Make your own free website on

System Description & Installation details.

Panel components  (For a graphic description see Panel Components page) Each panel consists of an aluminum-bracing frame, concrete core, reinforcing mesh and covers. The Aluminum bracing frame constitutes 4% of the total weight of panel. Aluminum bracing frames are structured with a four-channeled beamed aluminum profile. Three of these channels are used for coupling to other panels in the same plane (same wall) intersecting structural planes (wall corners), and the internal channel of the aluminum frame profile is used to house the reinforced concrete core as wall filling material. Aluminum alloy bracing frames extruded with the matrix C-2146 is 3.25 inch thickness; the finishing covers 0.75 inch for a total wall thickness of four (4) inches (6 inch total wall thickness is obtained using matrix C-2147) The wall panel core is casted in site by pouring inside the panels, a mix of lightweight aggregate concrete or foamed ( cellular) concrete of equal compression resistance of 1300 PSI minimum (Recommended for extreme wind pressure resistance, density of 63 PCF).
Vertical casting Mode
Panel Cover Boards as Casting Forms (Wall surface finishing materials) The finished board covers work as casting forms to  tightly retain the cement slurry poured inside the panels. They are also the finishing material of the wall panel's external surface. These boards are fixed to the panel frames by attaching snapping clips to the side channels on both sides of the panels.  The panels can be standardized in their dimensions to adapt to available boards in the market. The STD wall panel size meets the STD board and sheet size of 4 ft. by 8 ft. Reinforcing Steel mesh. Truckson type steel wire electro-welded, e = ¼ @10cm. Makes 2% of total panel weight. Elastizell´s Zell-crete  reinforcing polymer fiber can be used to enhance concrete  properties. 
The concrete mix is poured into de panel after installing the reinforcing steel mesh. A STD panel of 4' by 8' contains 0.24 m3 (8.5 CF) of concrete core. makes for 94% of total panel weight. Cellular (aerated) concrete of equal 1300 PSI resistance  is recommended for Tornado Alley Stated and Tropical Coastal Zones. Foamed Concrete is easier to handle and has better thermal insulating properties K= 5.4 BTU/hr/in/F. than regular concrete because it has no solid aggregates. Foamed concrete  is supplied throughout the US by
Elastizell Corporation of America
Installation sequence. vertical casting mode. Assembling wall panels
The STD or rectangular aluminum bracing frame is structured with 4 channel beams profiles and eight corner braces that groove into the lateral channels of the panel profiles (See Finish Graphs and Inst. Details). The assembly 
of each panel is done with the steel mesh inside). 
Installation of panels. Assembling the structure. Once the aluminum panels have been individually assembled, the next step in the vertical casting mode is to assemble the house structure. The wall panels are coupled together by means of linear connectors that form structural pinned joints, studding the wall panels from top to bottom. The installation is done in a specific sequential order for each home building project. The sequential order is previously defined and provided with a set of instructions. For this task no tools are necessary. The connecting elements or "Connectors" are inserted vertically through both panel channels simultaneously along the total junction of the (collinear or  intersecting) panels, see Panel sequence from Installation page. 
Installing tie beams Installation Details sequence
Tie beams slide through the top channels of the wall panels with linear connectors. Connectors effectively join Tie beams to the wall panels. If steel tie beams are selected, they are arc welded at the interceptions (120 amps Arc welder and 3/32"steel welding rods are required for this task). The tie beams provide both a perfect alignment of wall panels and a bracing frame plane to support and anchor the roof structure to the house wall structure and foundations. Installing finishing boards (Casting forms.) The finishing boards make up casting forms by retaining the cellular concrete foam poured inside the panels (vertical casting installation mode). These are also the finishing material of the wall panel’s surfaces. These boards are fixed to the panels by attaching snapping clips or tapping screws to the side channels on both sides of the panels. The panels are standardized in their dimensions to adapt to the available boards in the market. The STD panel size meets the International STD board and sheet size of 4 ft. by 8 ft. (1,2m by 2,40m). 
Finishing materials
Finishing boards can be made out of wood, cement, gypsum, vinyl, etc. these finishing materials are previously selected by house owner, designer or Architect. 
Concrete casting.
Next step is pouring the concrete Rcc= 1300-PSI  minimum Compression Resistance recommended for Tornado prone areas and coastal zones. 
Horizontal casting
mode.  In the horizontal casting mode, panels are pre-casted horizontally over the slab using a polyethylene lining to avoid adhesion, and installed after a setting period of 24 hr.  
Roof Structure installation
. This depends on the particular type of roof selected for the house. Steel and aluminum tie beams create structural bracing-frames that provide strong support for the roof structural members. See Site Photos. Rafters In this type of roof they are made out of structural steel I- beams IPN-8 (80 mm) arc-welded to the steel tie beams. Hard wood Rafters can be used if an all-wood roof is preferred. Roof panels can be made out of different materials and components. Roof panels can be pre-casted with a reinforced concrete core before installation or casted in site after installing them. Roof structural elements and covers can made out of Different materials such as steel, aluminum, wood or others, according to selection or design. Anchoring of structures to foundations  The monolithic foundations shall comply with the applicable provisions of subsection 2404 of the SFB Code. A concrete slab foundation of minimum thickness of four (4) inches, reinforced with no less than 0.029 square inches of reinforced steel per linear foot of slab in each direction. The structure is anchored to foundation slab by means of a top floor cement mortar anchoring mechanism. (See instalation Details sequence). A 4 cm cement mortar top course of floor engages the lower horizontal channels of all wall panels, which lay 1.5 cm. from bottom end of structure. The cement mortar protrudes in the lower horizontal channels on both sides of all wall panels thus anchoring  the structure to the foundation slab. See Installation details seq. Additional anchoring is provided to the roof bracing frame structure by connecting tubular columns embedded foundation slab welded and/or bolted to tie beams. See site photo page. 
Time required for Installation.
Standard installation time for a 1500 ft2 home structure is 3 days with a crew of 4 men (unskilled), using the vertical installation mode. A crew of 8 unskilled men is required in horizontal installation mode. If steel tie beams are selected, an additional 6 hours of one qualified welder is required.
  Horizontal casting mode.  In the horizontal casting mode the panels are pre-casted horizontally over the slab using a polyethylene lining to prevent adhesion and installed in place after a 24 hr. setting period. It requires additional labor (10 men crew) due to the weight of the pre-casted panels that need to be handled. 1200 PSI Lightweight cellular concrete of specific gravity < 0.9 is recommended for horizontal casting mode. 
Architectural style
has no limitations with this system. The only changes to original design will be in the structural materials used. Steel, Concrete and Aluminum will be the only materials used for structural purposes. The only requirement is to submit the plans for your dream home. Ask your architect to design it. Or you can select one from design collections of top architects like Home Planners ( or from Home Styles ( An estimate for the complete Structure kit Assembly will be sent at your request. Other Applications: CAVALVI also supports small and other types of customized projects like Sheds or Storage Bins ( see Small Projets), House extensions, Greenhouses, Hydroponics installations, Military installations, Emergency Housing and Fast Deployment Installations, Rural Installations, Clinics, schools, Hospitals, Malls and other Commercial Constructions. 
's small overhead allows it to provide builders with the the system and components to meet the lowest construction costs and  is backed up by very large Aluminum processing industrial infrastructures, CVG-Alcasa, Extrudal, Alcan, which provide CAVALVI with a certified production capability of 300 TON/D, sufficient aluminum to produce components for 500 small homes with CAVALVI's patented matrixes, molds and procedures. These hard facts will,  in the near future, make considerable impact on supply shortage of real affordable housing availability.