 Sep 2014 01:52 AM
rudi schubert getting ideas to saving energy perfectly.
cathsandUser is Offline
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12 Sep 2014 04:52 PM
I have finished framing with my metrock panels, and I have 9 left. They are 10" thickness and 10' tall. I live near Atlanta. I'll sell them for dirt cheap to anyone interested. Let me know if interested.
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