Second Floor of the Ventura-Gutek ICF House

As Larry lowered the galvanized steel joist (strapped to the boom of his concrete pump truck), Daniel and Ryan guided it into position in 2005. 

A galvanized steel hanger (bolted to the joist) supported the joist on the concrete wall.  Ryan cut a hole into the concrete wall (to line up with the hole in the joist) with a gas-powered circular saw.
 
Lock bars between the joists temporarily supported 4 x 8' sheets of 1/2" OSB. 

The joists were set 49 1/4" apart. After inserting a lock bar between two joists, Ryan turned it to lock it in place.

The lock bars along the edge adjust down to 20". For tighter spaces, the OSB was supported with 2 x 4's on one side and the protruding lock bars on the other. In other areas rebar was inserted into the joist on one side and into holes drilled into 2 x 4's on the other.  The top 2" of the joists had to be integrated into the concrete slab, so angle iron was used to frame and reinforce the balcony overhang. 
 
OSB was screwed to the outside of the wall to secure the 4" ICF blocks that were set around the perimeter. Vertical PVC pipes in the walls were for electric wires. Six by 6" wire mesh covered the entire surface. Rebar was added for extra strength (much more rebar should have been added, despite what the manufacturer said). Foam was screwed in place for HC vents and plumbing, then chiseled out after the pour.
 
Larry operated the pump while Chris and Daniel guided the concrete flow. Stewart Daniels, Fred Bellis, and Terry Miller finished the surface. The left part of the floor has been poured (notice the drips), while the right side has not (see the light at top of joists).  The concrete drips were hosed off the joists, walls, and floor with water during and right after the pour.  The lock bars and wood were removed a week later, leaving only the metal joists. 
 

Jeff Shelton used a float to smooth the surface of the concrete.

Stewart and Fred sprayed water onto the floor to help the trowel machines produce a slick finish. Terry angled a doorsill with a hand trowel. This later caused a problem with the door since the sill plate needed to rest on a horizontal surface.

Since the floors that are supported with long joists cracked and sagged, a structural engineer suggested that these joists be reinforced with I beams. So in 2009, one 4" I beam was welded to the bottom of the central joists of each room. Shoring left-over from constructing the roof add extra support.
William Baney, Derrick Puttman, and Seth Brazle cut and ground the beams to accommodate the narrower shoring brackets. A duct lifter helped William raise the heavy beams.  Seth arc-welded the beam only to the two central joists of the room to allow the beam to expand and contract. 

Link to slab construction.
Link to ICF wall construction.
Link to construction of walls of second story.
Link to ICF roof construction.
Link to stovepipe installation.
Link to insulated rubber roof installation.
Link to the window and door installation.
Link to steel framing.
Link to steel stairs installation.
Link to brick laying.
Link to overhang installation.
Link to gutter installation.
Link to electrical work.
Link to plumbing installation.

Link to septic tank installation.
Link to sheetrock/drywall installation.
Link to mudding / sheetrock finishing.
Link to painting of the walls and ceiling.
Link to the installation of the floor tile.
Link to the installation of the flexible solar panels.
Link to the installation of the exposed aggregate driveway.

Back to the ICF main page.

Web page, text, and photographs by Carol Ventura in 2005 and 2009.