Air Crete Shed Wall Panel Layout

[@kevinosborne169]

I like the explanation of the drawing. It helps to visualize the complete project. And to come up with my own ideas as well.

[@jamesnielsen347]

I like your projects with air create... I do appreciate your mindset, explaining the drawing information. Keep up the good work! Your Bride is an awesome asset to you and your project/ideas. Kudos to the Bride as well!

[@kgs2127]

I wish these vids were available when my kid's were young so I could show their Dad how it's done! Thank You for being awesome HDC!

[@PETERLINNAH]

Great video. Glad I watched this. Now I'm going to build my new shed -- out of 2X4s and plywood.

[@ziggy22shell]

Love the details, keep up!

[@moroniholm87]

I met you today in Twin Falls. Very nice family. Your boys are not shy. LOL

[@RedefineLiving]

What about striping the metal forms off and setting them with mortar like large blocks in addition to your angle iron? You might want to also do a bond beam or metal strap around the top. I would be skeptical to rely on the angle iron alone because Air-Crete is soft and that connection might fail over time.

[@kennybeans303]

Looks good! Keep the explaining going seems my nephews are really enjoying this! Told them bout the goat shed and they already talking about making one for the chickens. They already in the graph paper sketching up their ideas! Thanks you two are awesome!

[@joecoria3390]

Your drawings, very smart, keep sharing them, great for making corrections before final drawing and before final poring. Very educational. Easier to correct on computer than on final projects.

[@jameslybarger8786]

Great job keep up with the details. Love the explanation of what you are doing /thinking. I too would like to see more detail on how you attach the wall panels to each other and how the roof attaches to the walls. As well as cost breakdown. I think you are on to something exciting and fun. Just be safe. Thanks for sharing and being so honest and upfront. May God bless you both for all your efforts.

[@magicdaveable]

I enjoy seeing your design process along with building process. I am following this project very closely. I intend to use this process to build my new duck barn.

[@iposttube]

great job. Learn as you go, makes for a fun project. Thanks for sharing

[@carolynharmon7074]

Mrs. Honey Do you deserved that thumbs up. LOL

[@mikestraker2180]

I realize this is an old video set but was wondering about J lube { Questions will be asked} I remember making real strong bubbles for the kids and a pro said to use pure glycerin ,I might try that. Thanks for great info , I have hit your store for the pdf's to get started. Mike.

[@kgs2127]

Explaining is GOOD! LOL my ex used to complain that I explained too much to our kids....he was a "because I said so" kind of guy...my children were thinkers and needed to under the "why" of things...my explaining and giving them latitude to question and try has served them well! Anyway thank you for showing your process!

[@rodrigoaraya3992]

Vibro contigo cada vez que avanzas en el proyecto. Eso és, vamos adelante¡. Felicitaciones.

[@pheotonia]

#You just don't even know! We love it when you explain everything out & the evolving processes that you go through!

[@TheWicklunds25]

How are you attaching your odd-length panels to the tops of your standard 16-inch panels in the run of the walls, on top of them, around the window, etc...?

[@MrScoresby]

Darwin: Just use 'C' channel from the metal framing system for your top and bottom plates. Also you can bend the 'C' channel to make a wall/roof connector. the And if you like the look expanded metal lath and a stucco coat of air crete could finish the exterior and tie all the panels together. I would also use a metal to concrete adhesive between the 'C' channel bottom plate and pad to reduce corrosion as well as bond. There are other shapes and sizes in the metal framing system including thicker gauge where needed. More to come but for now I have errands to run. Bert

[@harveyboulanger2896]

bert skelton that is all you need 24 Gage is heavy enough.

[@50shadesofgreen]

great job with the drawings on the computer !! awesome start to making the frame work

[@danielsilvis203]

Have a look at how commercial walk in refrigerators are assembled. You may be able to incorporate the same panel locking cam and pal systems into your future designs.

[@davidwilson8088]

I like the post-hole digger in the tube to mix the air-crete. I would suggest modifying the plastic mixing (and rinsing) barrel to include a 3" PVC shut-off valve at the bottom of the barrel, and put it on a stand while mixing, or position it on a scaffold platform so the valve could be opened to empty the liquid air-crete into a section of wall that was enclosed on all sides except the top, and using a cook's large rubber spatula to wipe out the inside of the barrel out the valve when the barrel empties. When rinsing the mixer in water in the barrel, just leave the mixer in the barrel and use a spray nozzle on a water hose to clean everything, then open the valve to empty the water before lifting the mixer out.

