A Unique, Patented Construction System

The secret lies in our patented cavity wall system by which an acrylic resin cured fibreglass mesh is attached to each face of the frame. When plastered the timber performs merely a structural role, with a lime/cement plaster on each face providing the insulation and finish. The foundation takes one day to set. A house of 40sqm will be erected in one further day, and will be roofed on the third.

Foundations

Mass concrete strip footings 200mm deep by 350mm wide in a foundation trench 450mm deep support a rising wall of 190mm concrete blocks over a brick grip damp course.

Galvanised hoop iron is embedded at 800mm centres to secure a SAP 76mm x 38mm Foundation Plate.

Prefabricated Cavity Wall Panels

The walls comprise pre-fabricated timber wall panels of a standard 2500mm high by 1000mm wide, erected on and nailed to the timber foundation plate plus a ring beam wall plate at eaves level. Acrylic resin impregnated fibreglass woven sheeting (Duramesh) is stretched over and stapled to both inside and outside faces, with a sheet of bituminous paper beneath the outer face as an added precaution against damp.

Water pipes, electrical conduit, plug and switch boxes are installed within the panels at this stage, as well as door frames and clisco window frames of whatever size the house design requires. When erected and roofed, both wall faces are covered with a lime/cement stucco, starting with a stipple coat applied by a slush machine (or more properly a Tyrolean plaster machine) which is hand held. Thereafter two plaster layers are applied up to a total of between 20mm and 30mm. A typical mix is one bag of lime, one bag of cement plus three wheelbarrows of sand.

The result is a nominal 76mm cavity between the two stucco plaster walls which are structurally robust, waterproof and have a 60 minute fire rating. Thermal efficiency exceeds that of a clay brick cavity wall and results in the most energy efficient product available.

Roof and Insulation

The roof covering can be of any chosen material. A most effective and inexpensive insulation which can also serve as an alternative ceiling is Alucushion

Floor

An in-situ concrete floor slab of between 75mm and 100mm is thrown over a damp proof membrane after the walls are plastered, and before painting and glazing. The floor level is the same as the top of the lowest horizontal member of the wall panels, and should be about 150mm above ground.

House Plans

The system is suitable to adapt a wide variety of designs. Our most popular products are typically 52m² 2 bedroom, 67m² 3 bedroom and one bathroom, or 80m² 3 bedroom, 2 bathroom with dining extension. There is no limitation to size.

Established & Approved

The system was developed in 1993 and has been fully tested and approved by government, local authorities and the banks.

Houses erected during the test phase 1994/5 are still happily occupied by the original owners, and an office building for Portnet at Cape Town Harbour subsequently sustained the demolition of a corner of the building by a heavy vehicle, without damage to anywhere other than that directly impacted.

Temperature insulation is as good as, if not better than that of a cavity wall of clay bricks. The SABS strength and water resistance tests were passed easily, and there is a 60 minute SABS fire rating.

Download Our Technical File and
Sample plans:

• Technical File (pdf)
• 41m² Plan
• 45m² Plan
• 52m² Plan
• 67m² Plan