Join us at the Hilltop Project for a quick overview of how to install, brace, and pour BuildDeck ICF decking.
Welcome back to the Hilltop Project. In this installment, the family has placed their BuildDeck forms, and are now ready to pour the BuildDeck floor system. BuildDeck is a stay in place form to create an insulated concrete floor, or pitched roof. This project has more than 3,500 square feet of BuildDeck, and most of it will be poured today. Let’s review the process for building with BuildDeck. The family created temporary shoring to support the BuildDeck forms, put in place steel beams, and steel stud walls to carry the load for their specific design. BuildDeck engineering requires shoring to be placed every six feet. Though BuildDeck can clear spans up to 40 feet, the shorter the span makes it easier to design and build. Most BuildDeck spans are kept under 20 feet. This project has large open areas in the basement that required steel beams and steel stud walls. Shorter spans require less materials and are more cost-effective. Once the shoring was in place, the forms were assembled on the ground in 10-foot sections, and a steel c-channel track was added to create mechanical attachments for drywall.
The beam steel was laid in place and tied into the walls with 90-degree pre-bent corners. The rebar grid was created on top of the forms using rebar chairs to maintain the correct steel placement in the floor. And, the tubing for the hydronic radiant heat floor system installed and secured. Penetrations were made and sleeves installed where needed. All penetrations were sealed with tape to prevent concrete from sealing them. The day before they also completed a pre-pour checklist double-checking that all rebar has been placed correctly and that all shoring and penetrations were in place.
The team also reviewed the plan for the pour. The pour day begins early, with the arrival of the concrete crew and prep of the concrete pump. On the day of the pour, a quick walkthrough was completed. And, now that concrete is on-site, they’re ready to begin. When pouring BuildDeck, begin by filling the beams first, working in a given section then returning to pour the cap shortly after. The concrete will begin to slake, providing strength and reducing the pressure on the forms. Make sure the concrete inside the beams is vibrated and consolidated to remove any entrained air. Fill the cap to the finished height and screed smooth as you would a traditional slab. Continue this process until the floor is finished, working in manageable sections.
As the pour continues, members of the team spread, consolidate, and screed the concrete smooth when the concrete reaches the appropriate thickness. This process is repeated across the entire build deck floor area. For safety reasons, make sure that no one is underneath the BuildDeck while pouring. After the concrete sets up enough to walk on, a power trowel finishes the process. The BuildDeck shoring will remain in place for 30 days until the concrete has completely set. Though work can begin the next day on stacking the walls for the next level. If you would like to see more of the hilltop project, or more BuildBlock content, be sure to subscribe to our YouTube page and activate our notifications with the bell icon.