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ICF Commercial Applications

ICFs offer all the benefits that have made concrete the material of choice for construction worldwide. They provide solid, high strength walls that resist the ravages of fire, wind and Father Time.

But ICF's also do plain concrete one better – or rather, two better – by giving two built-in layers of foam insulation. ICF construction takes the three-step process of framing, insulating, and wrapping a structure, and ties it all into one. Forms are constructed from expanded polystyrene foam and stacked like building blocks to form the exterior walls of a building; then the forms are reinforced with steel and filled with concrete. The forms interlock and fasten one to the other to provide a seamless "foundation to rafter" fully insulated, reinforced concrete walls. ICF's stay in place as a permanent part of the wall assembly.

This gives an ICF structure some sizable advantages over other construction techniques. Home and building owners can enjoy greater energy efficiency, more peace and quiet, and enhanced day-to-day comfort. All of this is wrapped up in a solid, high-quality building package with an utterly remarkable feel.

Why Builders use it:

  • There is no stronger insulated concrete form on the market.
  • Unlimited design possibilities.
  • 4-hour fire rating in accordance with ASTM-E119-00a and CAN/ULC S101.
  • Tornado & hurricane resistant.
  • Made of regrind polypropylene, our brackets and ties are the heaviest and toughest on the market. This eliminates the thermal bridging and corrosion concerns.
  • Brackets are molded 1/2” below the surface of the block-not exposed, which can cause shadowing if you stucco or use EIFS products on the exterior. Many ICF’s require tin or metal for attachment of building materials.

Highlights:

  • Energy Efficient
  • Strength
  • Noise Reduction
  • Cost Effective

Contact a County Materials' sales representative for more detailed information on ICF Construction, and what products are available in your area.

ICF Applications:

There is no limit to the opportunities for ICF construction:

  • Multi-unit residential
  • Apartment complexes
  • Assisted living
  • Condominiums
  • Hotels
  • Restaurants
  • Warehouses
  • Box stores
  • Strip malls
  • Hospitals
  • Clinics
  • Manufacturing facilities
  • Swimming pools
  • Residential construction

Working with ICFs:

Note: It is strongly recommended that anyone building a structure with ICFs receive the proper training and consultation before starting any project.

  1. ICF Step 1Pour the footing. When concrete sets lay the first course of ICF block by setting and bracing the corner block first. Work your way to the center of the wall while adhering the block to the wall
  2. ICF Step 2Stack your forms to the desired height of your wall while building your window, door bucks and placing your rebar, rod ties, and zip ties as desired
  3. ICF Step 3Plum off your walls by bracing every six feet on the inside or outside walls depending on where there is room to brace. Then put your corner bracing on every corner. Now you are ready to pour your wall.
  4. ICF Step 4Fill the walls starting at the corners and work your way to the center only filling four foot lifts at a time. When pouring is complete finish the top of the wall and set your anchor bolts.
  5. ICF Step 5When concrete has set, remove your bracing and continue on with the rest of the house with more forms or wood frame.
  6. ICF Step 6Hang sheet rock, hang kitchen cabinets, hang stone or any other finishing material. Materials do not differ from what can be done with a wood-frame house. Exterior finishes; vinyl siding, brick, stone, EIFS, stucco, wood siding, etc. Possibilities are endless with ICF's!

Footings:

  • If the ICF bracing system cannot be used on the interior walls, make sure the foundation is excavated so that there is ample room for the bracing system to be utilized on the exterior of the wall.
  • Prepare for the wall depth, width and amount of rebar for the footing in accordance with state or engineering specifcations for correct wall, floor and roof loads.

First Course:

  • Use a chalk line to mark the footings where the forms are to be laid.
  • Glue the first course of the forms to the footing, using appropriate foam gun with Foam-2-Foam adhesive.
  • Continue stacking the forms, making sure that the plastic form ties are stacking correctly and that the wall is being erected plumb.
  • Never build an ICF wall higher than 12 feet per concrete pour.

Bracing:

  • Use only the manufacturer's recommended ICF bracking systems.
  • Start utilizing the bracing once the third and fourth courses of the wall are installed.
  • Once the bracing is set, the builder can reach to the height of the wall by using the scaffolding system incorporated with the bracing. In addition, the wall is now safe from wind gusts or high winds that could possibly move the wall.
  • Always consult with the distributor and/or manufacturer for correct bracing procedures.

Rebar:

For the Walls -

  • Use only state or the manufacturer's engineered recommendations for horizontal and vertical rebar placement in the wall.

For Lintel Openings -

  • Use only state or the manufacturer's engineered recommendations for any openings that are incorporated in an ICF wall.

