NUDURA Corporation presents an overview of

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NUDURA Corporation presents an overview
of Insulated Concrete Forms (ICFs)
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History of Concrete

• In 128 A.D., the Romans used concrete material to
  build the Pantheon. It still stands today
• Concrete mixtures were characterized by low
  cement material content, low water content, slow
  rate of development, and little shrinking or
  cracking during drying
• 40 years ago, EPS (expanded polystyrene) was
  introduced to the standard concrete wall because
  of its insulating value
• Today, ICFs offer structural integrity, thermal,
  moisture and acoustical barriers making them the
  highest performing wall system available

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What are ICFs?

• ICFs (Insulated Concrete Forms) are comprised of
  two layers of foam
• insulation
• Insulated material is usually manufactured of
  expanded or extruded
• polystyrene (EPS)
• Two layers of insulation are held together with
  webbing or ties creating a
• hollow block which acts as a form for a steel
  reinforced concrete center

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What are ICFs?

• Ties within the ICF keep rebar placement firm
  during pouring of concrete
• Resulting blocks are stacked like building
  blocks through interlock
• placement
• Concrete is poured within the hollow form to
  create a solid 4 to 12 core
• The result is a solid insulated wall assembly
  with good thermal resistance

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Types of ICFs
Panel
Waffle Grid
Screen Grid (Post Beam)
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Types of Flat Wall ICFs

• Ribbed interior cavity

• Smooth interior cavity

• Ribbed interior cavities allow the concrete to
  adhere to the EPS

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Design Considerations with ICFs
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Features of ICFs

• ICF Construction takes framing, insulating and
  wrapping a building and ties it all into one
  process
• Almost any finish can be applied to the inside
  and outside of an ICF
• Air leakage through and air movement within ICFs
  is far lower than frame construction due to the
  dense insulation and concrete

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Features of ICFs

• Fastening strips provide a face on the ICF to
  fasten internal and external finishes
• Webbing provides structural integrity during
  rebar placement as well as during concrete pour
• Webbing is usually produced of polypropylene
  which will not deteriorate over time when
  embedded in concrete

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Features of ICFs

• The performance structural, thermal, moisture
  and acoustic of an ICF wall is superior to a
  wood or steel framed wall
• Designed to withstand high wind, fire, elements
  and the test of time
• Resulting structure is very strong and exceeds
  code requirements for tornado and hurricane prone
  areas

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Types of ICF Structures
Residential
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Types of ICF Structures
Multi Residential
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Types of ICF Structures
Institutional
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Types of ICF Structures
Commercial
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Types of ICF Structures
Industrial / Agricultural
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ICF Structure Options
Flooring
Radius
Pool
Gable
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Building with ICFs - Footings

• ICFs can easily be cut to fit various height
  increments
• Reversible forms are ideal as they have the least
  amount of waste

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Reinforcements

• Placement of horizontal and vertical rebar
• Location of reinforcement determined by
  engineering
• Stirrups can be pre-bent or site bent

• 4 rebar (10M) footing dowels and horizontal
  vertical reinforcement as required by
  engineering.
• 5 rebar (15M) footing dowels and horizontal
  vertical reinforcement as required by
  engineering.
• 6 rebar (20M) and larger lintel bottom bars
  as required

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Minimums For Reinforcing Concrete

• ¾ (19mm) of concrete cover
• All lap splices must be a minimum of 40x rebar
  diameter
• 4 20 lap, 5 25 lap, 6 30 lap
• 10M 400mm (16), 15M 600mm (24), 20M 800mm
  (32)
• Minimum solid wall segment length is 2-0
• If the wind is perpendicular to the roof ridge it
  is 4-0
• Minimum percent of solid wall length along
  exterior lines 5.5 flat wall types 15-50, 6
  waffle-grid 15-60, 6 screen-grid 15-70
• Engineering is required for all structures in
  immediate hurricane prone coastline subject to
  storm surge. (i.e.. Beachfront property coastal
  construction zone)
• All post-and-beam ICF walls require engineering
  because they are analyzed as a concrete frame
  rather than as monolithic concrete wall
  construction.

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Lap Splices
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Windows Doors
Concrete Lintel Details
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Lintel Design Criteria

• Depth of lintel
• Width of opening
• Superimposed load
• Concrete strength
• Thickness of concrete
• Point loads

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Lintels

• Lintels are required over all openings greater
  than or equal to 4 in width
• Lintels in screen grid and post and beam ICF
  walls spanning greater than 4 are not allowed
• Lintels in all ICF walls except flat walls must
  be formed
• ICF must be cut away and a flat lintel with a
  uniform shape must be provided
• Minimum lintel size for flat or formed ICF walls
  is 8
• Minimum lintel size for screen grid ICF walls is
  12
• Stirrups must be a minimum of 4 rebar
• Maximum stirrup spacing is half of the height of
  the lintel less the depth of the bottom cover of
  concrete
• If formed with wood then the bottom cover is at
  least 1 ½

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Lintel Schedules
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Wall to Floor / Roof Connections

• Anchor bolts can be located anywhere in the cores
  of flat wall forms
• Anchor bolts can only be located in the main
  cores (thickest portion) of waffle grid and
  screen grid ICF walls

Anchor bolts for ledgers
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Wall to Floor / Roof Connections

