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GigaPanel March 52012 PPT Read Only

GigaCrete has developed a new construction system called GigaHouse that utilizes prefabricated insulation panels called GigaPanels. GigaPanels reverse the typical construction process by starting with rigid foam insulation panels that have channels cut into them to accept structural steel studs. This allows unskilled laborers to quickly assemble the panels into walls and roofs by sliding studs into place and screwing them. The panels are then coated inside and out with non-combustible, waterproof finishes. The result is a structure that can be built rapidly, is highly energy efficient, uses only non-toxic materials, and requires minimal labor and tools.

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172 views50 pages

GigaPanel March 52012 PPT Read Only

GigaCrete has developed a new construction system called GigaHouse that utilizes prefabricated insulation panels called GigaPanels. GigaPanels reverse the typical construction process by starting with rigid foam insulation panels that have channels cut into them to accept structural steel studs. This allows unskilled laborers to quickly assemble the panels into walls and roofs by sliding studs into place and screwing them. The panels are then coated inside and out with non-combustible, waterproof finishes. The result is a structure that can be built rapidly, is highly energy efficient, uses only non-toxic materials, and requires minimal labor and tools.

Uploaded by

AW
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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“first look” at GigaCrete’s revolutionary new

New Construction “GigaHouse”

“GigaHouse”
Utilizing GigaPanel
What is GigaCrete
• GigaCrete is a family of products based on low carbon footprint “Green” ceramic
binders significantly outperforming Portland cement: We do not use PORTLAND
CEMENT which is a high CO2 producer

• StuccoMax, a waterproof exterior coating that is non-combustible

• PlasterMax, a fire rated abuse resistant coating over foam replacing gypsum board

• All GigaCrete coatings bond permanently to EPS and PU insulation foam, concrete
products, bricks and plasters.

• All are one coat applications and fast to apply

• All are abuse resistant, non combustible, no VOC’s, no off-gassing utilizing only safe
and healthy materials that will not support the growth of mold or mildew.
What is GigaCrete’s unique “GigaHouse”
“GigaPanel” is not what you think….
It is not a SIP’s panelized building system at all….
It is a patented steel framed insulation system!

The building components are structural steel “stud” construction, proven for decades, signed off
by a local structural engineer who only has to agree with the calculations of leading structural
engineering already completed.

We reversed the building process Typically building with studs comes first,
then fiberglass insulation is added in between the studs, this creates thermal leaks and sound
transmission through the studs into the home…. Neither fast nor ideal.

GigaPanel Systems starts with the insulation first…utilizing variable density high R-Value rigid
EPS foam insulation panels with computerized insert channels cut into the foam. Structural
engineering dictates where the steel studs and connectors fit to meet code compliance for a steel
framed structure!

The structural components are then slipped into place and securely attached with self drilling, self
tapping screw. Exactly the same as steel framed construction only this can be done by unskilled
labor, purposely made to be very simple, guaranteed square and right the first time, no measuring, no
room for errors.
Overview of installation methodology
1. Layout steel track on slab and permanently attach

2. Locate wall insulation panels into track

3. Slide down connectors and screw to tracks top and bottom

4. Cut electrical outlets and link to conduits and secure with


insulating foam (same as ICF construction)

5. Coat exterior with 3,500 psi StuccoMax (same day as roof is


installed)

6. Coat roof with GigaRoof (StuccoMax)

7. Coat interior with fire rated, 8500+psi PlasterMax


Tools needed to build a house

2.5 to 3 meter Step Ladder

Screw Gun

Ramset Gun

Tape Measure

Metal Shears

Pry bar
6” to 12” thickness EPS GigaPanel components, (variable densities)
GigaPanel is designed for rapid assembly by unskilled labor

Large interior wall insulation panels


can be lifted with one hand
16 linear feet of wall GigaPanel is easily carried into position

No heavy machinery needed


Step 1: Lay out the bottom tracks according to plans and
include water resistant gaskets between the bottom track and
the slab.
Step 2: Attach bottom track to the slab with Ramset pins or screws
Step 3: Locate panels next to where they are needed
Step 4: Insert pre-cut foam panel into steel stud bottom track

Tools needed: tape measure, ramset gun, pins and load.

