Description & Installation details.
(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
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).
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
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
sequence. vertical casting
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
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).
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.
casting. Next step is pouring the concrete Rcc= 1300-PSI
minimum Compression Resistance recommended for Tornado prone areas and coastal
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.
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 (www.homeplanners.com)
or from Home Styles (www.homestyles.com).
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.
CAVALVI'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.