# Cellular Concrete Wall Panels — Design Basis (v1)

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" with basalt mesh, in the skin pour | Same as the roof |
| 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 | |
| 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 or small crane |

## 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

1. Stud gauge and spacing for a 10' wall with fill (PE); the 12'-6" wall-A panels are the governing case.
2. Joint screw pattern and whether a joint strap or cast-in weld plate is wanted at corners.
3. Slab anchor type (post-installed vs cast-in) and the base detail (recess, track on slab, or curb).
4. Fill density and strength; whether the fill needs a mesh or ties to the cladding.
5. Exterior finish over the cladding: excluded for the walls (Ken, 6 Sep 2026); the roof membrane is Eco Finish at $8/sf.
6. Window/door frame anchoring to the jamb studs.
7. **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).
8. **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.
9. **Clerestory frames**: fixed glass in the 40" × 24" band, frame type and anchoring to the shared jamb studs; flashing under the roof eave.
10. **Taller panel handling**: the 12'-6" wall-A panels in the bed (slot length, end board) and at the pick (~880 lb, taller lift, bracing until the roof is on).