Construction Overview

Recognized throughout the industry as the company that set the standard for training and technical support, American Polysteel is one of the most user-friendly building systems available. Below is a brief look at 10 of the basic steps to completing a successful project.

 
1. Footings
Install standard (level) footings with rebar placed at the intervals required by your building design, as outlined in the Polysteel User Manual.
2. Building the Walls
Starting with the corners and working toward the middle of the wall, set forms on the footing (or slab) by applying a bead of foam adhesive, such as Enerfoam®, to the bottom of the form. Each subsequent course of forms should be stacked in a running bond (alternating vertical seams) and vertical rebar placed as needed. Horizontal rebar is usually placed every third course.
3. Window/Door Openings
Forms are easily cut to accommodate any size and shape of window or door. Window/door "bucks" should be pre-made to rough opening size using dimensional lumber or, more preferably, the VBUCK II® block out system. Window bucks are installed at the proper wall height and forms should be stacked from the corners into the door/window openings and forms cut to size for a good fit. It is also important to remember to create the openings needed for utilities.
4. Bracing
Proper bracing will ensure straight walls. A variety of wood, steel and aluminum bracing systems and techniques are available. We recommend the Reechcraft Panel Jack Alignment System for builders who use Polysteel frequently. All window and door openings are braced and uninterrupted sections of wall are braced every 8 to 10 feet.
5. Placing Concrete
After checking the walls and openings for plumb and straight, and proper bracing, concrete is placed in the Polysteel walls, which are fully reinforced with the horizontal and vertical rebar required. Concrete pumps are the preferred method for placement and your Polysteel distributor can help ensure that an experienced crew is on hand.
6. Finishing the Top of the Wall
The top of the wall is leveled off (screeded) and anchor bolts are placed to secure the top plate. In high wind areas, anchor bolts would be replaced by hurricane straps placed directly in the concrete.
7. Install Floor/Roof System
For intermediate floors, the rim joist is anchored to the Polysteel wall with anchor bolts, and joist hangars are attached in the typical fashion. Steel joist hangars that can be cast directly into the concrete are also available. Install roof trusses as you would in any other construction project.
8. Install Utilities
Electrical and plumbing lines fit easily and in accordance with code requirements by simply cutting a channel into the foam and placing the wiring or piping into the wall. For plumbing lines larger than 1-1/2" O.D., you may need to set them in place prior to placing concrete.
9. Interior/Exterior Finishes
Sheetrock can be screwed directly into the Polysteel furring strips for all interior walls. Siding, board and batten, stucco lath and brick ties are attached to the strips on the outside which can accommodate any and all wall finishes.
10. Your Dream Come True
Whatever you originally imagined, you have now built with Polysteel Forms. You can now be proud to have provided your customer with the most comfortable, most secure, most energy efficient home in the neighborhood!

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