• Foam must be removed in the location of the
  anchors to insure a tight connection
• At least a 3 diameter hole with the anchor bolt
  in the center
• Ledgers shall be a minimum of 2x8 No. 2 Southern
  pine or No. 2 Douglas fir
• Anchor bolts shall be a minimum of ½ diameter, 6
  feet on center, embedded a minimum of 4 inches
  (on all size forms)

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Slump

• Should be 5 6

5 ¼
8
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Consolidation

• Proper use fast in, slow out
• ¾ to 1 head size

• Consolidated concrete shall be dense and free of
  cold joints, voids and honeycombing.
• Concrete shall be well bonded to all rebar,
  anchors, embedments etc.
• Precautions should be taken to keep the lintel
  area free of concrete spillage until that area is
  to be filled and consolidated.

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Placement Methods

• Pump Truck
• Line Pump
• Conveyor Belt
• Crane and Bucket
• Directly off Chute

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Electrical Installations

• Rough-In for electrical work is accomplished in
  various ways

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Plumbing Installations

• Up to 1 ½ PVC pipe with coupler
• Rough in as for electrical

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Exterior Finishes
brick
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Exterior Finishes
stucco
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Exterior Finishes
siding
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Features and Benefits of ICFs

• Save on Labor Costs
• ICFs are designed for speed. You can save on
  both labor and financing costs
• Reduced Maintenance
• Conventional construction is prone to maintenance
  problems such as drywall pops and basement leaks.
• Building with NUDURA solves these problems, and
  gives you a stronger, more durable, and more
  energy efficient home.

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Features and Benefits of ICFs

• Save on Construction
• Less sub trades to coordinate
• The same ICF installers are used for
• Foundations
• Walls
• Interior / exterior studding
• Insulation
• Vapor / air barriers

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Benefits and Specifications

• Energy Efficiency
• Lack of thermal bridging, thermal mass, and air
  tightness are real, measurable and significant
  benefits of ICF
• Up to 70 heating cost savings
• Thermal resistance of R22 (RSI 3.89 6 form
  unit) with performance running up to R50
• Thermal performance of an assembled wall can be
  double that of a typical wood framed wall,
  dependant on certain climatic conditions

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Effective R-Value of Typical Walls)
FRAMING MEMBER NOMINAL CAVITY EFFECTIVE
WHOLE AND SPACING INSULATION WALL
R-VALUE   FRAME WOOD FRAME
STEEL 2 x 4 16 o.c. R-13 R-10.1
R-6 2 X 4 24 o.c. R-13
R-10.7 R-7.2 2 x 6 16
o.c. R-21 R-16.2 R-7.4 2
X 6 24 o.c. R-21
R-17.2 R-9.0   Source ASHRAEs 90.1
Committee   Nudura
R22.4 Up to R50
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Benefits and Specifications

• Water Vapor Transmission
• Can sustain flooding with no structural damage
• ICF as a high mass substrate is not susceptible
  to
• Dry rot
• Termites
• Mold
• Maximum water permeance rating of 3.50 perms-in
  (200ng/PA.s.m2/25mm)
• Tested average based on total EPS 1.68 perms-in
  (96ng/Pa.s.m2/25mm)
• Waterproofing / damp proofing and drainage as
  required by building code compatible with EPS

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Environmental Elements

• Options for very heavy termite hazard areas
• Protective exterior peel and stick coating
• Chemical spray for exterior area of site
• 6 cavity in EPS foam to expose concrete
• Embed flashing barrier into EPS/cavity prior to
  concrete pour

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Benefits and Specifications

• Fire / Flammability Resistance
• Non-combustible self extinguishing materials
• Mandatory flame retardant in all foam plastic
  insulation (bromine)
• Flame spread 10
• Smoke Developed 300
• from UL File R5817(A)
• Code dictates all foam plastic protected with
  thermal barrier
• Exteriors of multi storey buildings protected
  from flame propagation
• Flame ignition temperature of 698F and self
  ignition temperature of 806F in accordance with
  ASTM D1929
• Concrete core provides a fire resistance rating
  of up to 4 hours. Rating is based on how long
  you can safely get out of the building. Stick
  frame rating is 20 minutes (ASTM E119 CAN/ULC -
  101)

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Benefits and Specifications

• Sound Transmissions
• 6 concrete core provides a Sound Transmission
  Class Rating of 50 (totally inaudible) (ASTM E336
  E413)
• Wind Resistance
• Reinforcing dictated to higher degree per wind
  speed and earthquake zone classifications
  providing greater impact resistance than wood
  frame or even concrete block
• Up to 250 mph
• Structural Design Considerations
• Wall design principle is a monolithic structural
  concrete wall. It is up to 9x stronger than a
  wood framed wall.
• Designed as reinforced concrete in accordance
  with all applicable US prescriptive tables per
  IRC, SBC, Florida Building Code, PCA/NAHB EB118
  or Engineered design per ACI 318

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North American Code Approvals

• USA
• ICC-ES ER-6163)
• NES NER-663
• Various Individual State approvals as applicable
• CANADA
• CCMC (NRC Canada 13063-R)
• Ontario Ministers Ruling

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For More Information

• Visit www.nudura.com
• Call 1-866-468-6299
• Enroll in NUDURAs one day training course