Altering the ICF Form Teeth

At this point both sides of the ledges are cut now you need to make sure the proper modifications are made in order for forms to stack on top of a regular corner form and a corner form will sit snugly on top. As well as making sure the cavity is conducive to concrete flow and support of the entire ledge.

Notice the raised flat foam areas in the 90-degree corners. The interlocking teeth will not seat all the way down in those locations.

Rasp down half of the height of the interlocking teeth on the interlocking teeth that will bear on the flat raised foam areas so that the ledge form sits down properly on the 90 degree corner.

Now that the ledge form fit snugly on top of the corner form, we need to remove some foam to allow for free flowing concrete. Where the two mitered pieces of ledge form meet at the very corner, trim the foam within the concrete core corbel area at a similar angle of the corbel on both sides.

This opens up the concrete corbel area for sufficient concrete volume.

Cut and remove half of the interlocking teeth on top of the ledge form that will meet the flat raised areas of the 90 degree corner that will stack on top of the mitered ledge form.

Once the mitered corner is cut and dry fit for acceptable appearance and function, glue the mitered cuts together and stack on top of the 90 degree corner.

Lastly, Secure Your ICF Corners!

Use horizontal and vertical wire hooks to secure the mitered ledge form to the immediate straight forms. The mitered ledge could also be taped together to add further support to the glue.

For Thursday on our Mitering a Ledge Form Series we will go over cutting and placing the one and only xLerator- ICF Ledge reinforcement system. And then we’ll go over BRIEFLY how to do an inside miter cut (The principles are the same, just reversed really)

Cutting the Ledge Form

Now that you’ve cut the ledge side of the block now you have to do the other. Mark and cut the straight foam panel, opposite the ledge side, at the 90 degree bend location where the outside foam starts. (Noted by the arrow)

After the both cuts are made, the plastic tie insert must be cut to separate the two pieces.

Sounds simple enough huh? Now you have one side of your corner cut. Repeat those procedures to cut the other corner return as well.

Cutting the Second ICF Return

Reminder: Make sure ledge form extends past the corner far enough to allow for a 45 degree cut on the ledge side AND make sure plastic furring strips are lined up.

ICF
For the other ledge form for the opposite return, cut at the inside 90 degree bend where the core starts. The cut is to be a square cross cut. After the both cuts are made, the plastic tie insert must be cut to separate the two pieces.

Now use the rasp to smooth out corners edge to ensure a snug joint and even surface to apply foam glue.

For next Tuesday we will go over some slight ledge form adjustments you’ll need to make to make sure the forms will stack correctly on top of the ledge as well as go over the xLerator modifications so it fits in the corner properly.

We get a lot of questions on mitering our ICF ledge form in order to make inside and outside corners. Most people get hung up on dimensions and measurements but really there isn’t a whole lot of need for measuring. You need the proper tools to get things done correctly and use a little patience while putting your ICF ledge corners together.

In the following posts I will be outlining a few steps each time to successfully miter you corner ledge forms and reinforce them properly. After we cover those items I will go over a proper bracing strategy for ledge forms as well.

Mitering a 90 degree ICF Ledge

The first thing you need to make sur you have is the proper tools. This will ensure you can move smoothly through the process and make the whole task simpler. Tool you need are:

• Saw
• Straight edge
• Speed Square
• Rasping device
• Tape measure
• Also don’t forget- Tape or Glue and a wire cutter to cut xLerator

Next you need to place the ledge form on top of a 90 degree ICF corner. Make sure to place the ledge form far enough past the corner to allow enough room for the 45 degree cut and be sure the furring strips are lined up with each other.

Using the speed square and straight edge, mark and cut the LEDGE side at 45 degrees from the INSIDE edge of the 90 corner form.

Come back on Thursday for Mitering a Ledge Form part II, as we continue on our ICF ledge form corner tutorial.

When Dr. Waters, owner of Silverton Surgical in Silverton, Oregon planned their new 3-story, 13,020 square foot medical building, they wanted to lower operational costs to improve the profitability of their investment.

Over $10,000.00 per year in utility savings increased the profitability of the project starting the very first month.

The Waters’ specified Reward Wall Systems Insulating Concrete Forms (ICFs) for the exterior walls of the project. To complement the insulated concrete walls, the Waters’ upgraded the roof insulation, windows, and the HVAC equipment to create a high-performance building envelope. The conservation upgrades for the project increased the cost of construction of this $2,100,000.00 project by $112,000.00 compared to a 2 x 6 wood frame building that meets Oregon energy code. The Waters’ justified the investment by counting on lower utility expenses.