[@forageforage3520]

I love the chicken foot imprint in the air crete slab! It really ads character..

[@EssentialMountainHomesteading]

Awesome video, keep them coming!

[@Mike_Neukam]

I would like to see as much of the construction details as possible. Are you going to use carriage bolts to thru bolt from the outside flat bar to the inside angle? And how do the wall panels tie to other wall panels and the roof?

[@jesusrenemedinasanchez689]

How much cement did it take to make the normal pannels and what are the meassurements of the sheet frame? Thanks

[@traceyluck8722]

Just a idea, could you put some of that hardware cloth inside your mixer then put your suds and cement in it and thus eliminate the auger work?

[@williamterry3177]

That might be a good idea! easy to bolt on some hardware cloth to the existing fins inside the mixer.

[@duanethieme4186]

To prevent rust, could you raise the concrete a few inches where the walls contact the floor?

[@robertwilkinson8115]

The CFS is coated to protect from rusting, and it is basically there only to form the concrete anyway. Personally, I wouldn't worry about it. I'm more concerned with storm damage or the bench grinder throwing the part, because the panels are brittle and could put a hole in them. I want some additional protection inside and out.

[@zwarst]

Hey love the go to attitude and air Crete panels, suggest to use galvanised C Chanel’s to slot the panels into on the slab. Similar to SIP construction.

[@jarryd1011]

Try using those little mesh pieces you used to push it down and place them on both sides of the frame back and front centralising the mesh and thus allowing the Crete to get under it easier and stop that air bubble gaps on the back , you will also be able to fix steel bars to this stabilising them and a set distance of a set amount for a panel at set size and place these in pre drilled holes in slab with apoxy already in

[@sharonglazier2552]

How long does a panel to dry and cure?

[@thomassutherland1026]

Hey Darwin. Love the videos of the project. I have two possible suggestions for framing and pouring the wall. As they do in tilt wall construction they frame and pour panels on slab with connections incorporated in the wall and any openings framed in place so when you stand them up you just attach with bolts. Other option since your using metal studs. Is frame the shed out with a studs standing in place(as you normally would frame prior to adding your sheeting. place a piece of ply wood or rigid foam board Interior and exterior and pour from the top by either leaving top plate off and cap once wall is filled doing back to back studs to simulate the each panel. Or cut fill holes on the top plate and fill level in each cavity. So your pouring walls in place. Same with the roof. Frame it. Attach plywood or foam board to underside and pour from top. Keep up the good work. I would like to try this doing my driveway. Mainly for water Penatration so it can keep the natural order of the moisture being absorbed into the ground instead of causing run off and have a solid surface to keep from tracking mud.

[@hypernaj]

the sheer forces at those localized drill holes is going to be too great have you thought about maybe putting in an insert to help with the tension forces ???

[@FernandoGomez-vi7fd]

Would the structure be stronger if you didn’t have to do forms for the Gabe’s ends and just make the forms longer with the angle built in the form ?

[@acsa0108]

What quantity of foam you added w.r.t cement ,w/c ratio, grade of cement & sp dosage.

[@atubeviewer4942]

In reference to a full scale building -The metal stud walls are used all over the world, the roof is metal stud and wood so summed up, this air crete boils down to just being insulation on buildings? Is that right?

[@moroniholm87]

What happens to aircrete when you mist wet quick lime over it while curing?

[@muharremozkocak3232]

Dear sir, which program are you using in the drawing.

[@melinda5777]

Like the drawings, you talking your way rhrough. What i was wondering, you said 3inch sheet metal for the outside, bottom panels with self taping screws. Not the andle iron part i got that. But the e inch outside, bottom to help hold the panel in place. 3 in wide x how for long, sheet metal? What thickness. Or am i up to late??

[@dLimboStick]

What are you using for sketches on your computer?

[@docase4932]

Darwin I’m curious why you don’t use the C channel the thickness of the wall panels run pan head screws inside channel set panels in C channel and small screws to fasten panels to C channel neat clean and secure. It’s the way we do steel stud walls in commercial buildings? Your doing a great job! Enjoying the videos!

[@robertwilkinson8115]

On a project that small, I think I would have tried to build each wall with the CFS laying on the ground, you could have put any plumbing and electrical in the wall, then poured the whole wall with the aircrete. The same for each half ot the roof. A couple of friends could have pulled the walls up and put the roof in minutes. Right or wrong?.

