At the base of all framed wall systems is a free-standing and self-supporting steel frame. Constructed of custom designed square tube and angle steel, our unique steel framing system allows your wall to take on nearly any shape, at any angle, at any height.Not only is our framework custom designed for your installation, our walls have more steel framing than a lot of other contractors. We reinforce all of our geometric panels every two feet, compared to every four feet or not at all on some other manufacturer’s walls. This inter-bracing strengthens the overall structure, and adds to the rock-solid feel of the wall. Walls with less inter-bracing are more prone to flexing, which results in cracking or chipping of the surface texture and a ‘hollow’ feel to the walls.
Our texture really sets us apart. The texture itself is a two-part application of blended polymers and cementious products. This texture is specifically engineered for our climbing gyms, and is designed to be quite flexible while appearing and feeling very rigid. Despite our ‘beefed-up’ building practices, all walls experience some degree of settling or flex as strains and time take their toll. Our texture can actually move with the structure, eliminating cracking and chipping that is common as a result of flex.
We attach our texture both mechanically, by using wire lathe, and chemically, through bonding. Many companies rely on chemical attachment alone. Obviously, more attachment means less chipping and cracking. We also provide a vapor barrier between the plywood and concrete to alow for expansion and contraction in the plywood. Some companies offer a surface ‘patch kit’ to do repairs as needed. We have never been called back to do a warranty repair on any Gym Rock texture ever.
The texture is stamped with micro-features molded from actual rock, and closely resembles flat granite.(not necessary for smooth walls) It is thicker than most surface textures, allowing us to round out edges for a more natural looking seamless construction. The surface looks great, and climbs even better. It is perfect for edging and smearing, can be molded into holds in tricky placement areas, like the outside edges of arêtes and the inside corners of dihedrals, and provides positive, realistic feeling for jamming in cracks.
A minimum of 12″ will be left behind all climbing surfaces to serve as the maintenance and inspection area for the ongoing maintenance of the climbing wall and modular hold attachment hardware (T-nuts). If the design permits, this area may also be used as storage area. It is not to be intended to be used by the general public and will not be built as such. Access into this area will be provided by the inclusion of doors or hatches (as appropriate) which will be finished with the same texture as the climbing walls and which will not detract from the visual or functional aspects of the climbing walls.
The process begins with a 3D CAD model. Once final modifications and features of the design model have been completed and approved by you, the internal structure is designed and engineered. Reaction loads are calculated and footings are designed. Complete footing construction drawings will be sent to site contractors for incorporation into the existing slab.In your case it may be good to have a general idea or design loads intended for you footing and foundations considering this is a new build.
The climbing wall will be completely prefabricated and assembled in our facility before it is disassembled and shipped to the job site. This process will allow us to meet the tight time-schedule as well as control our costs by reducing the on-site time required.
The entire climbing wall framework and surface paneling will be manufactured using welded steel. Surface panels will be prefabricated using 2” angle material. The structural framework of the climbing wall will consist of welded tubular steel and/or I-beams. Exact size and location of the structural steel will be determined by final engineering.
The steel superstructure will be prefabricated in the Rockwerx facility and shipped to the job-site upon completion. Erection of the steel will occur once the footings have cured. This process involves epoxy anchors into the footings. Large base plates welded to vertical posts begin the structure. Horizontal and diagonal welded steel braces are added as per engineering drawings. All work will be completed by the Rockwerx Canada Inc. road-crew personnel who are experienced in field installations using our own welding equipment (The Canadian crew are all covered by WSIB and have their WHIMIS and Fall Arrest certificates). Rented equipment will include scissor lifts, boom lifts and articulating boom forklifts. Once the steel structure is completed the surface is attached. The polymer fiberglass panels will be attached to steel plates and welded back to the superstructure with a series of bracing.