The Waters’ commissioned an independent energy audit to determine if the investment in the conservation upgrades would be cost effective, and the results were astonishing.

The utility expense of the building constructed of 2 x 6 wood frame to meet Oregon Code was calculated to be $1,151.00 per month. The building with the Insulated Concrete exterior walls, increased roof insulation, window and HVAC upgrades was calculated to be $312.00 per month for a savings of $10,068.00 in utilities per year.

Even with the cost of construction increased by $112,000.00, this building is less expensive, and more profitable for the Waters’ starting the very first month of operation. The combined monthly mortgage and utility expense for the project is actually $175 less than the same building built with the less expensive 2 x 6 wood frame construction to meet code.

The Waters’ contracted a consulting firm to submit an application for the State of Oregon’s Business Energy Tax Credit (BETC). BETC was created to offer an incentive for investing in conservation upgrades. The incentive totals 35% of the $112,000.00 upgrades for a tax credit of $39,200.00 to be taken over five years.

Even with a higher cost of construction, the utility savings for this project result in a lower cost of ownership and increase profits for Silverton Medical Properties starting from the very first month of operation.

• 13,020 square feet

• CMU and brick exterior finish

• PVC sheet roofing over 3.5″ Polyisocyanurate R-22

• 5 AC units, total 25-ton inheat pump

• Energy Wise utility cost average, $312 per month

• Estimated $10,000 per year energy savings over wood

• Stairwells and elevator shaft built with Reward

• 11″ iForm for top two levels

• •13″ iForm for basement and crawl space

A net zero building is a building that offsets all energy use by creating energy as well so by the end of it all there is an energy use of net zero. Now frequently at trade shows or talking with people in general about the future of green building and the new way to build homes, I always cringe at the people who jump right into wanting to create energy without taking the necessarily steps to use less in the first place.

Net Zero homes usually have a setup, through solar or wind, to create energy to offset any they use. However, the concept makes use of the most important part of creating energy.

YOU HAVE TO USE LESS ENERGY.
icf

I can’t imagine the size of a wind turbine, and cost of a solar panel (about 285 sq feet at $16-$30 thousand dollars) to generate the amount of electricity that is needed to power an average (14,400 watt-hours per day) home. That’s why ICFs are an ideal building system for net zero, they will reduce energy needs.

ICFs and Net Zero

That’s why insulated concrete forms have always been a great option when our customers want to built a net zero home. They reduce your energy so the owner can create a  surplus of it and actually sell it back to the energy company!

Here is our Hyde Park example below, one of the first net-zero homes in the country to use ICFs and a first in New York. General contractor Bill Reilly of Hyde Park, New York, became interested in ICFs in the early 1990’s, but he never went any further with it at that time. However, when he started planning to build an energy efficient home for himself, ICF construction came to mind again. As a contractor with 40 years of experience, Reilly wanted to build the house himself and make it extremely energy efficient.

New York Energy Efficiency

The result was the most energy efficient house in the state of New York. With a geothermal HVAC system and photovoltaic cells on the roof to generate electricity, Reilly pays nothing for electricity. Part of the reason is that he is able to re-sell the excess electricity he generates back to the utility company. But would never be able to do that had he not built with insulating concrete forms.

Quick Facts about the Hyde Park Net Zero home in New York

• One-story house with walkout basement
• 6,300 conditioned square feet
• 3,160 finished square feet
• HERS rating of 93.4 by Energy Star
• Highest Energy Star Rating to date in New York State
• Stone and vinyl exterior finish
• Asphalt shingle roof materials
• Climate Master Tranquility 27 geothermal heating and cooling system
• 70% smaller than it would have been with traditional construction
• Projected utility costs: Zero dollars
• 11″ iForm insulating concrete form

Very well T. Jeff, we will be happy to oblige.

Thank you to all of our service men and women protecting our freedoms and independence.
Reward wants you all to have a safe and happy 4th of July.

Reward offices will be closed on Monday  July 5th.

An important aspect that insulating concrete form contractors must always be cognizant of is safety when working with concrete boom pump trucks. A successful ICF project can be ruined if a major catastrophe or injury would happen to occur. Safety should always be a top priority. The concrete pump operator and contractor must be aware of potential dangers and take proper precautions.

Setting Outriggers

The contractor must evaluate the site conditions and communicate them to the pump truck dispatcher and operator. They need to know the size of pump needed, back-filled areas, underground obstructions, soil conditions, muddy or soft areas, and site restrictions. The outriggers should be firmly placed before unfolding the boom. Cribbing is used to spread the load out to the soil from the outriggers. The general rule is to use as much cribbing as is practical; too much is better than too little. After placing the cribbing on even soil, place the weight of the truck on each outrigger one at a time. If the pad starts to sink, retract the foot and add more cribbing. Continue setting each outrigger using the same process.