[@michbushi]

Also, for getting rid of air pockets, you could jig up a vibrating table to set your forms on. I've seen concrete blocks being poured this way in a manufacturing plant. Not sure if that would not harm the Aircrete's own bubbles though. They seem fine and firm enough, but you'd not know without testing. You could test it by trying out a jigsaw on any old airpocket -prone pour form from your arsenal.

[@sc0rpi0n0]

Aircrete must not be vibrated. For panels, wire mesh is usually dipped into the poured concrete, rather than pouring onto the mesh.

[@mallorylangford7699]

My idea for a foamcrete machine is, it will make the foam, mix and pump the mixture as needed. It will take some experimenting to get the consistency . Enjoy the videos, thank you !

[@handleismyhandle]

I am wondering if there is a way to render this material completely impervious to water. I am imagining that you could pour a basically unsinkable ship in one shot. It would be a pretty amazing thing.

[@tomrobertson3236]

You have thermal pass through with the metal forms. Heat or cold can travel though the metal to the other side . Probably not a big deal though . An easy fix is to cut. The metal vertically with a right angle grinder . Modern metal framed windows no longer sweat because of a thermal break

[@tubularguynine]

No doubt! The drawings make it easy to understand the workings of your mind! 👍🏻, Mel!

[@craigtegeler4677]

Hi There! Wouldn't a 48" door door made of aircrete also simplify your delema??

[@ScooterFXRS]

Two thoughts for you. Instead of fighting with your mesh and the voids it causes use those mesh "clips" you made to keep the mesh near center buy cutting a slit in the mesh where the mesh clip bends, run the clips thru the slits before you start mixing, pour about half your volume of AC then insert your mesh and finish the pour. When you finish the pour to settle the AC take a reciprocating saw [SawZall] without a blade in it and vibrate the sides, should settle quickly.

[@probinson7967]

The pace and detail of your videos seems just right to me. Did you consider a different size of panel? 24" or 48" wide?

[@MrKrishluv]

What is the thickness & size of this panels? What is the weight of each panel?

[@clarencementor4862]

Hi, Mr Honey Do Carpenter. What are the actual size of the shed in height width and length?

[@HeathHunnicutt]

Very glad to see you working on your family project. I fear the energy of working on a dirt patch Buckminster Fuller is going to be like last fall, when the energy from working on refractory aircrete resulted in no new videos for months. Your family is grounded and appreciates using a relatively straightforward project - a shed - to help you perfect your DIY aircrete system. There's this other person who gets you spun up and watches you strain yourself. It's like Lucy holding the football for Charlie Brown. Aircrete never made sense for a thermal mass in a rocket mass heater. You were installing insulation instead of mass, and the resulting design was sending excessive heat up the chimney. Building a circular dome on a square, below-grade foundation is another setup for an inherently flawed project. You're (admirably) learning about things like using CAD to detect your need to move the shed door 4 inches from the east wall. That's on a type of structure (square and plumb) that you're familiar with, you've seen thousands of them. Just trying to get the CAD to handle a geodesic dome will be a multi-month energy drain. Maybe I'm misguided. Was the geodesic dome your idea, or did someone bring it up in conversation and plant a seed of challenge in your head?

[@williamlattin]

Here's an idea. Have vertical corners pre erected which have slots on either side. Then drop panels in horizontally with a mortise and Tenon type joint. That way you could make larger panels and either have them pre-made to length or cut them to length as needed.

[@williamterry3177]

That would work too, but too late for this project. Interlocking similar to the steel overhead doors. Channels like the precast highway sound barriers.

[@1963gecko]

Can i buy a full kit from you please

[@cschnitker8865]

Seems to me you need a corner frame that is easily slid together so as to make construction starting at corners. That will give you faster assembly and and may eliminate the need for bracing as you go down the wall.

[@EddiCurrent]

Would make sense to make your panels wider. Do you really need a metal frame?

[@grnmacheen1knowledge837]

What are the 3 dimensions of the panel , and what is the overall weight of the panel? Thanks

[@nachokittytacocat9640]

Hey chief... an idea for you. Why not form your walls without the bottom metal stud attached. That way you can attach the metal stud to the floor and set your formwork into it after its poured. Then you only have to screw your bottom plate into your wall. It would save you a lot of steel and a little bit of room in your building.

[@nachokittytacocat9640]

also for your gable end walls... I would consider doing them in single panels.... not the whole wall but instead of an 8ft panel take it all the way to the peak. ;)

[@michaelsallee7534]

Might consider a bead of sealant at base and up 4” or 6” on each seam.

[@davidschwartz5127]

You need a small hook to pull the wire mesh up into the aircreate an inch or two.

