Door augment on an Ecoshell with a 6ft stemwall

General
1

This is going to be a weird one to explain.

Using 6mm braided basalt rope at 8in OC grid between two layers of 1.5in shotcrete and an additional grid to fix 3in XPS insulation panels on the outside covered with plasticised, basalt fibers sprayed mortar coat. XPS is foam glued, then HILTI plastic mushroom anchors screwed through the XPS into the concrete layer by 1in. Grid covers that.

My issue is trying to frame a door opening.

Sheets of thick PVC are readily available in India and quite cheap. My thought is to place Hot Dipped Galvanized J hooks, 4in long, threaded, with 2 nuts and a wide washer at slots around the framing for the sliding door. That is the outside framing, not the door framing itself. This is to ensure that the basalt rope is anchored to that augment.

  1. Build the PVC frame with corner bracing at a 2in thickness and 7in width.
  2. Cut slots at every 8in around the frame, that are 1/4in wide to a depth of 1 1/2in from the inner edge touching the airform, to match the grid depth of the first shotcrete layer.(1st shotcrete layer depth from airform)
  3. Cut another series of slots at 10in spacing where the slot depth is 6in to match the XPS grid after the 3in shotcrete and 3in of XPS shell thickness.
  4. Slide in the HDG J hooks so one nut is on the outside of the PVC and an oversized washer and nut on the inside, which will protrude slightly.
  5. Since the custom door manufacturers in India can build a door with a 10-15mm gap, that leaves room for the end of the J hooks to protrude inside, and that is covered by foam insulation anyway.
  6. This leaves me a solidly anchored, sprayed in place frame with tensioned J hooks and basalt rope embedded in the center of the 3in shotcrete layers.
  7. Since the hooks for holding the XPS are still in place, but covered with little plastic bags, to keep them clean from overshoots, they will be sprayed in with .5 to .75in of plasticised mortar or plaster.
  8. Then spray the joints to encase the PVC frame edges so only the front edge is seen. This will be covered by a thin strip of aluminum to protect the PVC from UV, which can break it down over time.
  9. Door can then be installed normally with a low threshold for wheelchair access.
  10. I am probably modifying my airform quote request to a 7ft stemwall, instead of the current 6ft, to make a nice vertical frame out using rectangular dimensions, instead of curving the upper part of the augment.
  11. Would love to hear what anyone thinks… PLEASE!