Do not place the outriggers on a hill or too close to an excavation or cliff. The one-to-one rule must be followed by keeping the outrigger back one foot from the edge for every one foot of vertical drop. If necessary, move the truck to a different location to avoid any of these areas.

When unfolding the boom, continue to keep an eye on the outriggers for any shifting or sinking into the soil. Keep people out from underneath the boom whenever possible.

Operating the Boom and Pumping Concrete

The pump operator should show the contractor the locations of the emergency stop switches. It is important to wear personal protective gear such as goggles or safety glasses, hard hat, ear protection and rubber gloves. Never stand between the ready mix truck and the pump. Stand off to the side where the driver can see you. Always be aware of overhead electrical power lines. If the pump or boom becomes energized with high voltage, anyone or anything that touches it will be at risk of electrocution. Be sure someone is always monitoring the location of the boom and that it stays at least 17 feet away from electrical wire.

Do not let the concrete level in the hopper become so low that you can see the top of the valve mechanism. If this occurs, immediately stop the pump as air can be compressed into the cylinders. This creates a dangerous situation; as the air is expelled from the hopper or pump line it could act as a cannon shooting out concrete. Slowly restart the pump with caution.

The person at the end of the hose should hold the hose loosely with both hands, keeping it out away from him. He should also be sure not to hug the hose. Spend as little amount of time as possible standing under the boom. Two important issues to avoid at the end of the hose include never kinking the hose and never hanging heavy devices from the hose. If the hose becomes kinked it will cause the pump to have maximum concrete pressure. A heavy device at the end of a hose can cause extreme hazard to the individual holding the hose. If the hose were ever to whip, it could easily knock him down. A heavy device at the end of a hose can cause extreme hazard to the individual holding it. If the hose were ever to whip, it could easily knock the person down.

Read our series on Concrete Placement in ICFs to get a good understanding of the type of concrete to use and the proper placement in insulating concrete forms. Remember if the concrete is not what was specified: SEND IT BACK

The wall features:

• NoricF4 Custom Metal ICF Frames
• tieKey ICF masonry anchor
• xLerator reinforcement for ledge and taper top forms
• Waterproofing options
• Wire Hooks

Click the picture below to get started!

Project Details:
Quantity of Insulating Concrete Forms – 2,200 13″ Forms

Ready Mix used: 11,000 cubic yards

The Cascade Meadow Science Center is a research and education facility dedicated to environmental education, with a focus on energy, water and wetlands. Upon completion, the Center will house a reception area, interactive exhibit spaces, a large conference and meeting space, a science lab for the study of native wetlands, a conference room, and offices for staff and on-site educators. The grounds will feature a restored wetland and lake with outdoor learning stations and trails.

In pursuit of LEED® Platinum Certification, one component of the 16,000 square foot center is Reward® Insulating Concrete Form (ICF) technology for the above grade exterior walls. ICFs offer many sustainability benefits for both commercial and residential structures, including energy savings of up to 50-80 percent over traditional wood framed buildings. ICF walls have also been tested to withstand tornado winds exceeding 200 mph. They are far quieter and provide for a clean indoor air environment that eliminates the possibility of mold growth within the exterior walls.

“The Cascade Meadows Science Center will serve as a catalyst for meaningful and enduring learning that promotes sustainable living through exhibits, events, seminars, conventions and more. Cemstone and Reward are proud to play a role in this important and significant endeavor by demonstrating how the use of ICF technology can help create a more sustainable structure.   The ICF portion of the Cascade Meadow Science Center went really smoothly. We’ve done several ICF projects together with Reward and Cemstone. It’s easy construction in terms of design – and our contractor has lots of ICF experience. The most important advantage for the building owner is energy efficiency and a higher R-value. In addition, ICF buildings are quieter inside, which is very important in many residential applications.  Using concrete in an ICF building also helps contribute to LEED points. It’s also a benefit to LHB to have representatives from Reward and Cemstone available to answer questions. We’d recommend ICF construction – the buildings speak for themselves!”

Anne Ryan, Project Architect, LHB, Inc.

Well I’ll do a quick picture update on a project with Leading Edge Building Products. They finished the concrete home in Texas we previously posted about while it was being constructed. (ICF Concrete Home Texas & ICF Concrete Home Texas II). Wow.