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2013WinShotcreteEMag

methods. Through consultation with our opera- Sustainability Benefits tions and design team, a solution was born and • Reduction of lumber to build forms for walls. the project proceeded. No one area of curved walls had the same radius, so every inch of the project required custom-built Unusual Project challenges radius forms if cast-in-place concrete was to be • An oscillating up-and-down structure with used. With the use of shotcrete, standard shoot convex and concave curves throughout the panels were able to be used—there were no project, similar to a roller coaster, made con- radius panels whatsoever on this project. ventional forming of this project a very daunt- • Reduction in trucking due to less need for ing task with time-related milestones difficult lumber. to overcome and to remain in budget. • Producing the structural walls for the project • A uniform concrete finish on the exterior and reduced time. Less carbon footprint realized interior of the wall. Both sides were to be on the site. sandblasted and remain with an exposed con- • Eliminating the need for patching and parging crete finish. materials as per usual with cast-in-place • Internal insulation sandwiched in the wall itself. concrete. • Designing the means, in collaboration with the engineer, by which to tie the two separate structural and architectural walls together with the integral insulation inside the wall, to sup- port the intricate roof design that had addi- tional loads from the green living roof on it. To cast-in-place this structure with the integral insulation in the middle of the wall would have been difficult enough to achieve on straight walls, but to add in the extensive creative design of the oscillating curved structure and to achieve perfect elevations for the roof attachment made this Fig. 2: Diagram of the construction process for project uniquely suited for the shotcrete process. a rammed-earth wall Solutions Torrent created custom shoot panels made for the shotcrete industry. These panels were ideal for one-sided forming of the complex wall shapes on this project. The ability to use our custom shoot panels and adjust them on the radius area was a huge time saver on this project. The one-sided forms worked well because only the exterior troweled face needed to be finished. Additionally, the ability to produce a perfectly curved radius, and a finished product with no need for any patching or repair work was unheard of on such a complex project. As the shoot panels were removed, spray-on insulation was Fig. 3: Completed feature wall prior to applied to the exposed formed surface and became sandblasting. Exterior area view, post-shoot the inside (middle) of the wall. Once the insulation was applied and the steel reinforcing bars were installed, we then shot the inner wall. Thus, we created two superior exposed finish faces with multiple hand cut-in reveals and a smooth steel- troweled finish. Once completed, the exposed wall surfaces were sandblasted and the resulting finish is amazing. Unlike cast-in-place concrete, with shotcrete, the higher density and compressive strength of the shot wall when sandblasted does not open up as much as normal cast-in-place concrete, leaving a much more uniform finish than possible with cast- in-place concrete. Fig. 4: Torrent custom shotcrete panels Shotcrete • Winter 2013 37


2013WinShotcreteEMag
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