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Process 2018-04-04T21:41:52+00:00

Locate Your Land

Securing land is the first essential step in building a custom home. Considerations in land choice include surrounding developments, zoning, property dimensions, utilities, roadways, adjacent properties, land views, schooling, property hold time and budgetary guidelines.

Land Preparation

Homeowners on average, spend between $1250 and $4200 to clear land and prepare a project site for construction. Land preparation starts with surveying and comparing the land with construction plans to determine the necessary tasks before construction can begin.

Site preparation begins with clearing the land, grading, drainage control, erosion prevention, staking, securing access roads, and utility connections.

Architectual Design

The architectural process can be divided into distinct phases, which may vary in order and definition with each architectural firm.
1. Pre-Design
2. As-built Measuring
3. Schematic Design
4. Bidding
5. Design Development and Permitting
6. Construction Documents
7. Construction Administration

The key to ensuring a quality architectural process is the management of clear communication and expectation. Spray Rock partners with a variety of diverse architectural firms to accommodate any necessary building specifications and design details.

Structural Engineering

Although the structure of a home is first considered by the Architect, ultimately the Structural Engineer considers the supporting framework to ensure it will withstand the stresses and pressures of the environment, the specific requirements of the architecture (clear-span, fenestration, economic considerations, materials, etc.) and remain safe, stable and secure throughout its use.

Spray Rock’s engineering department specializes in complete steel shell construction to accommodate all types of design and load requirements.

Construction Permitting

Permitting is traditionally handled by the building contractor and serves multiple purposes which include but are not limited to:

  • Legality – Avoid Fines
  • Structural Safety
  • Contractor Honesty
  • Building Guidelines
  • Code Requirements
  • Insurance Benefits
  • Real Estate Value

Generally, the permitting process takes between 6 to 8 weeks to finalize with local building and zoning before officially “breaking ground”. Traditional construction methods (block and wood) are postponed until the permitting process is complete.

However, Spray Rock not only exceeds current building codes until 2030, but also affords a headstart to begin the fabrication and assembly phase once engineering is approved to expedite production and save build time.

Foundation

The foundation, which is generally a concrete slab, is the underpinnings of the structure. The typical house foundation is a four inch, uniform thickness, concrete pour over a compacted soil surface. It includes a termite barrier covered by heavy-duty polyurethane sheeting and heavy gauge (typically #4 or #5) rebar and wire mesh to allow for concrete expansion due to temperature change. The foundation thickness is determined by structural engineering based on load requirements and can increase up to 8 inches or more.

Factory Wall Assembly

The Spray Rock building system uses quality American made, 85% recycled, 16-gauge galvanized steel for all exterior walls. The interior walls (also made of galvanized steel) are 18 – 22 gauge, depending on structural requirements, far surpassing interior wall thickness typically found in U.S. building.

The floor trusses (aka floor joists) and roof trusses are made of 18-gauge galvanized American made steel. Galvanization of steel studs and trusses ensures lifetime durability within even the harshest salt & high humidity environments.

All wall and truss assemblies are manufactured in our own factory using computerized steel roll forming machines to exacting engineering specifications. Each panel is stamped with an identification number to indicate its exact location within the building. Both interior and exterior walls are pre-punched for electric and water service holes during fabrication.

Wall Installation

As wall assembly is completed in our factory, the wall panels are shipped to the job site for erection by qualified installers.  Each wall panel is bolted to the foundation on the first floor and to the floor trusses on subsequent floors.  All panels are secured to each other using high strength screws.  (Note:  there are no nails in a Spray Rock building). 

Truss installation is performed in the same manner as wall assembly as each truss (floor or roof) is fabricated and assembled in our controlled factory environment.  Each unit must pass inspection before being shipped to the job site for installation.

Foam Board Installation

Spray Rock exterior wall panels are covered by an outsulation / insulation Spray Rock expanded polystyrene (EPS) board on the exterior side.  Each EPS panel is precision factory cut on CNC (computerized numerical control) machines to fit the exact matching exterior steel wall panel.  Each panel is 3-inches thick (1” outside & 2” inside the wall cavity). 

Spray Rock EPS boards are infused with borate, aka Borax (composed of naturally occurring minerals safe for humans) at the EPS factory as an insect barrier.  The standard panel insulation rating is R14 (75% higher than Florida building code) however, can reach R40 for extremely cold temperature environments.

Once fabricated and passed inspection, Spray Rock EPS board panels are shipped to the job site for installation.  As with the steel panels, each Spray Rock EPS board is stamped with its unique identification number to correspond with the matching exterior steel panel.

The Spray Rock EPS boards are fastened to the steel wall panels with high strength isoplastic (fiberglass) bolts to prevent heat or cold intrusion into the building.  The final step in the EPS board installation is to attach galvanized 14-gauge steel wire mesh and D-Wire to each wall panel in preparation for concrete spray.

Concrete Spray

The final step in the installation of the Spray Rock exterior wall assembly is to spray a monolithic & seamless 3 inches of concrete gunite (same as used in swimming pools) to the entire exterior surface area.  As the concrete is sprayed on it is troweled to a scratch coat finish, ready for final exterior cladding (stucco, brick, stone, wood or any other veneer) of the client’s choosing.  (Note:  prior to concrete spray all window & door opening frames are covered with a protective barrier to prevent the steel from ever coming into direct contact with the concrete).

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