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BIG IDEAS FOR BIG DREAMERS
Resources
Explore comprehensive resources detailing how our printer works, our processes, and adherence to construction codes.
Camber order and build process
01. Needs Analysis
With our dynamic application, we learn your needs and use case and then render 3D models from your input and 2D plans.
How we do what we do
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Camber wall panelsMeets all IBC 2018 & 2021 codes, including most stringent seismic and structural specs. Rated for 170 mph winds 50 pound snow load Engineered for Southern California seismic loads Ss = 2.3
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Camber concreteFiber reinforced 4000 concrete mix with rebar reinforced during printing for added strength. 2 #4 rebar section in top header 2 #4 rebar sections in bottom plate 1 #4 rebar in each 2 inch wide stud 1 #4 rebar through center support
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DimensionsTotal wall width is between 5.5 and 7.5 inches thick with face layer between 1.5 - 2 inches thick. Concrete studs on the backside are similar to traditional framing dimensions (2x4, 2x6, 2x8… etc). Same dimensions and spacing as traditional framing, (ie. 16 or 24 on center) allowing for use of similar construction materials (ex. Same insulation, etc.).
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Exterior finishOur walls are printed face-down into molds which allows us to replicate practically any type of exterior finish (lap siding, brick, board and batten, etc.). Walls can be colored during printing, or post printing with stain or concrete paint.
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Installation speedJust how fast? Our panels are engineered with a 4k - 5k max weight to ensure traditional telehandler capacity. Panels have J-bolts placed throughout the header to allow jig attachment for lifting. Each panel has labeling for placement instruction. Once delivered, all panels can be placed in a day or two (based on home size).
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Footing attachmentCamber wall panels are attached to the footings with either a bolt or weld plate. In situations where plates on footings were not installed in the correct location, titan anchors and plates can be used.
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Roof joist attachmentJ-bolts are placed at the top of each wall panel during printing to allow for the installation of a treated 2x6 top plate. With the treated top plate attached any approved roof joist bracket that meets your local code can be used to secure your roof joist.
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WindowsWall panels have built-in headers to every wall. Headers comprise of two #4 rebar sections that span the entire length of the wall on the top of the wall. This allows for window openings up to 7' with no additional engineering required. Windows are trimmed with treated 2x6 boards with tapcon anchors which allows for window attachment the same way you attach with traditional framing.
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DoorsBuilt-in headers to every wall with 2 #4 rebar pieces spanning the entire length of the wall at the top. This allows for door openings up to 6 feet wide with no additional engineering required. Door openings are trimmed with treated 2x6 boards secured with tapcon anchors, which allows for doors to be attached the same way as with traditional framing.
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ElectricalSpacers / inserts are placed in each stud during printing to quickly run electrical lines.
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PlumbingStuds can be cut to allow for plumbing lines. Up to two studs can be removed in any wall to accommodate running of plumbing lines without adding additional structural support. If additional studs need to be cut a structural plate or rod can be added to studs to provide additional strength.
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Vapor barrierWe apply Deco20 waterproof barrier with ASTM E 96 - permeability rating of 0.102 perms. This places it at the threshold of Class I and Class II barriers. Class I requirement is 0.1 perms or less and Class II is 0.1 - 1.0 perms.
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CornersUtilizing interlocking corner method, makes for only a 3 inch portion of exposed concrete that doesn't have the exterior finish. This is easily covered with traditional corner trim boards.
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Wall interlockingWalls are adjoined together with bolt plates.
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Top plateJ-bolts are placed during printing to allow for installation of a treated top plate. With a top plate, roof joists can be attached using any approved traditional joist brackets that meets code.
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Polymer studPolymer is laid on the last layer of printing to allow for traditional drywall attachment.
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Face-down printingPatent pending - filed May 11, 2022 - allows us to print a studded wall that resembles traditional framing dimensions (2x4, 2x6, etc.) and spacing (16” or 24” on center) offering familiarity to subcontractors.
Our manufacturing process is brings speed and accuracy together in a refreshing new way. With keyturn technology, Forj offers familiarity, affordability, speed, and customization for both board form concrete and steel shipping container appplications.
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