Building the Exterior Walls with Nudura–October 2011

Task – Building the walls

The Process – We took the Nudura blocks and built them up like Lego (they snap together with the clips that are built into the blocks).  We inserted rebar horizontally on each level.  All the blocks are also clipped together at each joint on both sides at each level.  After all the levels were built then rebar was inserted vertically.  We put 2x12 frames where the windows and doors would go.  We put braces on the inside of the walls to prevent the concrete from braking the forms during the pour.  We had to order a special pump truck to pump the concrete into the walls.  The day of the pour we had to take everything out of the area so we could get around easily.  We also had to build railing for up on top of the braces so that we could stand up there and pour the concrete easily.  While the concrete was being poured we had to use a vibrator to help get rid of air bubbles. 

What I Thought About It – It was interesting.  The pouring was interesting because of all of the different tools we had to use.  Building the walls was interesting because it was working with giant Lego. 

Backfilling the foundation and tamping–October 2011

The Office – is a shed that me and my dad built out of old fence boards and that is where we stored all of the tools and supplies for the build until the roof was on the new house.       This is the shovel that dad drove over with the bobcat.

Task – Backfilling the footings.

The Process – We ordered in all of the gravel.  Then we took the bobcat and move the gravel into the area inside the forms until it was level.  Then we had to pack it and make sure it was level after we packed it.  Then we got a tamper and packed it in again and we did that four or five times. 

What I Thought About It – I liked the tampering… it relaxed your arms… gave you a good massage. 

Pouring the Footings–October 2011

Task – To pour the concrete footings.

The Process – We ordered concrete to be delivered.  When the truck arrived we extended the concrete shoot to the forms and then started pouring the concrete and shoveling it to be level.  We went along with a stick of rebar and push all the air bubbles out.  Then we leveled off the top with concrete trowels.  We put rebar vertically every 4 feet to attach the walls to.  Once the concrete was set up we removed the forms and backfilled the center with gravel (pit run gravel then 1/2 inch and smaller gravel).

What I thought About It – It was interesting watching everyone working to level it all out before it set up. 

Forming the footings–September 2011

Task – Putting up the forms for the base of our house

The Process – First thing we did was to pound in wooden stakes into the ground to hold up the forms.  We built the forms out of wood.  The forms are 24” high and 18” wide.  We used 2” thick Styrofoam on the outside of the forms.  We also used void form foam on the base of the forms.  We bent the rebar into a “c shape and then attached the rebar to the 4 corners.  We alternated the “C” back and forth and ran wire between them to hold them in place.  We ran wooden planks made out of 2x4’s across to hold the forms together. 

What I thought about it – Pounding stakes into the ground is not something that is fun.  Cutting the rebar was one of the best parts of this stage.  You can actually start a fire with the sparks that fly when  you cut it… I tried and succeeded.