[@SunnieDIY]

I would love to build a goat shed out of aircrete. Maybe domed would that work with aircrete? We get snow here and a lot fo you think aircrete will hold up all that snow possibly?

[@SunnieDIY]

Ps we live in Maine so when I saw we get a lot of snow I mean so very much snow lol.

[@williamterry3177]

This looks like a perfect application for Aircrete. You could make a form with hardware cloth and plastic, then layer on the AirCrete. Making a cool igloo shape. When finished, you can easily hose it out every so often. Form like gunite pools.

[@nathanrogers8713]

You could make a geodesic dome from this extremely easily. The panels could be framed the same way he is doing here with the C channel and assembled into a dome. Would be pretty straight forward and virtually indestructible. You could even top coat it with another layer to completely seal it.

[@SunnieDIY]

Nathan Rogers ooh that sounds really amazing. I would love to do that. I think its passed my skills but with some more research on geodesic domes its possible. I knew before I build it I would likely redo and redo the way I plan on doing it and thats definitely given me something to mull over not just for the goats but other animals too. That would probably keep it safer with our heavy snow loads. We just get so much snow lol.

[@SunnieDIY]

William Terry that too sounds like a good idea. Dome shaped however it gets that way would help with the balancing of the weight with the heavy snow.

[@georgeelmerdenbrough6906]

Am I wrong in suspecting that there is going to be corrosion between that angle iron and aircrete panel ?

[@forageforage3520]

Could you give a rough estimate on the cost per square foot with your air crete... I'm curious as to how this compares to other materials per square foot.

[@williamterry3177]

Depends on what you are comparing the per square cost to. If plywood and studs, or a HD pre-built shed, this is not for you. But I am sure the HDC will have the cost when complete. His building will be fireproof, vermin proof, fire hose washable.....

[@kosh123rivendale7]

Plz keep us informed, it is a huge help.

[@johntingle455]

If everyone is going to make suggestions.....I will too. But first...are you capable of handling panels four ft. wide? If so...all your windows and doorways could be completely within the panel. Poured in place on the slad....much like tilt wall construction.

[@mfredricknew]

have you used self tapping bolts into aircrete before?

[@Quake81270]

What is the name of the computer design program you used for this? My brother wants to try an aircrete shed for his new place

[@williamterry3177]

Goggle SketchUp

[@elizabethmcgovern9731]

Darwin dear friend 99-9% of Americans are wishing you were their Son in law ,man you are something else ,E&P. Paul.

[@randyl9071]

Why not cast the end wall pieces from floor to their full heights with the angles needed as they work towards the peak?

[@jerryfigueroa6194]

Nice..

[@johndunn3386]

why not when casting the slab have a recess to locate the panels saving anchoring with angle iron

[@duanethieme4186]

Thank you for all the info and keep up the great work!! Question; how does foam compare to haydite and lava rock in concrete in cost, insulation, weight, and strength?

[@moroniholm87]

Darwin I think you should sell water glass along with the foam generator.

[@laytond4501]

Dude, I love your videos. What program do you use to create your plans?

[@philliptoone]

I like the explanation. How much do these panels weigh? Could they be wider or would they be to heavy?

[@williamterry3177]

About 100 Lbs

[@HoneyDoCarpenter]

80 lbs

[@AARBTC]

I think the support steel plate that holds the wall with the foundation is abit short, raise it up higher.

[@pucketts57]

Hi All Was thinking I may buy a house that has burnt down to the foundation Does have the blocks in the basement but I will tear those out & build new walls Was wondering what you thought of laying the blocks on top of each other - No mortar & filling the voids with air crete Any hope of it holding under the stress of a house on top of it Hoping since Im not that great at masonry & dont care to get that great at it My thought was that its just mortar & an empty void & the air crete would be a lot stronger

[@standforsomethingorfallfor5812]

Just stumbled onto here. Looks great mate! Just a thought though... Please forgive if its captain obvious, but... If you were to drill holes up the side of the frame and place threaded bar right through so it comes out the other side of the frame you could use that to secure a number of the panels together as they stand, maybe inside a threaded metal tube.. In fact if you were to think a little further through that you could design a corner brace that each of these threaded bars feed into and the structure would be easily made square and super strong. Just screw the threaded bar through as you go and tighten up at the corners.

[@1voluntaryist]

If you only need the window for natural light, replace it with a tubular skylight. That won't compromise the R-value of your shed.

[@jarcfrance1916]

How hot is it in your barn, thank

[@robertjauregui253]

Show as you go!

