This is a Sound Barrier Wall that we built in Marana Arizona last week. It was 65 feet long, 14′ 8″ tall and made out of 12x8x16″ block that weigh just under 46 lbs. apiece !! We had some tired workers those three days!!
This is the “before” picture of a Fence block column that we repaired for a customer in Mesa Arizona. We found that the Column didn’t even have any re bar inside of it.
Here is the “After” Picture. We epoxied rebar into the footing, and left our customer happy and content with a column that is stronger than it ever was.
Now that the floor is poured, the Block are delivered along with the Integra rods. These rods are 7/16″ wide, galvanized, and are screwed into the couplers in the stem walls. they are designed to be 3-4″ higher than the top of the wall so that the wood top plate can be attached.
The blocks are then layed around the rods in sections called “runs” until the walls are built to full height.
Notice in the photo below that the block are open on the ends in the shape of an “H”. This helps increase the efficiency of the wall by reducing “Thermal bridging” which occurs when heat travels from one side of the wall to the other through material that conducts it. The foam that is sprayed into the wall is a great insulator!
Custom Integra Block house
Once the walls are complete, Superlite block comes out and places a tension plate, a washer, another “Tension indicator” washer, and a nut over each rod. The rods are then tensioned to 7000 psi. Notice that the top block at each rod is a different “Tension Block” designed to distribute the tension through the rest of the wall.
After the walls are tensioned, Superlite’s technicians spray foam into them. It is important for the masons to lay a “tight” wall because the foam will enter and come out of any voids left in the mortar joints. This can leave a big mess, and some annoyed Superlite Techs! In the picture below, you can see only three places where just a small amount of foam came out of our wall. The foam that you see coming out of the top of the wall is normal. It is allowed to dry, and then is cut off and recycled.
Phoenix, Arizona Custom Block Home
A happy Superlite Block Tech shows how much they enjoy working with the Darrin Gray Corporation. Here, he is adding the wood top plate after the foaming and tensioning of the walls. The house is now ready for the Carpenters.
One of the things that Darrin started doing back in the early 90s, was to add an extra rebar at all gate columns. Gate columns get extra wear and tear on them due to the weight of the gate, or heavy use. Darrin decided that it is easier to add an extra rebar to each gate column, than to go back and fix the occasional loose one.
Double Rebar at the gate Columns adds Quality
Notice the two rebar coming out of the footing in the above photo. Adding an extra rebar to the gate columns is just one of the many ways that the Darrin Gray Corporation adds value to your Block Fence.
Gate opening after the block is layed
This is the “After” photo. From the outside of the Columns, you can not see that there are two rebar inside. Beauty may be skin deep, but quality penetrates to the core.
This particular fence will soon be painted, have wrought iron panels attached between the columns, and a custom gate installed to complete this project.
The Integra wall system, http://www.superliteblock.com/integra_introduction.htm was invented in the 1980s by Paul Scott; a structural engineer in the Phoenix area. He partnered with Superlite Block to produce this energy-efficient building system. It didn’t take long for homeowners to see the advantages of Integra… Combining the strength,and durability of Post-Tensioned block construction with the energy efficiency of a proprietary polyurethane foam insulation that is sprayed into the masonry cores after construction.
The above photo is of an integra block shop that we built for “Grandma’s Farm” in southern Phoenix. We used 8″ wide C.M.U (Concrete Masonry Units). As you can see, the Integra Block looks just like a conventional Masonry building once the construction process is complete. An Integra wall can be finished just like any other block wall with Paint, Stucco,or even a Brick veneer.
Integra Block Barn for Grandma’s farm in Phoenix Arizona
In the next month, we will be building another large custom Integra Block home in the Phoenix-Metro area. We will be documenting the wall construction process so that you can see the differences, and advantages of the Integra wall system.
Adding brick to your home will add value and durability to your new or existing home. At the Darrin Gray Corporation, we are committed to help you realize your dream.
Thinbrick Remodel Finished Product
See the difference that brick can make to your home. Brick does not need to be painted. However, it is a good idea to apply a quality water-resistant seal to it every couple of years. This will increase the lifespan of your walls, and keep them looking like new for years to come.
Here is an example of what can happen when you burn wood in a fireplace that was designed for gas. The Homeowner burned wood in his fireplace for a while, and then decided to switch back to gas. He neglected to clean out the ashes that had piled up over the burner. When he turned on the gas, it built up under the ashes and exploded when he tried to light it. This fireplace was not built properly and could not withstand the explosion. The insurance company called us to rebuild and repair it because they knew it would be done right!
This outdoor fireplace was constructed without rebar (reinforcing rods) and grout (concrete) in any of the open cells in the walls. The result was a destroyed fireplace,and a seriously injured homeowner. There would have been considerably less damage to the fireplace had it been constructed properly. As it was, the homeowner was lucky to be alive after being knocked unconscious and blown into the swimming pool with 100 lb. chunks of the fireplace found up to 50 feet away. Luckily for him, his wife was inside the house, heard the explosion, and decided to investigate.
There are many people who trust landscapers, or unlicensed contractors to build their fireplace,or repair your wall, fence, or BBQ. You wouldn’t trust a plumber to do electrical work at your house would you? You can count on The Darrin Gray Corporation to make sure that your masonry barbecue, fireplace, home,fence or block wall repair will be done right.
This is a residential BBQ/Outdoor Fireplace/Pizza Oven designed by Darrin, and built by our employees from the footings, to the pavers to the brick, and even the tile.
When you need a Barbeque, Fireplace, or even a Brick oven, you can feel confident that the employees of Darrin Gray Corp. Masonry Division will get it done right, on time, and at a reasonable price.
Darrin Gray Corp. 