Concrete Pours:

  • Always follow the distributor's and/or manufacturer's pre-pour checklist prior to pouring and ICF wall.
  • Pour the wall in 4 foot lifts. Never pour an ICF wall to the top of the desired wall height in one lift.
  • Use a concrete mix of 3,500 psi with a slump between 4-6 inches. When building with 4-inch ICFs, use only a 3/8" aggregate mix for better concrete flow.
  • When the pour is complete, re-check and straighten the ICF walls as needed.
  • Place anchor bolts for the sill plate, or place dowels for the next level of ICF forms to be installed.

ICF Frequently Asked Questions:

What makes County Materials' ICF forms better than the competition?

Our form supplier is the only in-house manufacturer of ICF forms in the industry. This allows them to maintain strict quality control standards. The brackets are the toughest on the market, made of regrind polypropylene, which eliminates the thermal bridging and corrosion concerns. The brackets are molded 1/2" below the surface of the block eliminating any shadowing concerns when finishing with Stucco or EIFS products on the exterior of the building. In addition, the brackets run the full height of the forms, and the bracket is a full 2.5" wide which is unique in the industry, making it much easier to attach both external and internal wall products.

How many ICF forms will I need for my project?

County Materials sales representatives can help you with your estimate for ICF forms, concrete, and accessories you will need for your project.

How high can an ICF wall be poured at one time?

It is recommended that an ICF wall be poured one story at a time, no higher than 12 feet. The pour rate should not exceed 4 feet per lift. ICF forms are used for both single and multi-story residential and commercial projects.

What is the R-Value of ICF forms?

With 2.5 inches of EPS foam on each side of the form, an ICF form itself has an R-value of 23. With concrete in the forms, a structure can achieve an R-value of R-28 to R-32 using Thermographic Testing.

What kind of wall coverings can be accomodated with ICFs?

County Materials' ICF forms come with a full 2.5" bracket located every 8" on center. This makes it easy to attach any type of wall covering, including EIFS, stucco, siding or ties for brick or stone veneers. The interior walls will easily accept sheet rock screws for attaching standard sheetrock.

How much rebar will my project require?

The amount of rebar is determined by the design of the building. County Materials sales representatives can help with determining how much rebar will be needed for your specific project (in accordance with local codes and engineering specifications only).

What is LEED®?

LEED® stands for Leadership in Energy and Environmental Design.  It is a green building rating system developed by the U.S. Green Building Council (USGBC).  The purpose of LEED is to promote buildings that are environmentally responsible, profitable and healthy places to live and work. The LEED system was developed for designing, constructing and certifying the greenest and best buildings possible. ICF’s and concrete can help a project achieve certain LEED credits in specific categories. Consult with a County Materials sales representative for info on LEED points.

Are ICFs resistant to mold and rot?

YES. With traditional stick building, moisture can become trapped within the open cavity of a wood stud wall causing, mold, mildew and rot problems.  Since ICFs are closed cavity construction, there is no place for moisture to accumulate. In addition, EPS foam, rebar and concrete are resistant to mold and mildew.

Can an ICF home or structure be remodeled?

YES. Most contractors have the ability to create openings in ICF walls using concrete cutting tools that are available at many rental centers.

Are County Materials' ICF forms code approved?

YES.  Every major code body in North America, including ICC and CCMC, has approved ICFs.

How quiet are ICF walls?

ICF walls have a sound transmission classification of STC 48, which is twice as high as a wood-framed wall. Structures built with ICFs provide a quiet, comfortable interior.

Are termites a problem for ICFs?

Just like wood frame construction, local building codes do require methods for protecting foam below-grade in high termite areas. However, ICF’s do not provide any food value for insects or rodents and termites cannot affect the structural integrity of an ICF wall because it is filled with concrete.

Are vapor barriers needed with ICF construction?

Some states have a code that requires a vapor barrier no matter what type of construction is used.  ICFs, however, provide a natural barrier against air and moisture because of the concrete and two layers of foam.

Do ICF structures provide extra safety?

YES.  ICF structures are up to 8 1/2 times stronger than wood framed structures.  The standard wall design can withstand winds greater than 160 m.p.h. and do not support combustion, making them highly resistant to severe weather and fire.

How are doors and windows installed in ICF walls?

A wooden, steel or vinyl buck is built and incorporated into the ICF wall prior to pouring concrete. Once the concrete has cured, doors and windows can be installed.

Do ICF walls need to be waterproofed?

YES. As with any below-grade construction, the industry recommends waterproofing no matter what kind of soil or grade is present for your project. Ask a County Materials' sales representative for available waterproofing products for ICF foundations.

Consider the Advantages for Commercial Construction:

Insulating Concrete Forms make it easy to achieve sustainable construction and optimize a building’s lifetime performance. Because of their numerous advantages, ICFs are rapidly gaining market share in both above and below grade commercial applications.

