Construction Process / Technology

1. Architectural design

Geodesy, Soil Mechanics
Building Plans, Construction Plans
Statics
Technical Specifications, Mechanical Engineering, Energy Systems
Material Specifications, Cost Estimate Preparation, Project Management Structure, Construction Schedule Development – Spectrum House Technology

2. The process of locating and leveling the building includes the following steps:

After the survey leveling of the construction site, we designate and document the ±0.00 point of the building with photographs. This procedure is recorded in a protocol, which is signed and accepted by the Client, Responsible Technical Supervisor, and Contractor, all of whom can be found in the construction log.
Should any party reject the layout or leveling, or if the Client wishes to position the building elsewhere or at a higher elevation than indicated in the approved plans, the Contractor may only make such changes based on written instructions from the Client. Notification and approval of such modifications are solely the responsibility of the Client unless otherwise agreed upon in writing.
The Contractor assumes no responsibility for these changes, and any liability related to the modifications rests solely with the Client.

3. Foundation

In accordance with the building foundation plan, we excavate the soil using both mechanical and manual force. The default depth of the foundation is 90 cm and the width is 40 cm.
If the terrain is not level, we employ "foundation stepping" to ensure that the lower plane of the concrete foundation remains horizontal.
For the Schiedel chimney, a foundation of 1 m3 is prepared.
The foundation is filled and compacted with concrete of C20 24 KK mixer concrete quality.

4. Basement or Underground Garage (Optional)

The construction of the basement or underground garage takes place following the planned foundation and the completion of the floor concrete.
The walls of the basement or underground garage are composed of concrete basement wall elements, securely fastened to each other with factory mortar.
At the top of the basement or garage wall, a reinforced concrete crown is created in accordance with static requirements.
The external walls of the basement or underground garage are equipped with a 12 cm thick foundation insulation, which is applied using adhesive.
For the foundation insulation, we create a water barrier from welded rubber sheets, covered with geotextile, and then protected with insulation-proof sheets. Subsequently, we backfill the soil above the walls.
The ceiling structure of the basement or underground garage is made with an "E" beam system, reinforced with concrete lining elements.
The ceiling is reinforced according to static requirements, followed by the execution of floor concrete casting.

5. Foundation

Upon the completed foundation, we place Frühwald formwork bricks measuring 30 cm in width, 50 cm in length, and 23 cm in height.
Between the rows of formwork bricks, we insert a reinforcement made of 8 mm horizontal concrete rebar, 2 X 1 piece, fitting into the factory-formed nests.
We position the extensions at least 2 meters apart on both sides.
For corners, we bend "L"-shaped bars, each leg measuring 2.3 meters.
The height of the formwork is determined according to the specifications in the drawing.
We fill the foundation formwork with C16 24 KK quality mixer concrete. Mechanical vibrational compaction is applied during concreting.
Depending on the current weather conditions, we regularly water the foundation for 3-5 days.
We spread soil between the foundation walls and compact it in layers.
We place the drainpipes and incoming water pipes into the soil layer of the foundation.
The space below the floor is filled with a 15 cm thick layer of 15/50 mm gravel, compacted with machinery.
We lay geotextile on the gravel bed and install 8 mm reinforcing steel with at least a 25 cm overlap.
We raise the reinforcing steel at least 3-5 cm above the level of the gravel bed.
Upon the completed foundation, we attach the foundation insulation, positioning it at least 11 cm above the upper part of the foundation stone. This way, the insulation serves as both the building's foundation concrete formwork and insulation.
Depending on the weather, we regularly water the finished floor concrete for 3-6 days.
Note: During the foundation work, we request a concrete sample block from the concrete manufacturer for the client, providing information on the composition of the foundation and floor concrete. The price does not include the cost of laboratory testing.

6. Soil Vapor Barrier

A 4.2 mm thick VTG bituminous heavy-duty sheet is adhered as a soil vapor barrier beneath the concrete layer. This insulation layer later integrates with the complete floor waterproofing of the building.

