We won the CFA national project of the year award!!

On Saturday, July 25th, the Bartley Corporation proudly accepted the 2015 CFA Project of the year award (Concrete Foundation Association)!! Jim Baty of the CFA presented the plaque to four Bartley Corp leaders during the 2015 CFA Convention in Williamsburg Virginia. If you didn’t know, this is kind of a big deal !!

 

The CFA Project of the Year is an annual national competition seeking to recognize the best concrete projects. The recognition made its way into several national publications including the June 2015 Concrete Facts magazine and the 2015 July Concrete International magazine. For the complete press release, click here: CFA-Project of the Year 2015 Winner.

 

Bartley Corporation thanks all those who support the project with their votes. A special thank you also goes to the fantastic Bartley Corp customers and all of the dedicated employees that helped create this award winning work.

 

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Award 2015 CFA Above Grade Concrete Home

CFA Above Grade Concrete Home 2015 - Concrete Facts

CFA Above Grade Concrete Home 2015 - Concrete International

 

2013-07-16 Strip Walls & Remove Panels

2014-09-11 Finishing Concrete Slabs

You can read more about the entire project on the Clifton Concrete Home project BLOG.

 

With permission from the Concrete Facts Magazine, we present the content of their article below:

ABOVE-GRADE CONCRETE HOME

2014-09-22 Completed Slabs and Conrete Work-1Since the start of the new millennia, the recognition of performance and aesthetic advantage for all concrete homes has been a focus for the CFA and many throughout the concrete industry. Over the years, many fine works of construction and design have been recognized in this award category. Certainly not less impressive is this year’s “Above-Grade Concrete Home Project of the Year,” Clifton Concrete Home by Bartley Corporation.

“We were selected for this project when several recommendations for this type of complex structure pointed our way,” stated Jim Bartley, president of Bartley Corporation. “The construction manager hired for the project desired to partner with us based on our previous experience in building a concrete home.”

Bartley was asked about what makes this type of a project such a challenge. “Working with owners, construction managers and architects as well as other trades that are new to concrete homes can be a major time commitment,” stated Bartley. “Meeting on site and collaborating with the entire team was the key to success. Having an architect that saw the project all the way through construction made everything go as planned.”

Prior to the kickoff meeting the homeowners wanted to see a sample of the normal cast-in-place wall finish, one delivered on any foundation project. Bartley built and poured the mockup and made sure it wasn’t “perfect.” To their surprise the owners loved the bug holes, imperfections, ties and form- lines. They are in the building industry and like the industrial construction look with natural imperfections. Therefore, extreme measures were taken to avoid using any patching materials on the walls. With the exception of one or two spots honeycombs were avoided. Surprisingly, a crew patched one of these honeycomb regions and when the homeowners saw the patching they asked that it be removed. This kept the project on track and consistent with the approved aesthetic negotiated early in the project.

Another unique characteristic of this design was the presence of two different insulation systems, Thermomass and ThermaEZE, both products that the company had prior experience but separately on projects. The standard wall section consisted of two reinforcement bar mats, Thermomass in the center with all the connectors, conduits, block outs and wall ties. However, where the weight of steel could not bear on insulation, the ThermaEZE system was brought in to provide an alternative support system. All walls were to be left exposed concrete as the final interior and exterior finish.

The most complex part of the project was the first and second floor walls. Gang forms were used to provide the large structural walls and Bartley engaged their commercial crew and a full time commercial superintendent to take the lead in these areas. Difficult block outs and forming along with many recesses for utilities, electronics and built-in features had to be as accurate as possible. Further complicating these walls was the flashing detail. The design called for flashing between the second floor and roof deck to cover the inside of the wall through to the Thermomass insulation sandwiched in the center of the wall. Although Bartley preferred to approach the design with a monolithic roof and second floor based on their experience, the design called for flashing to separate this interface into separate placements with flashing installation between.

Some of the other challen2015 - Copyges faced on the project included unique window jambs and an elevator shaft. Many of the windows called for the sides of the window block out to be at 105-degrees rather than perpendicular to the face of the wall. The 3-story elevator shaft challenged the safety on the jobsite with openings that were constantly managed. The shaft was produced by first forming the outside of the elevator shaft and then, when the walls were ready to be closed, a crane carefully placed large interior panels on the inside of the wall.

For more information on this foundation project, contact CFA Member Jim Bartley, Bartley Corporation, at [email protected] or (301) 384-2700.

 

Your VOTE = National Project Win?!

Can we count on your Vote?

vote_for_bartley

Bartley Corporation has an award winning entry in the 2015 CFA (Concrete Foundation Association) Project of the Year. The CFA Project of the Year is an annual national competition seeking to recognize the best projects from a variety of categories including small, medium and large residential foundations, commercial and multi-family projects, agricultural works and much more.

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The answer to these three questions determines the winner:

  • How difficult would this project have been to estimate?
  • How difficult would this project have been to construct?
  • How difficult would this project have been to turn a profit?

