Building with PolySteel

#1 Footings

Install standard (level) footings with rebar placed at the intervals required by your building design, as outlined in the PolySteel Installation Manual.

Construct Level Footing

Place Rebar Dowels

Finished Footing

Proper Reinforcement

#2 Building the Walls

Starting with the corners and working toward the middle of the wall, set forms on the footing (or slab), by applying a bead of foam adhesive, such as Foam2Foam®, bottom of the form. Each subsequent course of forms should be stacked and vertical rebar placed as needed. Horizontal rebar is usually placed every third course.

Cut Forms to Size

Band Saw Speeds Horizontal Cuts

Place Cut Forms With ½” Clearance

Foam Adhesive

Carolina Clipper Works Horizontally and Vertically

Rebar Saddles Save Time

Place Rebar

Plumb Corners Early and Often

#3 Window/Door Openings

Forms are easily cut to accommodate any size and shape of window or door. Window/door “bucks” should be premade to rough opening size using dimensional lumber or, more preferably, the VBuck® block out system. Window bucks are installed at the proper wall height and forms should be stacked from the corners into the door/window openings and forms cut to size for a good fit. It is also important to remember to create the openings needed for utilities.

Pre-fabricate Window Bucks

Install Window Bucks at Proper Height

Create Ports or Channels for Concrete Below Windows

Continuous Stirrup Saves Time

Brace Openings

#4 Bracing

Proper bracing will ensure straight walls. A variety of wood, steel, and aluminum bracing systems and techniques are available. We recommend Reechcraft™ Panel Jack ™Alignment System for builders who use PolySteel frequently. All window and door openings are braced and uninterrupted sections of wall are braced every 6 to 10 feet.

Bracing

#5 Placing Concrete

After checking the walls and openings for plumb and straight, and proper bracing, concrete is placed in the PolySteel walls, which are fully reinforced with the horizontal and vertical rebar requires. Concrete pumps are the preferred method for placement and your PolySteel distributor can help ensure that an experienced crew is on hand.

Placing Concrete

#6 Install Floor/Roof System

For intermediate floors, the rim joist is anchored to the PolySteel wall with anchor bolts, and joist hangers are attached in the typical fashion. Steel joist hangars that can be cast directly into the concrete are also available. Install roof trusses as you would in any other construction project.

Install Floor / Roof

#7 Finishing the Top of the Wall

The top of the wall is leveled off (screeded) and anchor bolts are placed to secure the top plate. In high wind areas, anchor bolts would be replaced by hurricane straps placed directly in the concrete.

Finish Top of Wall

#8 Install Utilities

Electrical and plumbing lines fit easily and in accordance with code requirements by simply cutting a channel into the foam and placing the wiring or piping into the wall. For larger plumbing lines, you may need to set them in place prior to placing concrete.

Set in Place

Electrical Installation

Plumbing Installation

#9 Interior/Exterior Finishes

Drywall can be screwed directly into the PolySteel attachment studs for all interior walls. PolySteel can accommodate any and all wall finished. For example, siding, board and batten, stucco lath, and brick ties are all easily attached to the galvanized steel attachment studs.

Interior Finishes

Siding

Attaching Stucco Lath

Brick and Brick Ties

Stone and Brick Ties

#10 Your Dream Come True

Whatever you originally imagined, you have now built with PolySteel forms. You can now enjoy the most comfortable, most secure, most energy efficient home in the neighborhood.