Cost Competitive

Over the last ten years, concrete prices have been remarkably stable. Recent price increases in other materials have generated interest in concrete building systems as never before. Labor savings and readily available materials make ICF's, feature for feature, one of the most cost competitive wall systems in the U.S. and Canadian housing markets.

Faster Building Process

For design and construction, ICFs offer an easy and reliable system. Foam blocks are stacked quickly and easily using common construction tools and equipment. Typical ICF installations can shorten a project’s construction schedule because experienced crews can install units faster, even in winter conditions.

Easy To Use

Although it looks new and different, anyone with construction experience can quickly get up to speed with ICF's. An ideal crew has a mix of concrete placement and carpentry experience. Once the crew has some practice, each ICF-build home requires less skilled labor and less total labor than a wood-framed home. And ICF's are very lightweight, so crews stay fresh through the day.

Likewise, ICF's present no problem for the sub-contractors who come after the walls are poured. Since holes, chases and rectangles are easily cut into ICF's with a knife or saw, installation of mechanical systems is a snap. The fastening of drywall and lap siding is just as fast and easy. And mid-course corrections, such as moving an opening, are no big deal – just saw it out and re-form. It’s not more difficult to make changes to an ICF wall – it’s just different.

Enhanced Efficiency

ICF walls can make a substantial difference to the thermal envelope and reduce a building's heating and cooling costs. The high R-value of the insulation, the thermal mass of the concrete, and the system’s ability to moderate temperature swings all combine to create walls that are extremely energy efficient.

Building Green

Because of their energy efficiency, ICFs can significantly contribute toward USGBC LEED Energy Optimization credits as well as credits for recycled content and local manufacturing. Additional "green" advantages include air tight construction, no off-gassing for better control of indoor air quality, minimal construction waste, durable building material and outstanding lifetime performance.

Lasting Building Envelope

Building owners can reduce maintenance and lifetime building costs with ICF construction. Long-lasting concrete walls are strong, highly durable and resistant to pests, fire and mold and mildew, far outlasting other building materials. The comfort, safety and health of occupants are also enhanced because the solid concrete walls provide superior soundproofing from outside noises and are highly resistant to strong winds and severe weather. In addition, the walls do not support combustion and meet 4-hour fire ratings.

Versatile System – Flexible Designs

ICF homes can be designed in any style, and will accept any traditional exterior finish including vinyl or wood siding, stucco and brick. Because custom angles and curves are easily created, it’s simple to build in bows, bays and radiuses. And ICF systems accommodate any of today’s most popular design features, such as tall walls, large openings, long floor spans and cathedral ceilings. Window and door openings of any size are possible.

Blocking for Windows and Doors

Cutting block is simple in ICF construction so, unlike the cumbersome concrete constructions of the past, custom window designs and complex angles are commonplace. When considering building with ICF's, be sure to discuss how to accommodate the doors and windows with your contractor. With ICF's, windows and doors must be cut and blocked before the concrete is poured. Blocking the openings accomplishes two things: it holds back the concrete to preserve the opening, and creates the frames for the doors and windows. Once a crew is experienced in ICF construction, scheduling and speed become key benefits. An experienced crew can put up a house faster with ICF's than with traditional framing.

Internationally Proven & Code-Accepted

Originally developed in Europe (where concrete home building is standard) ICF systems have been used successfully around the world for more than 30 years. Thousands of ICF homes have been built in recent years throughout the United States and Canada. They have proven successful in every region and climate, from Orlando to Calgary. ICF systems are accepted by all the major model codes in the U.S., and by the R-2000 program in Canada.

 

Specifications:

  4 inch ICFs6 inch ICFs8 inch ICFs

Straight Form dimensions:

Insulated Concrete Forms ICF Straight 48" long, 16" high 48" long, 16" high 48" long, 16" high

90-degree Corner:

Insulated Concrete Forms ICF Corner Right
Insulated Concrete Forms ICF Corner Left
17" x 33" long, 16" high 21" x 37" long, 16" high 21" x 37" long, 16 high

45-degree Corner:

Insulated Concrete Forms ICF 45 Corner 12" x 12" long, 16" high 12" x 12" long, 16" high 12" x 12" long, 16" high
Brickledge:   N/A 48" long, 16" high 48" long, 16" high
Core Width:   4.25" 6" 8"
Overall Width with Foam:   9.25" 11" 13"
Concrete Volume per Form:   0.07 yards 0.10 yards 0.13 yards
R-value for Forms only:   R-23 R-23 R-23
ICF Commercial Applications

Product Information:

Literature
Insulating Concrete Forms Brochure
ICF Commercial Construction 

Supplier of Fox Blocks ICFs:
www.foxblocks.com

 

 

 

 

 

 

 

 

 

Contact ICF Customer Service:

800-289-2569

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