Our entry, project #8, the Clifton Concrete Home, stands out as the only Above-grade home that made it through the nomination process. Here are a few interesting aspects of this project:

  • In addition to typical foundation walls below grade, there were 92 linear feet of first floor above grade wall and second floor walls
  • Both Thermomass and ThermaEZE insulated walls were used
  • The concrete walls were the final exterior finish for several parts of the home

2013-07-16 Strip Walls & Remove Panels 2014-09-11 Finishing Concrete Slabs

You can read more on the project BLOG.

 

Finally, we are happy to present a video of the construction process and look forward to your vote.

Vote by clicking here!

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Vote_cfa_for_BartleyCorp

Concrete work at Concrete Home complete

The final slabs were poured this month at the Clifton Concrete home which completed Bartley Corp’s scope of work! Although a complex project overall, with ease, the concrete flatwork crews prepped the garage slab, first floor slab, and exterior concrete. The grade beams, rebar and poly installed in the garage slab are easily seen from the time-lapsed photos. A concrete pump was used to place the concrete inside the walls of the first floor home. Bartley crews used powered trowel machines to finish the concrete surface followed by soft cutting the construction joints. Broom finishes were used on the exterior concrete stoops and slabs.

We are proud to complete yet another concrete home and continue to be the leaders in concrete homes in the Washington DC metropolitan area. Learn more about the benefits of concrete homes at: https://bartleycorp.com/residential-concrete-foundations/concrete-homes/

If interested in a concrete home, please contact us so we can connect you with a local builder familiar with concrete homes.

 

2014-09-03 Aggregate Pre Prep

2014-09-03 Prepring Garage

2014-09-03 Placing Aggregate

2014-09-09 Rebar

2014-09-11 Pumping Concrete Slabs

2014-09-11 Pouring First Floor Deck

2014-09-11 Finishing Concrete Slabs

2014-09-22 Completed Slabs and Conrete Work

Above Grade Walls of Concrete Home Complete

Until now, the Clifton Concrete Home was just a concrete foundation. With the hard work of setting and pouring the above grade insulated concrete walls, the project now is uniquely in a category that the industry calls a concrete home. The advantages are documented (http://www.concretehomescouncil.org http://www.cement.org/think-harder-concrete-/homes http://concretehomesmagazine.com to name a few) and getting to this milestone will reap ongoing rewards for the homeowners for decades to come.

 

To accomplish above grade walls, Bartley Corp started by tying rebar per the structural plans. Next, one of our crane trucks brought in our large commercial “gang” forms. The larger panels provide a bigger finished area, can increase the efficiently of setting the wall and are stronger than stacking several panels to boot. Only one side was initially set to allow the other trades (electrical, plumbing, HVAC, elevator etc.) to place their blockouts and material in the walls.

 

Next the Thermomass insulation was placed in the center of the wall which is key to creating an energy efficient concrete home. The crane truck returned to set the other side of the concrete wall panels. The first pour consisted of 90 cubic yards of concrete followed by 26 yards of concrete the next day in order to separate the concrete at the flashing (a specification that took Attention to Detail). After stripping the walls, a solid concrete home was revealed. Beautiful!

 

2014-04-02 First Floor Walls Start

2014-04-08 Gang Aluminum Forms

2014-04-14 First Floor Set One Side Walls

2014-05-09 Thermomass Insulation Installation

2014-05-13 Set Concrete Panels

2014-05-16 Pour First Floor Concrete Walls

2014-06-08 Above Grade Concrete Walls

 

Super Speed Concrete Home Construction Video

Check out a video of the Foundation level of the Clifton Concrete Home! This entertaining 51 second time lapsed video shows the unexcavated site through the basement slab pour.

 

Bartley Corp is back on site, so stay tuned for some more progress that will show the 1st floor concrete construction! Please enjoy, share and Like !! Yes this is the same video that was leaked from Vimeo last week (its also on YouTube.com ).

 

Seasons Change but Concrete Remains

It has been months since Bartley Corp has worked on the Clifton concrete house so we wanted to share an update. In the Summer, Bartley successfully prepped and poured the basement level slab (first picture: concrete slab is not visible from the Work Zone Cam angle). This marked the final stage of Bartley’s “typical” concrete foundation package. To recap the concrete foundation package, here were the steps: Excavation, Footings, Walls, Waterproofing, and Slabs. After the slabs, Bartley turned back the job to the builders.

Complicated jobs can take more time and effort by the whole construction team and this project is no exception. In the Fall, the builder and framers have been backfilling and installing the first floor deck. In the bleak midwinter, mother nature brought some snow and kept construction workers off the job (see last picture). Soon enough, Bartley will be back at the site to work on the first floor walls, which is the true difference between a regular stick built home and a concrete home!