7. Spektrum Profile External and Internal Load-Bearing Wall Structure

The "C" and "U" profiles are made of galvanized material and have ÉMI/CE certification.
The wall and roof structure is prefabricated based on manufacturing and assembly plans created by the structural engineer.
On-site, only the assembly and bracing of individual wall elements and roof structural elements take place. The factory assembly is precisely done in adjustable jigs, ensuring dimensional accuracy of +/- 1 mm.
The "U" profiles are fastened to the wall "C" columns with lens-head self-drilling screws. The spacing between the wall columns is 40-60 cm, following the static requirements of the manufacturing plan.
The stiffness of the walls (discs) is ensured by diagonally embedded steel straps between the "C" columns, made of the same material as the walls.
On-site, a 4 mm thick Bitubit GV bituminous heavy-duty sheet is placed under the wall structure, raised at least 10 cm in height on the external wall to prevent potential water ingress. The "U" profiles are secured to the floor concrete with 12 mm metal dowels, spaced 60 cm apart.

8. Internal Partition Walls

The internal, non-load-bearing partition walls are constructed from a 75 mm thick steel frame. Their final thickness will be 100 mm, as they receive a layer of gypsum board cladding on both sides. A 50 mm thick mineral wool insulation is placed within the walls.

9. Floor Structure

The floor structure of Spectrum prefabricated houses can be constructed in two different ways.

In all cases, a load-distributing beam is installed around the perimeter of the wall structure, distributing the load of the roof and floor on the wall structure, eliminating the need for columns beneath the floor and roof elements.
The upper U-profile of the wall structure is secured with passing screws and large washers.
For single-story, non-converted attic cases: We use a lattice truss structure sized by the structural engineer. The advantage of this approach is economical material usage, lightweight, and dimensional accuracy. The lower chord of the truss also functions as the floor joist, eliminating the need for separate floor joists. Only 0.1% of waste is generated.
For attic conversion or multi-story buildings: A double C200mm floor joist structure is installed beneath the load-distributing beam, braced together with strapping. Finished floor joists are screwed onto the completed floor joists, and external and internal walls are constructed on top in the same manner as the first level. (Later, sound insulation will be applied to the OSB board, followed by a 5 cm thick screed concrete.)

10. Roof Structure

The manufacturing of the roof structure elements is carried out pre-assembled in a workshop, similarly to the wall structure, with the aid of forced templates.
The roof structure is made from Spectrum profiles, using the same material as the wall structure. It is designed as a lattice truss.
The lower chord of the lattice truss roof structure also serves as the floor joist.

11. Sheet Metal Works

A semi-circular, powder-coated aluminum gutter system is utilized in the building. The price includes drainage of rainwater up to a distance of 1 meter from the building.
The chimney and the roof purlins are made from the same material as the gutter system.

12. Chimney

We incorporate a pre-fabricated, insulated Schiedel chimney, dimensioned to match the specifications in the drawing.

13. Roofing

The roof structure is counter-battened, and then a vapor barrier reinforced with mesh is secured to the battens. Subsequently, we install the 35×50 mm counter-battening.
For roofing, we use Mediterranean Danubia or an equivalent roof tile. Optionally, concrete tiles are available, and a separate cost estimate can be provided for this choice.

14. Exterior Openings

The openings feature REHAU white plastic profiles with galvanized steel reinforcement. They come standard with highly insulated, triple-glazed units filled with argon gas, boasting a U-value of 0.7 W/m2K.
The front door will be chosen to suit the client's taste and security preferences.
The external plastic sills for the windows are included in the color selected by the client. Optional choices include colored foiled plastic openings, wooden openings, and aluminum openings.

15. Roof Overhang Cladding

Made from 18mm thick ship deck pine, featuring covering elements on the edges. After the foundation, it is treated with a two-layer wood stain.
Alternatively, an OSB-clad option with 2-5 cm insulated facade insulation is also available.

16. Plastering System

The insulation of the building consists of certified facade graphite or ROCKWOOL plasterable board mineral wool insulation panels with thicknesses of 100-150-200 mm. The external insulation boards are fastened to the OSB wall structure using quick-setting adhesive foam. Mechanical fastening is done with stainless screws and thermal bridge-free plastic washer plates.
The surface of the external insulation boards is covered with fiberglass-reinforced mesh (Dryvit mesh), followed by the application of thin plaster in two layers. Afterward, the surface is uniformly sanded to achieve a smooth finish, and a primer is applied.
Once the primer is fully dried, in calm and shaded weather conditions, a thin-colored plaster is applied. Note: The work phase must be carried out between +5 and +25 degrees Celsius; otherwise, the work must be scheduled for a different time.

