Masonry Division

Posts tagged “Energy Efficient

Integra from the Ground up part 3

Now that the floor is poured,  the Block  are delivered along with the Integra rods. These rods are 7/16″ wide, galvanized, and are screwed into the couplers in the stem walls. they are designed to be 3-4″ higher than the top of the wall so that the wood top plate can be attached.

The blocks are then layed around the rods in sections called “runs” until the walls are built to full height.

 Notice in the photo below that the block are open on the ends in the shape of an “H”. This helps increase the efficiency of the wall by reducing  “Thermal bridging”  which occurs when heat travels from one side of the wall to the other through material that conducts it. The foam that is sprayed into the wall is a great insulator!

Custom Integra Block house

Once the walls are complete, Superlite block comes out and places a tension plate, a washer, another “Tension indicator” washer, and a nut over each rod. The rods are then tensioned to 7000 psi. Notice that the top block at each rod is a different “Tension Block” designed to distribute the tension through the rest of the wall.Phoenix, Arizona Custom Block Home

After the walls are tensioned, Superlite’s technicians spray foam into them. It is important for the masons to lay a “tight” wall because the foam will enter and come out of any voids left in the mortar joints. This can leave a big  mess, and some annoyed Superlite Techs!  In the picture below, you can see only three places where just a small amount of foam came out of our wall. The foam that you see coming out of the top of the wall is normal. It is allowed to dry, and then is cut off  and recycled.

Phoenix, Arizona Custom Block Home

Phoenix, Arizona Custom Block Home

A happy Superlite Block Tech shows how much they enjoy working with the Darrin Gray Corporation. Here, he is adding the wood top plate after the foaming and tensioning of the walls. The house is now ready for the Carpenters.

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Integra Block from the Ground up (Part 2)

Once the Stem wall is built, rebar installed, and Integra bolts layed out, it is time for it to be inspected, and grouted.

Stem Wall

This Integra stem wall is now ready to be grouted

On larger jobs, a concrete truck and a grout pump is used to fill up the block wall. Most stem walls are grouted completely solid. You can see in the photo below , a concrete truck, the grout pump, and the hose leading to Jason and Aaron while they place the “grout”.   (Grout is concrete that has smaller rocks in it so it will pass through the hose and flow properly inside the wall)

Jason and Aaron pumping grout (concrete) into the stem wall of this Integra House

Once the grout is placed, the grout is scraped level to the block, and the integra bolts are placed into the grout according to a plan outlined by the Integra Engineers.

Completed Integra Block Stem Wall

This is the Completed Integra Stem Wall. The Integra bolts have been placed precisely where indicated by the integra engineers.

Once the stem wall is complete, it is time for the plumbers and electricians to place their “underslab”  piping in its position. Then the stem wall is back filled with dirt, and compacted, a layer of  ABC (rock and sand) is placed on top of that leaving about 4″ remaining for the concrete floor to be poured to the top of the stem wall.


Residential Work

Chapman Residence built out of Integra block for Johnson Carlier

The Darrin Gray Corporation specializes in the Integra Wall System. We have many years of experience building these energy-efficient homes. We have built hundreds of tract homes, and many, many Custom homes using the Integra Wall System.

Let us build YOUR next Masonry home!

 


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