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Carnation Walling - EPS Flooring

Star Fit the EPS flooring blocks that form the concrete flooring.

Install Carnation Flooring EPS blocks

Carnation Flooring

To form the floor (of the house level above) and the associated concrete beams, 8'x4'x1' blocks of EPS are CNC hotwire cut with a custom profile by the EPS manufacturer to make the pieces of Carnation Flooring .

Carnation Flooring cross section

Fit Carnation Flooring EPS blocks

The EPS blocks cut to the Carnation Flooring profile slot in from above onto the 10.5" high floor beams.  The beams run East West.  Leave the EPS offcuts in the cuts that will form the concrete beams.  The edge of the EPS block is the inside edge of the wall concrete, ie either 8" or 12" from the house outline reference line.  You start in the center of the building (as indicated by the blue cross) and work outwards.  You typically need to cut the EPS blocks at the outsides of the building.

Ceiling Eps First Blocks 

Site First Ceiling Eps Blocks 

Ceiling Eps Looking Up 

Site Ceiling Eps With Plastic Tarp 

Cut the Carnation Flooring blocks to form the openings for stairs (and view hole between floors, and the elevator shaft).

Glue the blocks together on their edges using foam gap filler.

Form concrete lip round stair openings

This is done with 2-by lumber.  The lip width is specified in the structural engineering CAD drawings.  Forming the lip involves cutting the 10.5" tall beams.  Extra props and 2x6s are required round the edges of the hole.  The lip forming lumber is supported by the 2x6 beams and their associated props.  It is likely to be necessary to add additional 2x6 beams and props in the area of the floor cutouts.

Floor Opening Lip 

 

Temporary 9" strips of 2" EPS are placed over where the wood beams are sited so that the weight from the walking planks do not press on the weaker concrete beam positions.

Eps Strips On Flooring Eps 

Implement rain water pipes for column bases

The 4" PVC pipes route water from the center of each column to pipes that after the concrete pour will be embedded in the wall EPS.

Implement temporary roof over stair openings

There will be 2x6 wood beams across the opening but there will not be any 10.5" beams and no Carnation Flooring EPS blocks.  You will need to implement a temporary roof over the opening so that the tarp does not sag with the rain.  Make the temporary roof using 2x6 lumber and construction plywood (that will be reused in the attic).  Initially it will be supported by the EPS blocks round the outside.  It needs to be just strong enough to walk on and yet provide a hatch to get through for access.  It must not get in the way of forming the concrete ledge round the opening.

Fit 6mil polyethylene sheet

The benefits of having a 6mil polyethylene sheet are...

     Keeps rain out while building.
    Stops bleed water escaping from concrete and making a mess in the floor below.
    Keeps ceiling beams nice .

This continuous (no joins) sheet fits down into the concrete bean grooves across the whole house area.  In my case, including the porticos, the sheet needs to be 100' (north south) by 70' (east west).  Across each 4' wide block (north south) needs 7'2" of sheeting to allow for going into the grooves.  In the east west dimension each 8' just needs 8' of sheeting.

Don't leave any slack in the sheet, just concentrate on getting it to tightly follow the cut profile of the flooring blocks.  Fit the offcut EPS into the beam slots to hold the sheet in place.  If necessary, use wood planks and concrete paving slabs to hold the offcuts in the slots.

Initially at the external walls the sheet goes outside the 8" wall EPS.  You can attach wood weights to the edges to hold it, or you can fix the edge to the horizontal wall bracing.  Longer term, just before the concrete pour, the edge will get moved to the inside of the wall plywood, but for the moment it needs to be outside the EPS to stop rain getting through and to keep leaves and pine needles from falling into the wall cavity.

The 6mil polyethylene sheet forms a waterproof roof, but it is not UV resistant.

Cover floor with tarp

A tarp is used over the top to protect the 6mil polyethylene sheet from UV.

The Carnation Flooring EPS blocks form a flat surface that can support a big tarp being spread over the entire building.  It only needs t ocome down the walls by a foot or so because the wall EPS is waterproof.  Making a flat surface is helped by leaving the EPS offcuts in the cuts that will form the concrete beams.  The use of decking concrete lips means it rounds off nicely at the floor edges rather than being a water trap.

For my house I need a tarp that is at least 62' x 50', but I actually chose to use one that is 120x60'.

Tarp   Large tarp

The tarp must be well weighed down by eg planks of scrap wood.  If you badly install the tarp and it isn't fully supported and weighed down then the tarp will be wrecked.

The story so far

The ceiling is now in place, and with the polyethylene and the tarp, provides a roof to keep you dry while working.  The Carnation Flooring will move around a bit and is not yet fully capable of taking weight because most of the vertical 2x4 batons are not yet in the final positions so cannot fully support the ceiling.  You can walk on it if you are careful.  The ceiling is supported by spindly vertical prop 2x4s that are towards the center away from the walls and by the 2x8 batons round the outside that are supported by a few vertical 2x4 batons (in their final positions).  There are temporary wooden covers over the floor openings.

 

 

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