At GoldenLeaf Building Co., we believe that every home starts with a strong foundation—literally and figuratively. For the Eagle Farm townhomes in Wilson, NC, this process involves precision craftsmanship and thoughtful adjustments for weather and site conditions. The approach for this project ensures a durable, high-performance foundation using CMU (Concrete Masonry Units) and brick for the stem wall construction.

Step 1: Digging Footings

Footings form the base of the foundation, distributing the weight of the home evenly onto the soil below. Here’s how we approach this critical first step:

• Excavating to Specifications: Footings are dug according to engineered plans, ensuring they are the right depth and width to support the structure.

• Soil Inspection: The soil is evaluated to confirm stability. In instances where the engineer finds soils lacking sufficient bearing capacity, we over-excavate the trench until suitable soils are found and gravel or compacted fill is added to bring the overall footing back to what’s specified by the engineer. In some situations, the engineer may also specify adding reinforcement, like rebar.

Step 2: Pouring Footings

Concrete is poured into the footing trenches to create a solid base for the stem wall. During this process, we ensure:

• Weather Adaptations: First, we never pour concrete unless the temperature is 40 degrees and rising. In situations where the footing may experience cold weather after being set, we insulate the footing and/or use accelerators.

• Leveling: During the digging process, we used laser transits to make sure the trench bottom is set at a consistent elevation. After that, we set grade pins to make sure the top of the footing is poured consistently to the accurate depth.

Step 3: Building the CMU and Brick Stem Wall

The stem wall at Eagle Farm is constructed using CMU blocks and finished with a layer of brick for added durability and aesthetic appeal. Here’s how it’s done:

1. Setting Foundation Height: Foundation height plays a crucial role in our ability to set grade, manage water on the lot, and maintain a consistent street appeal.

2. Setting Masonry: CMU blocks and brick are set course by course. The bottom course (or however many are below grade) will typically be wider, so the foundation brick has a ledge to sit on.

3. Steel Reinforcement: Depending on the foundation height and the structural plans, rebar and appropriately sized rebar are placed in the foundation to tie the foundation together and enhance strength and stability.

4. Weather Considerations: In cold temperatures, we’ll typically use a specially designed accelerator to shorten setting times.

Step 4: Preparing the Slab Foundation

With the stem wall complete, the next step is preparing for the slab:

1. Slab Backfill: The interior of the foundation is filled with appropriate material, typically stone, sand, or similar material.

2. Under-Slab Rough-Ins: With the foundation backfilled, the plumbing drains and water lines underneath the slab are installed. The water lines are pressurized and sewer pipes are filled to ensure there are no leaks.

3. Slab Preparation: Before concrete can be placed, there are several key tasks that need to be addressed. The first is termite pre-treatment, which is applied to the entire surface below the slab. Once that’s complete, we’ll install a high-quality vapor barrier. When building high-performance homes, this is especially important because a poor quality vapor barrier or installation will allow water vapor into the home.

4. Slab Insulation: In tandem with the vapor barrier, we place both slab edge insulation and perimeter slab insulation. This is only required by North Carolina building code in climate zones 4 & 5, We install it in Wilson, which is climate zone 3, because an uninsulated slab can result in up to 30% heat loss. For our homeowner, that creates increased energy bills and reduced comfortability.

5. Reinforcement: Either welded wire mesh is installed in the slab or the slab is poured with fiber reinforcement in the concrete mix.

Step 5: Pouring the Slab

The concrete slab is poured within the perimeter of the stem wall, creating the base for the home:

• Weather Adjustments: Once again, special considerations need to be taken for weather. During cold weather, strategies including using heated water in the mix, concrete accelerators, and insulated blankets are used. During warm weather, the opposite is the case; we may use concrete retarders and spray the slab surface to keep the concrete hydrated during the curing process.

• Smoothing and Finishing: The slab is leveled and finished to ensure a perfect base for framing. Typically a power trowel is used to make sure we have a smooth surface for the house’s future finishes.

Building with Purpose at Eagle Farm

At GoldenLeaf, every detail matters. From the seemingly small footing and foundation details to the energy-efficient features of the slab, we’re setting the stage for homes that will stand the test of time.

As the Eagle Farm townhomes take shape, we’re excited to share more about the craftsmanship and care that go into every step of the process. Follow us on Instagram and Facebook for updates, and let’s build a stronger, greener future together!