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TOSALI   CONSTRUCTION

We construct commercial and residential buildings using a 40+ year old secret concrete recipe that provides our buildings with more flexibility, strength and insulative value, as well as far less cracking over time! This procedure also provides a more cost effective and faster construction method than traditional concrete construction. We can build forms of any shape – walls, roofs – without design constraints. While some copycat construction firms have tried to use similar spray methods, without the proper chemical combination, the construction failed. Our patented technology assures you the highest quality finished product!

Advantages:

 

The Temple Israel was built in 1969 and still not a single crack in the concrete! This time-proven technology allows unique shapes to be formed using spray concrete.

http://www.templeisrael.net/about_us/about_us.php3?page=106

With spray concrete, the roof and walls are all sprayed together as a single structure. This eliminates the need for connections and creates extremely strong buildings against conditions such as hurricanes, tornados and earthquakes. Buildings can be standard architecture as well as any unique shape!

On August 28, 1990 an F5 tornado (261-318 mph winds) tore through Plainfield, Illinois. Directly in its path was St. Mary’s Church. It took a direct hit from the tornado and was the only building left standing as shown in the aerial photo. Other than broken windows, no additional damage was done! St Mary's church was built using our spray concrete system.

http://www.youtube.com/watch?v=bWm_fqEjL6s&feature=related

Palm Island at Miami beach is one of the most prestigious residential projects we have built to date.

The shape of the building is formed using wire rib lath.

With the Spray Concrete System, concrete is applied directly onto a space-frame constructed of reinforcing bars and rib lath.  The concrete contains a proprietary admixture that allows it to be placed without the need for formwork.  The result is a building shell with the strength of reinforced concrete at a cost less than reinforced masonry.  Since no formwork is utilized in the system, both project cost and schedule are significantly reduced.

 

ADVANTAGES

CERTIFICATES

HOW IS IT DIFFERENT

LIST OF PROJECTS

Hurricane proof

Tornado proof

Earthquake proof

Termite proof

Roof top can be used as living space or terrace

15-20% less expensive than reinforced masonry.

50% stronger than similarly reinforced masonry.

Roof elements are reinforced concrete. No need for steel joists, decking, wood trusses or sheathing.

Roof is placed same time as walls.

No need for built-up roofing membrane

No formwork required. Concrete is sprayed directly onto the steel space-frame.

No secondary application of stucco is required since the final product is prefinished.

Any shape or configuration is possible since curved formwork is not required.
 

Spray Concrete contains millions of tiny air cells that provide outstanding thermal insulation, so it requires no additional insulating material. These cells give the homeowner reduced noise transfer as well.

Spray Concrete can also be used along high traffic highways near housing developments specifically to cut down on highway noise.

This material does not decay, mold, or require pesticides to protect against insect infestation.

When this system was first developed it was tested it for fire resistance; it showed signs of weakening after 12 hours.

When it was tested for wind resistance at University of Miami it started to buckle only after  200 miles of constant force. (that was part of the wall not tied down to footings; which means the structure built and secured to footings would be much stronger and should take about 250 mph sustained)

Spray Concrete provides a slow heat transfer that results in excellent energy efficiency.

1. ASTMC 109 Compressive strength of Hydraulic Cement mortars using 2” or 50 mm cube specimens.

2. ASTMC 307, 205 psi Tensile strength of chemical resistant mortars, grouts and monolithic surfaces.

3. ASTMC 3 96 water vapor permeability.

4. ASTMC 413 Absorption of Chemical resistant mortars, grouts and monolithic surfaces.

5. ASTMC 185 Density -dry 64lb/cu ft.-wet 75 lb/cu.ft.

6. ASTMC 580 Flexural strength and modules of elasticity of chemical resistant mortars, grouts and monolithic surfaces.

7. ASTMC 91 Water retention 89 percent.

8. ASTMC 165 Elastic modules.

9. ASTMC 926 Application of Portland Cement based plaster.

10. ACI-1R Making a condition survey of concrete in service.

11. ASTMB 117 Salt spray (fog) testing.

12. ASTM 870 Testing water resistance of coatings using water emersion.

13. ASTMD 968 Abrasion resistance or organic coatings by falling abrasive.

14. ASTMD 2243 Freeze & thaw resistance of waterborne paints.

15. Federal Specification AA 1555 Water paint powder cementation type including wind driven rain resistance.

16. Federal Specification 6271 Mold & mildew.

17. Color Gray

Spray Concrete- Spraying
"Spraying" means the wet (mixed on location in the hopper with a chemical mix) concrete is pumped through a tiny nozzle. The spray is fine and the operator dusts the rebar and rib lath which is pneumatically applied. It dries very quickly so the operator can dust the next coat without waiting for drying time. It has an expansion ratio of 20% and contains millions of tiny air cells that provide outstanding thermal insulation. Operator instruction is important only for application purposes, as there is no danger in application due to low velocity projection of concrete . Mistakes in application are usually far less critical than with Shotcrete and Gunite. Rebound or the waste created by sprayed concrete falling to the floor, is minimal compared to Shotcrete and Gunite. The finished product is usually a  4" wall at 3000 psi. The density is less compared to the density of Gunite and Shotcrete. The concrete contains a proprietary admixture that allows it to placed without the need for formwork. Secret list of chemicals that are in our system makes our product a perfect fit for home and building constuction.


