Ferrocement Photo Gallery

Ferrocement Photos

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fc roller


ferroroller2.jpg

2 files, last one added on Apr 25, 2010
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4_copy.jpg
41384 viewsWest view of well house
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261775 viewsPlaster noz that came w/quikspray rig
07_enterier_of_sports_hall.jpg
Interior View of Sports Hall1140 views
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Pour area1887 viewsThis is another area that is finished. Here we troweled on some plaster mixed with some of the foam that was trimmed off in places about 1 1/2 to 2 ft up from the floor. We whizzed it up in a blender then mixed it with the plaster and tried to fill in the holes with it. You can see the wall is smoother at the bottom. We then sprayed a mix of plaster with latex additive all over the foam areas to about 1/4 to 1/2" deep. Then sprayed paint.
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Photo 041005 viewsBecause of the sloping site and the ongoing house remodel at the time, much stair work was performed in the shop using a full sized mockup of wood. As a starting point I measured and transferred the slope and proposed footings at the site to a plywood 'floor' and 'wall' in the shop, accurate to within 1/16". The first fabrication job was having the 8" schedule 40 pipe bent at the roll formers following the plans. The curved pipe was not made as a compound curve to simplify bending. A longer curved stairway would have to have a compound curve spine. Using a simple curved pipe made the stair treads float at varying heights above the pipe yet rise was held at 7-1/2" consistently. With the pipe ready the wood mockup was begun and the pipe let in via forklift, with wood treads to follow. Many mockup components were handy as full size reference guides allowing me to easily figure these details of alignment and sizes before committing to metal and FC fabrication. A mockup was truly necessary to make this a one-shot installation with no screw-ups. Later the plywood shop tread templates served as handy on-site rod and mesh covers prior to mudding allowing the client, pets, friends, and contractors to use the stairs unfinished.
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gate lath1653 viewsIt took about 30 work hours to install the lath. We used rebar wire and vice grips for the inner areas. At the end I was finally able to twist the wire and snap off the end so nothing would stick out in one smooth motion. We also used hog ties on the edges where the lath and rebar met. The $8 manual hog tie clamper gave me some terrible blisters after three days of usage.
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Emerging Hawk mantel detail1868 viewsAgain there is considerable structure built in to this. All steel at #3 & #4 on 12" centers or less.
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7. Loren putting on the finishing touches3554 viewsLoren Impson putting the finishing touches on the stylized waves. The paint mixture was lime putty, white portland cement, Acrylic paint, and a little water.

Last additions
inside_cutout.jpg
1339 viewsAfter bolting and welding the roofs from outside, I begin to cut doorways.Aug 27, 2011
Seat_5.jpg
1233 viewsAug 15, 2011
Seat_6.jpg
1185 viewsAug 15, 2011
Seat_8.jpg
1164 viewsAug 15, 2011
Seat_9.jpg
1419 viewsAug 15, 2011
Seat_14.jpg
1246 viewsAug 15, 2011
Seat.jpg
1184 viewsAug 15, 2011
Seat_1.jpg
969 viewsAug 15, 2011