Shell Construction in Palm Beach County, Florida
Professional concrete shell construction for residential and commercial buildings throughout Palm Beach County and surrounding South Florida areas. Thum Co. Contractors builds complete structural shells from foundation through top of walls, including concrete foundations, concrete block walls, reinforcement, tie beams, bond beams, and all masonry work ready for roof framing.
Our shell construction team serves West Palm Beach, Lake Worth, Boynton Beach, and surrounding areas. We work from structural engineering plans to build hurricane-resistant concrete shells meeting Florida Building Code requirements.
Call (561) 366-2050 for a free shell construction estimate in Palm Beach County.
What Is Shell Construction?
Shell construction includes all concrete and masonry work from foundation through top of walls—essentially the structural “shell” of a building before roof framing, windows, doors, and interior work. A completed shell consists of:
- Concrete foundation (slab or stem walls)
- Concrete block (CMU) exterior walls
- Interior structural walls
- All reinforcement (rebar and tie wire)
- Tie beams and bond beams
- Lintels over openings
- Anchor bolts and embedded connections for framing
Shell construction creates the structural envelope ready for framers, roofers, and other trades throughout Palm Beach County.
Types of Shells We Build
Residential Shell Construction
Complete structural shells for single-family homes, custom estates, townhomes, and residential properties. Residential shells typically use 8-inch concrete block exterior walls with tie beams and bond beams providing structural integrity and hurricane resistance.
We’ve built residential shells throughout South Florida from modest homes to large luxury estates, working with homeowners, builders, and general contractors.
Commercial Shell Construction
Larger commercial building shells including warehouses, retail buildings, office complexes, and industrial facilities. Commercial shells may use heavier block, taller walls, larger tie beams, and more complex structural systems than residential construction.
We handle commercial shell construction working from structural engineering plans throughout Palm Beach County.
Multi-Story Shells
Buildings requiring multiple floors with structural slabs at each level. Multi-story construction involves coordinating floor slabs, vertical wall construction, and structural elements through multiple levels.
Pool Equipment Buildings and Accessory Structures
Smaller structural shells for pool equipment enclosures, storage buildings, garages, and accessory structures. These follow the same structural principles as larger buildings but on smaller scales.
Shell Construction Process
1. Foundation Completion
Shell construction begins after foundation construction is complete and approved. We verify foundation elevations, anchor bolt placement, and surface conditions before starting wall construction.
2. Layout and First Course
We snap chalk lines establishing wall locations per plans, lay first course of block on foundation using full mortar beds, ensure proper alignment and level, and establish corners accurately.
The first course is critical—it sets alignment and elevation for all subsequent wall construction.
3. Wall Construction
We build walls course by course, install reinforcement per engineering specifications (vertical rebar in cells, horizontal reinforcement in bond beams), maintain plumb and level, and create openings for windows, doors, and mechanical penetrations.
Standard residential walls are 8 feet tall; commercial walls vary based on design.
4. Reinforcement Inspection
Building departments inspect wall reinforcement before grouting or placing tie beams. We coordinate inspections ensuring timely approvals throughout Palm Beach County.
5. Grouting Block Cells
Cells containing vertical rebar get filled with grout (fine concrete mixture) providing structural continuity and bonding reinforcement to masonry. Proper grouting is essential for hurricane resistance.
6. Tie Beam and Bond Beam Construction
We build forms for tie beams (usually at top of walls), install reinforcement per engineering plans, pour concrete tie beams, and ensure proper curing. Bond beams may also be required at intermediate heights.
Tie beams tie the structural system together and provide connections for roof framing.
7. Lintel Installation
Openings for windows and doors require lintels (structural beams) supporting masonry above. We install precast lintels or pour lintels in place per structural requirements.
8. Anchor Bolt and Connection Installation
We install anchor bolts, hurricane straps, and other connections required for roof framing following engineering specifications and building code requirements.
9. Final Inspection
Building departments perform final shell inspections verifying completed work meets approved plans before roof framing begins.
Concrete Block (CMU) Construction
Block Types and Specifications
Standard CMU: 8x8x16 inch concrete masonry units are most common for residential construction. Blocks may be standard weight or lightweight aggregate depending on specifications.
Specialty Blocks: Corner blocks, bond beam blocks (U-shaped for horizontal reinforcement), and other specialty units serve specific purposes in shell construction.
Block Strength: Engineers specify block strength (typically 1,900-2,500 psi compressive strength) based on structural requirements.
Reinforcement Requirements
Florida Building Code requires extensive reinforcement for hurricane resistance:
Vertical Rebar: Steel reinforcing bars placed vertically in block cells at specified spacing (typically 24-48 inches on center). Rebar extends from foundation into tie beams creating continuous structural system.
