Construction Notes – Here's a brief outline of how to install the SmartBlock system:

1. It's very important to get the first course of blocks level, straight, and square, so begin by making sure the footings go in just that way. You may want to do a dry run of the blocks so you know where to install the vertical rebar.

2. Once the footings have dried, snap chalk lines to guide block placement.

3. Start in one corner with an end block. Intersect this block with a second block and mark and cut the first block to allow concrete flow. Do the same to all inside and outside corners. Once this is done, lay the blocks, working your way toward the middle. You may need to cut block(s) to fit.

4. The second row is just like the first row but with one major exception: overlap the intersecting blocks to lock the corners together. Do this to every other row, just like building a log home. The third row is the same as the first, the fourth is like the second, and so on. It's also important to overhang the block joints by at least 10 inches to produce staggered joints. But check down inside the blocks to see that the cells line up with the ones underneath. (This is for the SF-10 block.)

5. Install the horizontal rebar as required, wire-tying it to the vertical rebar. Work your way up to the first level (unless this is the only level) – and don't forget to cut out for doors and windows.

6. Take the extra time to make sure foundations are properly braced before you pump in the concrete. You don't want a blowout in the middle of a pour! Brace all corners and tape the block at all cut joints. Plumb the walls as needed. Attach vertical bracing (both sides of the block) by fastening to the form with screws, or build a ladder bracing and place over the form according to the manufacturer's bracing schedule. Fasten a kicker, and stake it to hold the wall in the correct position. Brace all doors and windows. Be sure to leave an opening in the sill to pump the concrete. The manufacturer has detailed instructions on how to adequately brace their system (Figure 2-15).

Photo Courtesy of: American ConFormIndustries, Inc.

Figure 2-15: Bracing a SmartBlock wall

7. When pumping concrete, make sure the slump is correct and use a 2-inch hose (3 inches maximum). Pump slowly and away from the corners, allowing the concrete to flow on its own into the corners. Pump 4 feet high all the way around the foundation. This will give the concrete time to set up before you start the second pour. Do the pours in multiple lifts until you reach the top. If a second story is planned, tape the teeth before pouring the concrete below the last course of blocks. This will keep concrete out of the interlocking system so you can easily stack the next story once the tape has been removed.

8. Make sure the concrete flows throughout the system. Use a piece of rebar to poke the concrete to fill voids. You can also use a hammer and a piece of plywood to tap on the side of the form to get the concrete to flow. Always check for adequate consolidation (no air bubbles or voids) immediately after pouring.

9. Keep some plywood and extra bracing handy for quick repairs.

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