2013-09-04 1030 Basement Slab

2013-10-03 1200

2013-11-06 0730

2013-12-04 1100

2013-12-11 0800

Backfill Matters

Backfilling a foundation is an important step in building a home, but it can come with pitfalls. Once the concrete walls have cured, the foundation is waterproofed, draintile (and preferably drainboard) is installed, a qualified equipment operator “back” “fills” the area between the exterior wall and the designed grade level.

The fill can vary but a coarse, well-draining material  is recommend to help keep the basement dry. Builder Magazine says “Site soils are fine if the natural soil in the area is mainly sandy or gravelly, but don’t use the existing soil from the site for backfill if it contains clay or organic material.” The backfill material can be specified in the plans.

Bartley Corp typically includes backfilling in the excavation scope of work. In this case, the backfill design called for a loose crushed rock so the builder decided to complete the work as it is a more time consuming installation.

The big mistakes made when backfilling can cause a cracked wall or a long-term water problem. A qualified equipment operator places the proper loads and moves the equipment in a safe manner not to cause too much pressure against the concrete walls when compacting. In some cases bracing the walls is necessary to ensure the loads are not too much for the concrete walls when they are still curing.

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2013-07-24 1300

2013-07-24 1800

2013-07-24 Backfilled

2013-07-25 1400

2013-07-26 1300

Waterproofing the Foundation

Waterproofing is an important part of Bartley’s foundation package.  We are happy to use the EPRO Waterproofing system (www.eproserv.com) consisting of ECOBASE , ECOSHIELD, and ECODRAIN. Shown in black, ECOBASE is a water-based polymer-modified asphalt emulsion application which is sprayed directly onto the concrete wall. Next, ECOSHIELD, a blend of polyolefin copolymers, provides a vapor barrier protection over the first waterproofing membrane.  Then pictured in grey, ECODRAIN is a polypropylene filter fabric and dimple board combination. The filter fabric promotes proper water drainage and the dimple board protects the fabric.

Exterior Drain Tile is also installed along the base of the wall by our waterproofing team. The drain tile is perforated PVC drain pipe that helps keep water from building up at the base of the wall.

The EPRO system combined with the expert waterproofing installers makes it a Bartley foundation!

2013-07-17 Epro Waterproofing

2013-07-18 Draintile Shooting Stone

2013-07-18 Drainage Board

2013-07-24 Backfilled

Concrete Walls Poured

Measure thrice, pour once. Bartley successfully poured a 152.5 cubic yard wall in the heat of the summer (88 degrees). Inside the wall contained rebar, PVC blockouts, electrical boxes, Thermomass, ThermaEZE, wall spacers, wall ties, insulation blockouts and pressure treated window and door blockouts. All this material and labor added up to a price tag of $74,797 for the foundation wall portion of the contract.

The pictures show the wall pour assisted by a concrete pump and 16 ready-mixed concrete trucks. The next day, the wall crew was able to strip (remove) the panels off the foundation walls to get ready for the waterproofing.

Concrete is not a very forgiving material so all the work that went into getting the walls set correctly was worth the effort! Attention to Detail and Production meet value is our motto and it holds true especially in this case.

2013-07-15 Pour Foundation Walls

2013-07-15 Concrete Pour

2013-07-15 Pour Foundation Column

2013-07-16 Strip Foundation Walls

2013-07-16 Strip Walls & Remove Panels

2013-07-17 Concret Wall Reveal

Insulation for Concrete Walls are centered and placed

Given the go ahead from the other contractors who set their wall penetrations, the Bartley crews returned to finish setting the wall forms. Unlike the typical concrete wall for a foundation, the plans called for two kinds of insulated walls; one insulation system that is cast in the center of the concrete wall and one that is cast on the outside of the wall.

The first system, Thermomass (http://www.thermomass.com) is a rigid foam insulation that is placed in the center of the wall with fiber composite connectors that keep the insulation in place. The major benefit is the insulation eliminates thermal bridges which improves the thermal mass effect of the concrete wall. The effective R value of the system is 20.4 in the Washington D.C. area. Pictures that contain blue insulation are showing Thermomass.

The white insulation is a system called ThermaEZE (http://www.certainteed.com/products/foundations/foundation-insulation/311483) where the insulation is set on the inside or outside of the wall. The expanded polystyrene (EPS) insulation is set against the concrete panels during installation and the concrete is poured normally. In this application ThermaEZE was placed on the outside of the wall in order to assist the steel decking and support design. The R value of ThermaEZE is 9.4 for 2 inches of the material and a 10” wall.

Moving along the wall, the crews placed insulation, the rebar and then the exterior concrete wall panels. At this point, the walls were ready for the next critical step, the concrete wall pour. Get excited!

2013-07-08 Insulation Install

2013-07-08 Form Outside

2013-07-09 Forming Wrapup

2013-07-09 Inuslation Install from back of Home

2013-07-09 Inuslation Install Thermomass

2013-07-09 Inuslation Install Thermomas Closeup

2013-07-09 Inuslation Thermomass in center of wall

2013-07-09 Inuslation Install ThermaEZE