Taking a Slab at It: A Bathhouse Concrete Story!

Hello dearest reader and welcome back to the latest edition of the Rural Studio Bathhouse blog!

The past few months have been a very exciting and productive period for the Bathhouse. We are very happy to share what all we’ve been up to since we last spoke!

Students pose for picture on metal deck

At the time of our last update, we had just finished all the underground plumbing and preparing the CMU foundation walls for the floor structure.

We picked up on site where we left off by moving the structural beams into their places in the foundation walls and securing them in place!

View of students looking over metal deck from below
Greetings, Earthlings!

After cutting our metal decking to size, we were able to place the decking and began securing it to the CMU walls. Our good friend, Shane, helped us out by welding the decking down to the beams.

Once the deck was in place, it was time for Spring Break, but we did not take a break from the project. We had a very relaxing week in the woodshop building all the modular formwork for the slab!

Student screws pieces of wood together
Assembling base module supports

Once it was all built, we got busy on site installing the formwork. We started off with ledger boards on the CMU walls, then installed the base support modules and plywood base, and finally pulled strings to set the upright walls in place. We then braced these walls back to the base and added plywood to the inside face, completing the formwork.

image of completed formwork
Finished formwork

When the formwork was set, it provided a nice square base to measure all the penetrations in the slab from. We started off with the holes for the threaded rods.

Next, we marked out all the electrical and plumbing penetrations in the decking and cut them out.

While all of this was going on, we also began plumbing the whole Bathhouse and installing all the electrical conduit and boxes in the crawlspaces. While plumbing was occurring, rebar was being cut to size on the ground. We used bracing attached to the formwork walls to help support the PVC sleeves for the threaded rods and the plumbing and electrical stub outs.

After all the plumbing was completed and tested, we were able to begin putting the rebar reinforcement into place.

The team tied all the pieces together to form a large rebar mat for the slab. With the rebar in place, it was time to add in the last thing, metal mesh, which helps prevent cracking within the slab. The team finished this final step just in time to celebrate at Pig Roast!

We had a great time on Friday night of Pig Roast weekend listening to all the alumni lectures and really enjoyed getting to show off our project and the progress we have made to all our friends and families on Saturday. We finished the day off with an evening of festivities, great food, and wonderful live music.

The team speaking with former Rural Studio student
The bathhouse team meeting and looking at construction photos with original Supershed and Bathhouse team member, Jacqui Hart!

After a weekend of fun, it was quickly back to work for the bathhouse team! First thing Monday morning we got Concrete! An excellent team from JM concrete in nearby Uniontown made quick work of the pour and did a fantastic job with the finishing.

team posing with thumbs-up for concrete
Thumbs up for concrete!

We are so proud to have the heart of the project completed!

As she stands now

We are so happy to share the huge amount of progress being made! Next, we will be preparing to pour all the curbs under the timber walls and beginning the process of stacking the timber modules for the walls.

The team poses in front of project

Thanks so much for reading along and we hope to provide another exciting update very soon!

– Rural Studio Bathhouse Team

Carla, Ambar, Ashley, and Logan