LeConte Progress – Standing the Pre-Fabricated Exterior Foam Wall System
The first exterior wall section is stood. Once the wall is plumb and level, it is then nailed to the bottom plate. The wall is standing on the bottom plate which is bolted to the concrete.
Here is an interior view of the first wall panel section. This image also shows the bottom plate bolted around the perimeter of the concrete.
The bottom plate serves as a strong foundation to hold the exterior walls in place. Before the bottom plate can be set in place, our spray foam must be applied beneath the bottom plate to firmly glue it in place for maximum strength.
After applying the spray foam, the bottom plate is set in place and then bolted to the concrete. This provides an extremely secure footing to hold the walls in place.
This closeup of the bottom plate shows how our wall system is fastened to the concrete. As you can see, glue is applied to the edges of the plate. In addition to the glue, there will also be spray foam applied to the top of the plate to further adhere to the bottom of the wall panel.
The wall is then placed on top of the bottom plate and nailed once the wall is plumb and level. The result is our exterior wall system which is incredibly secure and now fastened in position.
In order to join panel sections together, splines are inserted into the edge of each adjoining panel which are then glued and screwed to tighten the joint.
This wall spline has been glued and screwed on both sides and is now ready to be joined with its neighboring panel.
The second wall panel has been attached to the first wall section. These two wall sections have created the first window opening.
Here is an interior view of the first two wall sections.
The third and fourth wall sections are attached creating a second window opening and the first corner of the home.
This image shows an interior angle of the newly attached third and fourth wall sections. Below the window openings, you can see that small cavities have been cut out which will become electrical outlet receptacles. You will also notice the top plate above the window openings. Although it is loosely resting above the wall, this top plate will be driven down flush with the top of the panels to increase the integrity of the wall system. In addition to reinforcing the wall system, this top plate also serve as a strong and solid surface for the roof trusses to lay on.
The electrical wiring is being fed to the outlet receptacle before we attach the next wall panel.
Inside the wall panels, electrical chases are pre-cut to making wiring simpler. Wiring is easily be fed through the pre-cut horizontal and vertical chases.
Here is a closeup of the rough-in outlet receptacle.
The fifth wall section is attached.
Another view of the walls showing the fifth wall section.
The sixth wall section is joined.
The seventh and eighth wall sections are added creating another window opening.
An interior view of the progress so far after joining of the seventh and eighth wall sections. The smaller window has been strategically located to take advantage of the incredible views.
The ninth wall section is attached creating the fourth window opening.
The home is taking shape. This view shows the interior after the ninth wall section is added.
The tenth and eleventh panels are joined together creating a 45 degree angle in the back left corner of the home.
This exterior view illustrates the 45 degree angle created from the tenth and eleventh panels.
Wall panel sections twelve through fifteen are joined together at the back of the home. There are some spaces left open for a sliding patio door and a hinged patio door.
Walls sixteen through eighteen are joined completing the back wall of the home.
Wall section nineteen is connected which defines the back right corner of the home.
This exterior view of the back right corner shows the joint of the nineteenth wall section.
The twentieth through twenty-second wall panel sections are joined furthering the right wall.
This interior view shows the wall sections along the right wall up the twenty-second panel section.