Assuming a crew of 4 persons that work 8 hours per day and the construction site (lot) is excavated flat with proper compaction and ready to dig the foundation:
Schedule / Timeline:
Day 1: Dig foundation, form pad, install re-bar, run plumbing, run electrical. Pre-cut re-bar & foam that will be needed on Day 3.
Day 2: Pour, & finish concrete pad and then cover with 6 mm plastic. Pre-tie re-bar cube roof panels. Construct all opening bucks (windows, dormers & doors) that will be used on Day 3.
Pad/Foundation must cure to strength required by local engineering. This is usually 70% of its final cure strength and generally takes 7 days to obtain.
Day 3: (after cure time noted above): Remove pad/foundation forms, set up airform and corner cage forms, install foam (pre-cut) and begin re-bar (pre-cut & formed) installation.
Day 4: Complete re-bar installation and opening buck (windows, dormers & doors) installation. Final prep for shotcrete. Prepare option Eve/Parapet Roofing System forms if being used on Day #6.
Day 5: Spray Shotcrete layer #1 (1.5 inches) on entire structure.
Day 6: Spray Shotcrete layer #2 (1.5 inches if using three structural layers, or 2.5 inches if using two structural layers). The option Eve/Parapet Roofing System is installed on Day #6 and increase build time by 1 day unless a second 4 man crew is brought in. The optional Eve/Parapet Roofing System requires the three structural layer process.
Day 7: Spray Shotcrete layer #3 (1.0 inches if using three structural layers), plus additional for stamping if required. If all structural layers were completed on Day #6, then Day 7 is devoted to spraying additional stamping layers if required. Dormers and entry areas are typically constructed on Day #7.
Note: Aggressive concrete stamps that imprint more than 1/4″ into the 4″ structural concrete layer, will require additional non-structural shotcrete layers to allow for the aggressive architectural design. Non-aggressive concrete stamps such as “fractured slate” can be applied to the final structural layer, ONLY with an experienced crew of enough persons to keep up with the shotcrete application. The majority of MAS units are built using a three layer process with the final 1″ layer being stamped with a non-aggressive architectural design at a rate the stamping crew can easily screed and stamp before the concrete is too hard to stamp.
Note: In most cases, the forming system can be removed during day 7 (thus in use for 5 days). Local engineering should conduct cylinder tests to verify the strength of shotcrete layer #1 and #2 to make the form removal decision. This allows the forming system to be used to construct SIX structures per month. If forms are removed on Day 7, it is suggested that all structural work, being performed on day #7, be completed before initiating such form removal.
AT this point the MAS™ system shell is complete and interior work can begin on Day #8 if structural concrete cure is approved by local engineering. Also door & window installation should begin on Day #8 so that the structure is made weather proof as soon as possible.
If using interior concrete walls, these would usually be formed on day 8 and sprayed on day 9 and day 10 prior to the optional spraying of insulating foam.
Simple interiors can be completed in just a few days. It depends on the complexity of the interiors. Because the plumbing and electrical conduit has been installed on Day 1, the finish electrical and plumbing can be done in less than 1 day.
Note: If using stain coloring on the concrete floor, it is recommended that this be done after all interior work is completed, including painting, but excluding baseboards. The 6 mm plastic coating on the concrete floor is removed just before the staining process is to begin but after all interior work is complete. After removing the 6 mm plastic slab coating, the slab should be cleaned (if necessary) and prepared consistent with the manufactures stain application instructions. Once the stain is complete and SEALED, the pre-painted baseboard can be installed and the MAS unit is ready for occupancy if authorized by the local engineer of record.
MAR