[@animalier2949]

To eliminate wire show through, why can't you put in about an inch of concrete in the form, let it almost dry and then put in the support wire mesh followed by the rest of the concrete?

[@pamcolechadwell1302]

Can you trim the panels if needed?

[@williamterry3177]

Yes, the Aircrete cuts very well with power tools. A abrasive masonry blade would cut it like butter with a hot knife.

[@mountainviews5025]

Need the wire mesh in the middle it's a must

[@davidwilson8088]

What are the proportions and the ingredients in your air-crete recipe?

[@danmallery9142]

Instead of the angle at the sole plate, use a metal stud C channel. This is what would work for a regular metal stud and should work in this case as well.

[@kellyschlumberger1030]

Thanks. How much does a panel weigh. Density calculation should be easy with your standardized dimensions. Looks like u moved it easy enough. Thanks for video. I liked and subscribed. I have enjoyed your other stuff but i want to try my hand at foamed concrete sometime in this coming year. Hopefully i will put some videos up of that and my house construction. It's gonna be very energy efficient i hope. Big geothermal loops built-in. Please keep these videos rolling!

[@troymcdonald9795]

Need to vibrate the panels right after pouring & will get rid of the air bubbles

[@nathanrogers8713]

The problem is that more than half the panel's volume is air bubbles. If you over vibrate this, you would end up removing all the air bubbles you intentionally placed in the concrete.

[@jamesowens2781]

Hey Darwin just for the record I am cheap I shop at habitat for humanity I save a lot there. If you have a store in your area? On the panels have you thought of when you build the panel could you use a PVC pipe to use rebar through the panels from the pad up through the roof? Also what program are you using to lay your project out? All my projects are small but I like using aircreet. Adios

[@RedefineLiving]

James Owens habitat is a great place to support because they do awesome things.

[@kgs2127]

Love Habitat Store!

[@vicbuckley8130]

kgs2127 habitat stores are expensive, they ask as much as the cost of items new. And no warranty.

[@arkansasmountainman]

He's using"SketchUp". It's a free program if I remember correctly. I used "Sweet Home 3d" to layout my little cabin. It's also a freebie. It allows you to layout rooms and customize the furniture to your actual size. and place the furniture in the rooms. It has walk-through and many other views available. Really nice to see how traffic patterns work. You can even do landscaping and see how everything looks. It's fairly easy to figure out.

[@moroniholm87]

Hi. Moroni here. I have so many things I wanted to talk about...but I can tell when children want to move on. LOL

[@jerrywhidby.]

Hmm a jig to align conduit that is placed into the aircrete.

[@taylorphillips5118]

Why 3.5" thick?

[@bobjoatmon1993]

Because metal studs replace wood 2x4s which are ACTUALLY 1-3/4x3-1/2

[@shawncerveny8354]

Hi, journeyman commercial carpenter here... Trying to wrap my head around the point of this "aircrete" panel system. Appears to be much more labor and material intensive that just framing the structure with the same metal studs. Also likely not as strong a structure considering the way these panels will need to be tied together. To each there own, but this system just doesn't seem to make sense.

[@williamterry3177]

This is a concept show. Using AirCrete in a building project. Spur new ideas... How about someone that wants to build a vermin proof smokehouse, how about a huge oven to cook large powder coat parts....

[@DarrellHughes82]

what is your cad software?

[@williamterry3177]

Free- Google SketchUp

[@danstrayer111]

CAD for a shed? OMG. WTF.

[@revtmyers1]

I would seriously look into a different design for attaching the panels to the floor. Since the floor is standard concrete a typical anchor bolt should work okay but I would use something like a PVC pipe to create a way for the anchor to go in through the bottom of the wall and use a wood form to create a pocket are in the wall to attach a nut and washer to the anchor running up through the PVC channel in the wall. I know clear as mud.

[@mikeblack5301]

Just drill holes in C channels and molly into the floor. Then stand slabs up inside track and fasten. Easy peasy!

[@wrong-waygo-back9355]

Instead of angle iron put a rebate or step into base slab design, less material cleaner line's

[@rubygray7749]

I really dig that chicken-foot theme!

[@JesusFreakJene]

Why are not using aircrete for the floor?

[@craigtegeler4677]

You could very well fab a exterior mounted top rail mounted topside slider door on the exterior! (Barn Door Type) slider is what i mean.

[@lisduffer]

How much does each one weigh?

[@williamterry3177]

About 100 lbs, very light weight for concrete.