17. Floor Preparation with Substrate Ready for Finishes

On the previously prepared screed surface, a 4 mm thick bituminous membrane insulation is applied, with 10-12 cm overlap, securely welded together.
Following this, a 14 cm thick, impact-resistant polystyrene thermal insulation is placed for water insulation.
As a technological water barrier on the polystyrene, a polyethylene film is laid.The floor concrete is made from 60 mm thick C12 8KK screed concrete.
As an option, an anhydrite gypsum-based floor can be created, offering the advantage of complete drying within 1 week, allowing for the application of wooden flooring, unlike traditional concrete, which requires 4-5 weeks of curing time before laying warm coverings.

18. Drywall Installation

For external walls and ceilings, we install reflective vapor barrier foil.
On the inner side of the external walls, we mount a two-layer drywall covering.
As an option for wall heating systems, Heratekta 35 mm cladding is applied to the steel frame, followed by a 25 mm plaster after the placement of mechanical heating pipes.
Edges are equipped with edge protectors.
Internal walls receive a single-layer red cardboard covering on both sides.
As an option, all internal walls can be covered with a 2×2 layer of drywall.
The drywall type used is Rigips or Knauf.
The thickness of the drywall sheets is 12 mm.
In wet areas, the drywall is executed with green moisture-resistant finishing on both ceilings and walls.

19. Insulation

In the ceiling, we install 280 mm thick rock wool insulation.
For the external wall structure, a 150 mm thick rock wool insulation is applied.

20. Suspended Ceiling

For the ceiling joists, we construct a "CD" 60 mm suspended steel-framed suspended ceiling or install a roof batten, which is covered with a vapor barrier foil, and its surface is equipped with a heat-reflective foil.
The frame structure is fastened with red 12.5 mm gypsum board.

21. Interior Doors

We install retrofittable interior doors, providing you with the freedom to choose from our online catalog.
The doors come with factory finishing, eliminating the need for additional surface treatment.
The calculated price for the doors: .... EURO.

22. Electrical Installation

We route the electrical wiring through protective conduits within the hollow walls and ceiling structure.
Connection and junction boxes are discreetly placed in the ceiling, ensuring their aesthetics remain unseen within the living space.
The wires are double-insulated and, for enhanced safety, are enclosed within protective conduits.
Electrical fixtures used in the installation are of the Prodax Classic type.
Basic fixture list: in rooms under 10 m2, there is 1 switch and 3 outlets. For rooms sized between 11-18 m2, there are 2 light switches, a lamp holder, and 5 outlets. Rooms larger than 19 m2 have 4 light switches, lamp holders, and 6 outlets.
The price includes the installation of wiring up to a maximum distance of 5 meters from the building.
In each room, one television coax connection is provided, and in the living room, two are made available.
For internet sharing, telephone lines, alarm systems, and cameras, a single outlet is installed.

23. Heating System

As per discussions with the client.
By default, there is an option to choose between wall, ceiling, or underfloor heating or the installation of heating-cooling air conditioning.
Our electric heating systems can be powered by solar panels, potentially reducing the heating bill to zero.

24. Domestic Water System

In utility areas, water pipes are routed through conduits, including within the floor insulation and the wall framework. Ensuring a long lifespan, the water conduits are constructed with 5-layer pipes, connected using a pipe crushing machine and corresponding fittings.

25. Wastewater Pipeline

For wastewater pipes, we use 110 mm pipes for toilets and 50 mm "PVC" pipes for drains from sinks and bathtubs. Pipe connections are secured with socketed rubber seals.

26. Surface Finishes

We skim-coat the gypsum board surfaces and paint them with white dispersion paint.
Edge protectors are applied on positive edges, while negative edges are reinforced with fiberglass mesh.
As an option, wall painting or wallpapering can be ordered, tailored to the unique preferences of the Client, subject to an additional fee.

27. Tiling

The cold and warm tiling of the building will be done according to the unique preferences of the Client.
For cold tiles, we estimate a cost of ... EURO/m2 for the procurement value of the tiles, adding ... EURO/m2 for auxiliary materials such as adhesive, grout, and edge protectors. The labor cost for mesh installation is ... EURO/m2, while for diagonal or patterned installation, it is ... EURO/m2.
For warm tiles, we calculate ... EURO/m2 for materials + auxiliary material costs, and add ... EURO/m2 for labor.
In bathrooms and wet areas, waterproofing is applied up to a height of 2 meters.