Concrete deck blocks repairing landing9/24/2023 During routine operation, one of its Wartsila 18V32LN engines suffered a connecting rod failure resulting in major damage to the engine block and the crankshaft. Such was the case for a leading cement producer in the Dominican Republic. If luck is on your side, emergency shutdown procedures can sometimes limit the damage, but when parts come loose from the engine the result is most often catastrophic. By enclosing the area underneath the deck and covering it in stone, we were able to create the illusion of a masonry porch.When reciprocating engine parts seize or break free at high speed, the results are never positive. Thanks to the advanced mix and the densifying, moisture transmission is dramatically reduced.Īll of the vertical areas of the deck, as well as portions of the house and garage, were then covered using cultured stone. When the grouting process is completed, the entire surface is densified with a lithium siliconate, then sealed. Each one of the impressions made in the wet concrete is then grouted to ensure the realistic look of a custom handmade concrete tile. We are able to use any one of our 25 different patterns as well as any integral color to achieve the final tile color and shape. The length and amount of fibers is reduced to allow for clean cuts from our stamping tools. We could then begin pouring our decorative layer, which becomes the cast-in-place concrete “tiles.” This mix is very similar to the structural layer except for the fiber dosage and the integral color. Once the structural layer is set, we were able to begin our formwork for the cantilevered edges on the deck and the steps. (If it is not, we must establish pitch in some way.) With the chemicals added to this mix, it is extremely moisture-resistant, which is a necessity when pouring over a wooden substrate. This mix is applied to the deck and the steps at a thickness of 1 inch as long as there is pitch built into the deck. After this mix is placed, it is scarified to ensure an excellent bond with our concrete overlay. This mix also utilizes several admixtures that increase the hydration of the cement and minimize the amount of water needed to make this high-fiber mix workable. The next step was to pour our structural layer, which is heavily reinforced with PVA fibers and polypropylene fibers. This deck was built with 2-by-10s 12 inches on center, then wrapped with 3⁄4-inch pressure-treated plywood.Īll wood substrates were then wrapped with tar paper in order to avoid direct contact with the wood and concrete, and galvanized wire lath was nailed into place on both the vertical and horizontal areas. When this was completed, he was then able to finish the construction of the deck, stairs, and the roof over the deck. Once the footings were poured and the deck construction started, we came in to install a vapor barrier and pour a slab underneath where the deck and steps would go. The footings were dug, poured and inspected. He then determined the footprint of the new deck as well as the amount and placement of the footings that would be required to support it. The project began with a deck contractor removing the existing concrete steps, landing and bluestone sidewalk. With our deck construction process, we were able to save the homeowners thousands of dollars. This creates a continuous look over all horizontal areas, which typically can only be offered over masonry substrates. Since we are able to do our cast-in-place stone over wooden structures, we were able to use the same product on the elevated area, the steps, and the sidewalk leading to the driveway. This also eliminated the need to get another mason on-site to run up block and then fill in behind the block wall. Our way, all the deck contractor would need is a post-hole digger to remove enough earth to pour what would be considered typical deck footings. This was a major cost savings, since we are in a freeze-thaw environment and excavation would have to go down nearly 4 feet. Our idea was to go in the direction of deck construction rather than block construction, then put one of our cast-in-place overlay systems over the wood deck.Ĭhoosing a deck over block eliminated the need for large-scale excavation to pour footings. We could use our custom overlay product to create the illusion of a masonry front porch, which would get faced with cultured stone on all of the vertical areas.
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