Once the last tire in the last course has been pounded, leveled, and the space behind it filled with dirt, it was time to focus all our attention on concreting. In order to tie all the weight of the roof together, and have the tire wall support it, a bond-beam is needed. And since two thirds of the circular structure are “flying” that is not held up by the tires, we have to pour seven columns, called castillos in the local jargon. Also, where the tire wall tapers down to where the window is going to be, we need a second bond-beam on top of the tires. That is A LOT of concrete, even before we get to the part of the actual big bond-beam ring, called cadena.
Local Expertise
Mixing up sand, gravel, and cement with some water is not a big deal. Anyone can do it. Getting the right ratio for the right purpose, be it the footing, the beam, or the column, is a bit more challenging. But making the forms so that it won’t blow is something where someone with lots of experience is essential. For this reason we hired a mason, one that has done some quality work at the other property in La Boquilla. Though he was only available for one week, we took advantage of this great opportunity to work with him, and try to learn as much as we could during this week together. Needless to say, all of us worked overtime, even the volunteers, whose schedule normally is only from 8:00 a.m. to 1:00 p.m.
Debarking the Vigas
Another important job we had to do was preparing the vigas. The thirteen massive trunks of Royal Palm that will be the roof beams, had to be stripped of their bark, so they could be treated against rot and termites, before being set in place. Our neighbor happens to have the required infrastructure to immerse them in an acid bath. All we have to do is transport the debarked trunks to his place. But first we had to use a grinder to get all the bark off of the logs. A relatively fun and enjoyable job, we all took turns in doing, including Julia, who otherwise would keep her hands out of the concrete.
Shaping Rebar, and Pouring Concrete
Though we had prepared a few columns, or rather the rebar structure inside them, there was a ton of work tying them to the footings, digging holes for them or removing a tire to place the footing in its place, and eventually mixing and pouring the concrete. The same thing was true for the forms of the first bond-beam on the tapering tire wall. Actually all very straight forward, albeit with lots of repetitive work. And as always, the devil is in the details. We couldn’t have loose rebar rings at random intervals. They had to be tied firmly, and spaced evenly. Also the form had to support the pressure of all the concrete inside without bursting it open. Yes, I’ve seen it happen before, and it’s not pretty. In fact, it’s discouraging to see hours (or even days) of work vanish into a big and expensive mess in a matter of a minute. Fortunately, under the experienced watch of our mason, such a thing did not happen.
Upcoming Challenges
Finally, the lower bond-beam is successfully completed, and the column structures set in place. Now they just need to be poured, followed by the can wall on top the tires, which will make the form for the top bond-beam. Before that can be poured, we need to make the form for it, without doubt the most challenging part of the project. That is the part of work where a skilled mason is indispensable. Unfortunately, the one we have gotten to know and enjoy working with, won’t be available. There are a couple of possible candidates who have expressed a type of “maybe” but around here that is anything but encouraging.
The other major challenge we’re running into is the availability of materials. We certainly need to get more rebar, and probably more cement. But the building supply store where we’ve been getting our material has declared it will be closed for the next two weeks, due to the ongoing pandemic… or rather the reaction to it, prescribed from above. Ay caramba! They are the biggest suppliers of building material around, which may explain their strict adherence to government recommendation. Fortunately, not everyone follows the president’s advice to the letter. At a small builders’ shop in town they have told us that they would remain open until the police forces them to close at gunpoint. While that remains certainly possible, its current likelihood is rather slim. However, since their biggest competitor has closed its doors, we can expect the already higher prices at the small shop to be hiked up even further. But since we don’t know who their suppliers are, we might as well pay for it as long as they have stuff for sale.
Corona at the Building Site
Yes, these are the types of impediments thrown at us these days. Previously Corona at the Building Site would have meant cracking open some cans of beer after a successful pour, enjoying the cool light brew, then stuffing the empty can together with a handful of remaining concrete between two tires. Not these days… Oh well! We’ve had so many challenges already, from dragging building permits to shortage of volunteers, all of which we’ve managed to overcome splendidly. Why should a sudden virus outbreak be any different. All of us are certain to persevere, and it won’t be long now before the roof beams will be up. Mark my words!
Follow our Construction Adventure in This Series:
Earthship Build in the Time of Hive and Coronavirus
Machines Taking Over Work: The Day Everything Changed
Zome Building Workshop in Mazunte
The Ceremony of a Minka
Hay Pase, Got the Permit!
The Diverse Cars at Itínera
Waiting for the Man
An Impression of Hyperadobe in La Boquilla
Bending Rebar Like a Mexican
Working at Night for the Perfect Level
The Challenge of Scoring Tires
Creating Conditions to Work and Live
Previous series: A Theater on the Beach