Gunite- Dry Gunning
"Gunite" is a trade name for "dry gunned" concrete, invented and patented by a man from North Carolina. The term "gunite" has been used so much that, to most people, it means spray applied concrete. People often talk about a gunite pool, meaning a concrete pool where the concrete is pneumatically applied or sprayed in place using air pressure. Aggregate is part of the concrete mix. Gunite requires form work and certified operators as the application can be dangerous as the concrete is projected at high velocity.


"Dry gun" means the cement and sand are injected into an air stream conveying it to the nozzle. The nozzle operator then adds the water at the nozzle and has total control of the water-cement ratio. The delivery hose of the mix is generally quite light, the nozzle is about 11/2 -2 inches in diameter and the hose is mostly filled with air containing the mix of cement and sand. Dry gunning allows concrete to be placed drier than most "wet gunning." Often the concrete is stacked at a very heavy thickness and this can be a disaster for an Airformed structure. Operator training is very critical and can mean the difference between success and failure of application.


Shotcrete- Wet Gunning
"Wet gun" means the wet (already mixed) concrete is pumped to the nozzle. Air is added at the nozzle to carry the concrete mix to the target and again pneumatically applied. We call the system "wet gunning." Here too operator training is important, but not quite as technical for wet gunners. Mistakes in application are usually far less critical than with dry gunning in building construction. Rebound or the waste created by sprayed concrete falling to the floor, is usually half as much for shotcrete as compared to gunite. Aggregate is part of the mix. Shotcrete requires form work and certified operators as the application can be dangerous due to the high velocity projection and for success of application

Warehouse in Reston, VA

St. Mary’s Church in Plainfield,IL

5000 houses (roofs only) Mexico

8 “Little Shavers” daycare centers in south Florida

Temple Judea in Coral Gables, FL

Temple Israel in Miami, FL

Temple Shalom in Miami Beach, FL

Temple ZTL Sanctuary in Miami Beach. FL

Temple Beth Or in Southwest Miami, FL

Lemon Tree Restaurant in San Juan Hotel, Puerto Rico

Lemon Tree Restaurant in San Juan Hotel, Puerto Rico

Lobby Dome in San Juan Hotel, Puerto Rico

Lanais Hotel in Con Quistador Fajardo, Puerto Rico

Large daycare center in NY

Large daycare center in RI

Coslow residence Hibiscus Isle in Miami Beach, FL

Nocturnal Mountain in Busch Gardens, FL

Chalet at Little Switzerland in NC

6 Houses in Finger Lakes, NY

Amertec Office Building in Hialeah, FL

Porte Cohere Entry, Sea Coast Tower East in Miami, FL

Cabanas at Poolside, Sea Coast Tower East in Miami, FL

Alexander Hotel Activity Room in Miami

House at Lay Lake in Pell City, AL

Warehouse on the Golf Course at Pell City Country Club, AL

8 stall horse barn in Davie, FL

Skylake Bank Walkway in Hialeah, FL

Warehouse in Opa Locka, FL

Duplex in Miami, FL

Shelter in City of Miami Golf Course in Miami, FL

Team Shelters at Flagler Field Baseball Park in Miami, FL

Office Building on Biscayne Blvd. in Miami, FL

Villas, 36 St. in Miami, FL

8 Pod Homes in Key Biscayne, Miami, FL

Jose Marti Daycare Center in Miami, FL

Arby’s Restaurant, Coral Way, FL

Arby’s Restaurant, North Miami, FL

 

HOW DOES SPRAY CONCRETE COMPARE TO OTHER CONSTRUCTION METHODS:

  Residential and Commercial Low-end Residential High-end Residential/Commercial
  Spray Concrete 2x6 Wood Construction Block and Wood Truss Block and Metal Truss Reinforced Concrete Tilt Construction
Cost very affordable affordable affordable affordable expensive very expensive
Time to Construct fastest slow slow slow slowest faster
Round Walls no extra time or charge extra time and charges extra time and charges extra time and charges extra time and charges extra time and charges
Curved Sloping Roof standard expensive expensive expensive not possible not with concrete
Fire Resistance high very low low high high depends on roof material
Hurricane/Tornado Resistance very high very low low higher very high depends on roof material
Termite/Water Damage Resistance high very low low high high depends on roof material
Precision Requirements low high for truss high for truss high for truss low very high
Crane Requirement none low low medium medium very high
Weight of Materials low low low low high high
Minimum Thickness 4" 8" 10" 10" 6" 6"
Need for Stucco none very high high high high low
Connection Point Failure Possibility none very high very high high high very high
Roof/Structural Warranty 15 year 5 yr 5 yr 5 yr 5 yr 5 yr
Structural Termite Warranty  25 year 1 year 1 year 1 year 25 year 1 year