Basis: Ken's description, 6 Sep 2026, plus the roof-panel system this is derived from (../roof-panel-animator/docs/spec-v1.md); roof Option 3 chosen from docs/roof-options.html the same day.
Hand assumptions for the model and the cost sheet only — not for construction. PE to size the studs, the joint screws, the slab anchors and the fill.
1. Stated by Ken#
| Item | Value |
|---|---|
| Panel size | 4' wide × 10' tall, giving a 9' ceiling (the extra foot covers the slab recess / top track / roof bearing zone — to confirm) |
| System | Same build as the roof panel: cast flat in a form, cellular concrete finish layer, 6" cold-formed studs |
| Finish | The cast finish face goes to the inside of the building |
| Setting | Panels set at 4' widths and screwed together through the edge studs |
| MEP | Wire and plumb in the open stud cavity after the panels stand |
| Cladding | 2" cladding of the same cellular-concrete material on the exterior |
| Fill | Then pump the walls full of lightweight (cellular) concrete |
| Customer | A different customer from the roof — separate animation and cost sheet |
2. Model assumptions (change in public/config/wall.config.json)#
| Item | Value | Why |
|---|---|---|
| Stack | 2" skin + 1.5" channel/mesh zone + 6" stud + 2" cladding = 11.5" wall | Mirrors the roof stack so the same steel details apply |
| Skin pour | 5" (skin + channel zone + 1.5" into the studs) | Locks the studs into the finish layer before the pick, like the roof's 6.5" ground pour |
| Cavity fill | 4.5" between the skin pour and the cladding, 30 pcf | "Pump the walls full" |
| Studs | 600S162-54 @ 16" (16 ga) — lighter than the roof's 68 mil because the fill and cladding brace the wall | PE to confirm; jambs/headers at openings |
| Track | 600T125-54 top and bottom of every panel + a continuous top track | Roof bearing |
| Channel + mesh | 1-1/2" cold-rolled channel rows @ 48"; the basalt mesh sits on top of the channel at the 3.5" line, between the channel and the stud bottom flange, and is buried by the skin pour | Same as the roof; Ken, 14 Sep 2026 |
| Cladding | 2" cellular-concrete sheet with mesh, cast in the same bed, screwed to the exterior stud flanges | "Same material" |
| Joints | 8 × #10-16 screws per joint through the mating edge studs (assumption) | "Screwed together" |
| Slab | 4" slab; 2 anchors per panel through the bottom track (assumption) | |
| Building example | 10 × 7 panels (40' × 29'-11" outside), 1 door, 12 windows (docs/floor-plan.html) | Ken's plan: living zone across the front, bedrooms and baths at the back; edit building.* |
| Casting | 4-panel bed, 7-day cure, 34 panels = 9 cycles; slots sized for the tallest (12'-6") panel | The 7 days is a handling rule, not a strength acceptance. No accepted cure temperature range exists — quality manual §6.8, form QF-11, open item 11 below |
| Weight at pick | ≈ 40 sf × (5/12 × 35 pcf + 3 psf steel) ≈ 700 lb per solid 10' panel; ≈ 880 lb for a 12'-6" wall-A panel | Forklift boom. Method, checks and hold point: quality manual §7.8, form QF-16 §2. Provisional — not an engineered pick (open item 10) |
3. Roof — Option 3, shed roof rising to the view (roof in the config, src/geometry/roof.js)#
Chosen from docs/roof-options.html (Option 3, 6 Sep 2026). One roof plane rising 1"/ft toward wall A (the view side) and draining to the back; the ceiling goes from 9' at the back to about 11'-6" at the front glass.