Track positioned over moisture gasket and shot into slab


• Panels are laid in place in minutes not days
• CNC cuts are guaranteed to be square with studs
• located exactly where needed as per structural needs
• no measuring
• no room for errors

NO SPECIAL SKILLS NEEDED


Step 5: Insert studs

Double stud connector equals a 4”x4”


every 4’ with additional stud @ 24” O/C

Tools needed: Step Ladder


Screw gun, pry bar.

Patented connectors based on


“steel framing” construction methods
Slide down engineered grooves in panels
forming panel to panel connections and the
structural members both at the same time.

Note: the GigaPanel designs determine where the structural studs and connectors are placed
Finished top track

Top track inserted into EPS panel and screwed to vertical studs
Exploded view of connections
Section through a typical interior panel shows double studs
connecting panel to panel and 24” on center steel studs for all
walls. Exterior walls and roofs may have studs offset within
thicker foam wall insulation panels to minimize thermal bridging.
Pre-cut “T” sections
Pre-cut corner sections
Column
made from 4 pre-cut corners

Columns are used for additional


Structural support, HVAC
(heating ventilation air conditioning
systems) Plumbing and venting
chases. Typically used in corners
90 Corner and T connected together
Foundation to wall connection
Hurricane anchors… solid steel connection from the roof to the foundation
Step 6: Laser level and brace walls before adding roof trusses
Step 7: Roof trusses added to walls a few hours after building walls
Compression ring holds 200 mph roof trusses securely
together
Step 8: Install doors and windows and screw into steel studs
Window and Door framing
Step 9: Roof panels are laid onto trusses and studs slid into
location holes cut into foam panels
Step 10: Roof studs are screwed to trusses with steel brackets
Roof panels from inside the house
Showing stud perlins prior to be
covered with additional EPS panels
Step 11. Install electrical conduits and wires for outlets and switches.

Conduits are pre cut into panels ready to pull wiring.


Conduit or plumbing passing through walls
Must meet local electrical codes

Electrical wiring inside chase


Retrofit electrical after house is completed

PlasterMax
Cut flush
-----

Mesh Foam not yet cut


-----

Note the conduit and box is


Foam glued into place and
excess foam shaved flat, ready
to be coated with PlasterMax

Walls are rasped where needed to make flat


Step12: StuccoMax is direct applied over the foam insulation panels
Window and Door trims cut from EPS foam are covered with StuccoMax
Step 13: Colored GigaRoof spray applied directly over the
EPS foam (non USA projects)

GigaRoof is now approximately R-45


Insulated Spanish Tile GigaRoof
Step 14. PlasterMax over interior walls

GigaCrete coatings are added directly to the EPS


foam, note the imbedded mesh
Note:
Gutter system integrated into molding for rain collection

Doors (by others) added


Step 15. Add insulation sheets on underside of roof and over trusses

Foam shapes are pre cut and fitted over trusses


PlasterMax applied directly over EPS foam panels.
All panel seam lines are covered over to create a
seamless and durable ceramic finish.
Ceiling underside of roof panels and beams covering
structural roof trusses

Fire rated PlasterMax applied over the EPS foam

Foam sheets are screwed into the steel studs


Finished PlasterMax over the foam interior wall panels

Note optional storage area above bedroom and bathroom


Optional Magnesium board ceilings (no gypsum board)
With PlasterMax roller texture knockdown finish
Step16: Window trims are added, screwed into steel studs,
patched and ready for paint.
Step17:
StuccoMax is washed to remove dust particles, primed and painted.
Simonton vinyl windows (no wood) come in all standard sizes
End result is a very energy efficient and virtually maintenance
free living environment
StuccoMax (exterior) is sprayed or troweled over foam

3/16” thick StuccoMax is tough enough to drive on!


SUSTAINABLE
“GigaPanel”
build strong, build safe, build fast

1. Completed rapidly with supervised local labor


2. Simplicity = speed = reduced cycle time
3. High “R” values means less operating costs to heat or cool
4. Only healthy materials are used
5. No Portland cement used in the house structure
6. Exterior StuccoMax is WATERPROOF
7. Interior PlasterMax is the Worlds only fire rated, 8,500+ psi abuse
resistant plaster designed specifically for applications over insulation
foam

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