1. Panel Delivery
Panels will be delivered to your job site. Some orders may require more than one truck, depending on the size of the project.
Flat, inside corner mesh, outside corner mesh and “U” mesh bundles. This mesh is used to attach the panels together once the panels are in place.
2. Foundation & Flatwork
Here is an example of a garage floor with the #3 rebar dowels in place. The rebar is 18-24″ in height and placed two feet apart. The TridiPanel attaches to the rebar.
3. Attaching Panels together
This picture shows how the flat accessory mesh attaches to the joint between the panels. The tool used is a pneumatic “hog ring” gun. This process locks the four foot wide panels into one continuous wall.
4. Window & Door Openings
Here is an example of a window buck made of pressure treated 2″x6″ wood. The desired opening can be easily cut out of the panel using a reciprocating saw or a manual keyhole saw and wire cutters. The corners of the opening have small sections of flat mesh attached to aid in strengthening the concrete at the corners. The long piece of #3 rebar over the top of the opening is the only “header” required. The rebar at each corner is not required by the ICC report. We added it because the scrap rebar was available and it only makes the corners of the openings stronger.
5. Electrical Outlets
Placing conduit and electrical boxes is very easy and quick. We use a small propane torch to melt a channel in the foam then run the conduit behind the wire mesh. Placing the box is achieved by simply cutting a small area of wire and putting the box into place. We sandwich the wire mesh between the box and the mud plate to hold it square and plumb.
6. Attaching Wooden Floors
A. Melting the foam in the panel to make a concrete bond beam. Rebar will be placed in this melted area and “J” bolts will be wire tied to the rebar.
B. Ledger board attached to the “J” bolts in the bond beam. The ledger is spaced 3/4″ away from the wire and acts as a form to hold the concrete. The ledger boards stay in place so the joist hangers can be attached to them.
C. Another example of the ledger board with floor joists attached. The calculations for this floor only required us to melt out smaller concrete pockets for the “J” bolts to be placed into.
7. Using Panels As Stemwalls
We no longer “form and pour” concrete stem walls. All you need with the TridiPanel system is to pour the footing, place the rebar dowels then place the panel over the dowels. The second photo shows the crawl space vent placed in the panels. This will provide an insulated stem wall for your home. During the construction of the home, you can continue to work on the jobsite even if you don’t shoot concrete onto the stem walls. There is no waiting for the concrete to cure or forms to pull in order to keep building.
8. Preparing for Wooden Trusses
We have a few details for using wooden trusses on the TridiPanel system. The top picture shows a pressure treated double top plate. The “U” mesh is placed over the bottom top plate; this anchors the board between the mesh on both side and at the top. The top plate is then attached per local building code.
The second picture shows just how strong the TridiPanel system really is. Tridi panel is 9.5 times stronger than 2″x6″ constructed walls. The trusses can be placed on the walls prior to concrete. This also helps keep the construction process moving forward.
9. Applying Concrete
We use a stucco mix that has a compression strength of 6500 psi. The International Building code only requires 2500 psi strength. Concrete application is very easy with the stucco pump. If you are interested in how you can improve concrete strengths go to our products page and read about Kalmatron.
The bottom picture shows a worker brushing the “scratch” coat.
10. Interior Wall Finishing
The picture above shows a worker applying the plaster to an interior wall. We do not attach drywall to the concrete walls. This would detract from the thermal mass benefit of the TridiPanel system. The interior walls can be finished in any look desired by the owner.
11. Enjoy A Comfortable Home
This entire home was built with the TridiPanel system. The finish is warm and pleasant. If you didn’t know the walls in this picture were concrete you wouldn’t be able to tell the difference.