| Item | Value | Why |
|---|---|---|
| Roof plane | Underside at the wall C top (120") rising 1"/ft over the 29'-11" footprint depth = 29.92" to the front | roofPlaneY(cfg, z); rise = footprint z / 12 × roof.slopePerFoot |
| Wall A panels | 150" (12'-6") — building.wallHeights.A; walls B, C, D stay 120" | The front wall carries the high end of the plane; the audit refuses a wall A that misses the plane by ≥ 1" |
| Clerestory band | 40" × 24" opening at sill 120" in every wall-A panel above its door/window (roof.clerestory) — 10 openings, 66.7 sf of glass | Light and view without bigger panels; sits on the 10' line so the standard window framing is untouched |
| Framing on wall A | 4 channel rows (12, 60, 108, 138); the clerestory and the 40"-wide windows share jamb lines; cripples below the window, between the window head and the clerestory sill, and above the clerestory; a header and a sill piece for the band | panelStuds, panelChannelRows(cfg, 150) |
| Rake infill | Triangular cellular-concrete wedge on the wall B/D tops between the 10' line and the roof underside (0 at the back, 29.9" at the front), 11.5" wide, cast after the top track — 2.48 yd³ | rakeInfill(cfg); the B/D top track is sloped |
| Roof strips | 3 strips 14' wide × 33' along the slope (plan 42' × 32'-11" with 24" front / 12" back / 12" side overhangs), 1,387 sf | The roof-panel system: 2" cover + 1.5" channel + 8" 800S162-68 @ 16" + 2" cap = 13.5"; spans 15.5' + 13.5' over the interior bearing wall |
| Roof casting | Ground pour 6.5" flat in a second yard bed (27.8 yd³), craned onto the walls (heaviest pick 10,617 lb), top pour 7" on the roof (30.0 yd³), membrane | Phases roof_set, roof_pour, roof_membrane (12–14) |
| Roof steel | 36 studs @ 33' = 1,189 lf, 84 lf track, 9 channel rows per strip = 378 lf, 648 screws, 324 spacers, 24 lift inserts, 1,387 sf mesh | roofTakeoff(cfg) |
| Estimate | ROOF category: strips (studs at the 6" 68-mil list price as a proxy, track, channel, screws, spacers, inserts, mesh, ground + top pour at Ken's $200 + $20 per yd³), rake infill, roof liner + edge forms, clerestory glazing $60/sf, crane day $1,500, roof labor (0.12 / 0.03 mh/sf, 1.5 / 2.0 mh/yd³, 32 mh pick), Eco Finish membrane $8/sf on the roof only | $49,969 before contingency; total walls + roof $92,177 |
Bed and pick: the 4-slot bed is sized for the 12'-6" panel (48" × 150" slots, 200 sf liner, 132 lf edge form); a movable end board shortens a slot for the 10' panels.
4. Open items#
- Stud gauge and spacing for a 10' wall with fill (PE); the 12'-6" wall-A panels are the governing case.
- Joint screw pattern and whether a joint strap or cast-in weld plate is wanted at corners.
- Slab anchor type (post-installed vs cast-in) and the base detail (recess, track on slab, or curb).
- Fill density and strength; whether the fill needs a mesh or ties to the cladding.
- Exterior finish over the cladding: excluded for the walls (Ken, 6 Sep 2026); the roof membrane is Eco Finish at $8/sf.
- Window/door frame anchoring to the jamb studs.
- Roof studs: 8"
800S162-68@ 16" is the roof project's assumption for the 15.5' + 13.5' spans — PE to size (and price: carried at a proxy list rate). - Rake casting detail: formed in place on the wall B/D tops vs a precast wedge; the sloped top track and how the roof strips bear on it.
- Clerestory frames: fixed glass in the 40" × 24" band, frame type and anchoring to the shared jamb studs; flashing under the roof eave.
- Panel handling and the pick: the method is written and is a hold point before the first lift of every panel (quality manual §7.8, form QF-16 §2) but it is not engineered. PE to set the attachment points, the stripping suction and dynamic factors, whether the 12'-6" panel at ~880 lb needs a designed cast-in insert instead of a boom pick, the rated truck and attachment capacity, the sling arrangement and angle limit, whether the flat-to-upright turn may be made in the air, and the dunnage and support points. Plus the bed side (slot length, end board) and bracing until the roof is on.
- Accepted cure temperature range at the bed (PE, on this plant's own mix qualification). Quality manual §6.8 requires the cure log QF-11 to show every daily reading, and the pre-strip hold point cannot be signed against a range because none is stated anywhere. No published source gives one for this material: ACI 523.1R-06 §5.6 gives a curing method and no temperature at all, and its 32 °F and 100 °F are placement triggers (§5.7, §5.8), not curing criteria; ACI 306R-16 and ACI 305R-20 are written for normalweight structural concrete and 305R is understood to set no maximum at all. The range therefore goes on the mix design record QF-07, set by the PE, proved by the qualification at manual §6.2, and copied into the QF-11 header. Until then the readings are recorded and unjudged and release is on the 7-day rule alone.
- Erection on site is now recorded, not engineered. Panels for the house are stood by the builder; the record is quality manual §13.7, form QF-35 Panel erection record, signed by the erector's site supervisor. It captures the measured cumulative run per wall, out of plumb, joint gap, joint screws and slab anchors as fixed, the temporary bracing used, and the AHJ's approval of the rough-in before the fill. Every criterion on it is still [PE TO SET] — items 2, 3 and 10 above and manual §13.5 — and QF-35 does not close any of them.