Step By Step Construction Process:
Contractors establish exact positioning of all ground slab locations for housing units with GPS survey equipment.
Earth moving equipment crews also use GPS coordinates for precise site leveling so structures are precisely placed within the development.
Using GPS coordinates trenches are dug for footings and utility lines such as electrical and plumbing.
Close-up photos below show trenches being hand-dug on-grade for footings with steel, plumbing and electrical conduit.
Slab forms are set up to form slabs. Plastic vapor barriers are used to keep concrete from soaking into the ground and to create a moisture barrier after homes are completed. Steel, electrical conduit and plumbing are then tied in place.
After all steel, and utility lines are in place, footings and slabs are poured. Concrete is then vibrated, and leveled with a variety of troweling methods.
After slabs are poured and concrete has set overnight, all steel, and utility lines are installed for vertical walls.
Aluminum forming systems are then set up, starting in the corners and working out.
Above grade slab ceiling/deck forms are placed after vertical walls are set up.
Concrete is usually poured in the afternoon after all ceiling and wall forms have been set up the same morning.
Concrete is poured into all wall forms and over all above-grade slab deck forms at the same time.
Note: A monolithic pour is completed of all walls and ceilings at the same time.
Crews use vibrators to ensure concrete flows throughout entire wall.
Wall Forms last longer when they are properly cleaned and maintained. Forms are power-washed after concrete is poured to remove any excess concrete from the forms. This simple maintenance procedure reduces the weight of concrete build-up. This simple procedure allows crews to cycle the forms more efficiently with lighter panels.
Forms are typically stripped and removed the following day after concrete has cured overnight.
Finishing crews apply a 1 to 2 mm gypsum skim coat, filling bug holes and tie slot holes after forms are removed.
Interior walls are then sanded and painted on both exterior and interior.
Housing units are typically completed and ready for move-in by home buyers in 21 days.