Horizontal Reinforcement: Wire reinforcement or rebar in horizontal joints or bond beams as specified by engineers.
Tie Beam Reinforcement: Heavy reinforcement in tie beams (typically 4-6 rebar minimum) per structural engineering plans.
We install all reinforcement exactly per engineering specifications throughout Palm Beach County shells.
Hurricane-Resistant Construction
South Florida shell construction must withstand hurricane wind loads. This requires:
Continuous Load Path: Reinforcement creates continuous structural connection from foundation through walls into roof framing, resisting uplift and lateral forces.
Proper Connections: Anchor bolts, hurricane ties, and strapping connect framing to shells following engineering specifications.
Wind Pressure Resistance: Reinforced masonry walls resist wind pressures from hurricanes common in Palm Beach County.
Quality Construction: Proper mortar joints, full grouting, correct reinforcement placement, and quality workmanship ensure shells perform as designed.
We build shells meeting Florida’s stringent hurricane resistance requirements throughout South Florida.
Coordination with Other Trades
Shell construction coordinates with:
Foundation Contractors: Foundation completion and approval precedes shell construction.
Plumbers: Rough plumbing through walls coordinates with shell construction timing.
Electricians: Conduits embedded in walls or penetrations through masonry coordinate with shell work.
Framers: Shell completion and approval must occur before roof framing begins.
Window/Door Installers: Opening sizes and rough openings must match plans for proper installations.
We coordinate all trades throughout shell construction projects in Palm Beach County.
Materials and Quality
Concrete Blocks: We source quality CMU meeting specifications from approved suppliers.
Mortar: Type S or N mortar as specified, mixed to proper consistency for strong joints.
Grout: Fine grout mixture fills reinforced cells, bonding rebar to masonry.
Reinforcing Steel: Grade 60 rebar meeting ASTM standards.
Concrete: Tie beam concrete meets specified strength (typically 3,000-4,000 psi).
All materials meet Florida Building Code requirements throughout South Florida construction.
Timeline and Scheduling
Residential shell construction typically takes:
- Small homes (1,500-2,000 SF): 2-3 weeks
- Medium homes (2,000-3,500 SF): 3-4 weeks
- Large homes (3,500+ SF): 4-6 weeks
- Commercial buildings: Varies based on size
Timeline depends on size, complexity, weather, inspection schedules, and material delivery.
Quality Control and Inspections
Daily Quality Checks: We verify plumb, level, alignment, reinforcement placement, and workmanship continuously.
Inspection Coordination: Scheduling building department inspections at required stages ensures timely approvals.
Engineering Compliance: Following structural plans exactly ensures shells meet design requirements.
Documentation: Maintaining records of inspections, materials, and construction for permit closeout.
Frequently Asked Questions
How much does shell construction cost? Shell costs vary based on building size, wall height, reinforcement requirements, and complexity. Residential shells typically range $15-$30 per square foot of building area. Contact us at (561) 366-2050 for a quote based on your plans.
How long does shell construction take? Most residential shells take 2-4 weeks depending on size. Larger homes or commercial buildings may take 6-8 weeks or more. Timeline depends on size, inspections, and weather.
Do I need an engineer for shell construction? Yes, all shell construction requires structural engineering plans. Engineers design reinforcement, specify materials, and ensure shells meet Florida Building Code and hurricane resistance requirements.
What is a tie beam? A tie beam is the reinforced concrete beam at top of walls that ties the structural system together and provides connections for roof framing. It’s essential for hurricane resistance throughout Palm Beach County.
Can you build shells from my architect’s plans? We build from structural engineering plans. Architectural plans show design intent, but structural engineers provide the construction details, reinforcement specifications, and calculations required for permitting and construction.
What inspections are required? Palm Beach County requires foundation inspection, wall reinforcement inspection before grouting, and final shell inspection before framing. We coordinate all required inspections.
How long before framing can start? Framing typically starts 3-7 days after tie beam completion, allowing concrete to gain strength. Final inspection approval is also required before framing begins.
Do you handle plumbing and electrical in shells? We coordinate with plumbing and electrical contractors for work embedded in shells but don’t perform those trades. We ensure proper coordination throughout shell construction in South Florida.
Related Services
Shell construction often involves additional work:
- Foundation Construction – Concrete foundations
- Concrete Construction – Complete concrete work
- Concrete Block & Retaining Walls – Masonry construction
Get Your Shell Construction Estimate
Ready to build a structural shell in Palm Beach County? Contact Thum Co. Contractors for professional shell construction from your engineered plans.
Call (561) 366-2050 for shell construction.
Thum Co. Contractors 468 Tall Pines Rd. West Palm Beach, FL 33415
Licensed building contractors providing shell construction throughout Palm Beach County and surrounding South Florida areas since 2017.