Special Olympics of Massachusetts 2
April 15th, 2010 | Project Showcase
This wonderful ICF project won a 2009 ICFA Excellence Award for Large Commercial, along with Carleton College (Gold/Sustainability) and Dunkin’ Donuts (Gold/Small Commercial)
Life-cycle costs and more efficient heating/cooling costs to maintain the Special Olympics Yawkey Sports Training Facility were a result of Columbia Construction providing value engineering- essentially by making the decision to deviate from original CMU plans and use insulating concrete forms they were able to improve the function of the building with an opportunity to lower costs.
Energy conservation and being able to build during the winter months were initially the main reasons for using Insulating Concrete Forms. Significant savings were realized due to the fact the project did not suffer any winter conditions penalties. The added benefits of strength and safety were greatly appreciated as well, due to the nature of the users of the building.
The principal architect, since discovering the ICFs, is now specifying it for several new national drug facilities he has underway. His reasons for using this product are:
- Energy conservation and the LEED benefits associated with this product, which increases the R-value to R-32.
- Constructability: utilizing ICFs allows construction during winter months and decreases the cost of winter conditions.
- Labor: utilizing ICFs allows for one trade to construct from the frame footing to the top of the parapet wall. That fact also saves up to two (2) months of overall construction, which for a retail client, is a major benefit.
This isn’t just a facility, it’s a facility for a cause, that everyone was happy to be apart of. It was able to be built with safety in mind, and will reap the benefits of energy efficiency, for all users of the site. The SOMA Yawkey Sports Training Facility will serve as a baseline and as inspirations for ICF growth in the Northeast. This project brought a new architect on board, in a region that will benefit immensely from ICFs and a community program that will enjoy the building for generations to come.
Special Olympics of Massachusetts
April 6th, 2010 | Project Showcase
It’s a great time to highlight a beautiful project that is also a winner of a 2009 ICFA Excellence Award. This is the year the Special Olympics games are being hosted in Nebraska as well. (We are out of Omaha)
Yawkey Sports Training Facility
Columbia Construction Company served as Construction Manager for a new state-of-the-art headquarters, the Yawkey Sports Training Center, for the Special Olympics of Massachusetts (SOMA). Centrally located in Marlborough, MA, the new 20,000 s.f. training facility and athletic fields is located on a five-acre site. This new building houses their executive offices, along with all of their support facilities. In addition, there is 4,000 s.f. of flexible classroom space that will provide a suitable venue for fundraising and banquet functions. The new SOMA headquarters facility will enable the organization to better serve the more than 10,000 athletes, in more than 118 athletic competitions in 26 sports. It will also enable SOMA to consolidate disparate and expensive field operations, and provide top-notch and more frequent training for its growing base of volunteers, coaches and athletes.
ICF design
The design includes a processional walkway leading to a plaza containing a “Hall of Fame”, which will introduce visitors to the unique nature of this facility. As they enter the lobby, further images and interactive displays will reinforce the educational aspects of the organization. ICFs were utilized for the training facility and gymnasium to allow the construction to continue during the harsh winter months of New England. Utilizing ICF allowed Columbia to place concrete all winter and also provide the exterior insulation to install EIFS in the spring.
The Gymnasium is located on the North side of the building and was originally designed with CMU. The Reward ICF system offered a structural wall system with high energy efficiency and low heat loss. In fact the ICF was added to the design plans after CMU was already spec’d. It was apparent as soon as the benefits were understood, this was the way to build. Adjustments were made in the plans and by using the expertise of an experienced installer, a successful project was built.
ICFs Save Time and Reduce Labor Costs
The ICF system offered a structural system that allowed Columbia to remove the columns and perimeter beams. By utilizing ICFs they were able to simplify the construction to one trade, reducing materials and scaling back on extra labor to get the building in use faster. The insulating properties of ICFs also help to keep construction schedules on time, as they were able to continue to work and pour concrete when the weather was not ideal – temperatures typically average under 35 degrees in December and January.
More on the Special Olympics Yawkey Sports Training Facility next post.
ICFs and Cold Weather Concrete Part IV
December 15th, 2009 | From the Field, Lets Get Technical!
Here is our final post, for now, on insulating concrete forms and cold weather concreting. This is a testament from our regional sales manager, Thad. The pictures and story was described from a Colorado school job site in November, where insulating concrete forms were used as the exterior shell of the building and CMU blocks were used for the restroom areas. These notes and the pictures show a real life scenario of the benefits of ICFs.
Three observations of using ICFs and CMU
Thad points out three huge observations that communicate cold weather benefits of insulated concrete forms in relation to CMU.
- The General Contractor has to pay for any cold weather material that is used for CMU construction- including heaters, plastic tenting, blankets etc . If it is windy they will have to repair all of those elements as they whip around and become damaged due to the weather. The GC spends more money in order to continue to keep the job on schedule and for safety of the workers. The tent is heated so that they can grout the walls, which ICFs no grout is needed so tenting is eliminated.
- The mason contractor can bid both ICF and CMU packages.
- The masonry workers had to shut down the day Thad was there because it was too cold and the tent was destroyed throughout the day by high winds. Generally the crew would have to be sent home and a day of work is wasted. The ICF portion of the building was not effected by the cold or the wind and construction was still moving forward.
For more information on cold weather and concrete see our previous posts or access our insulating concrete form product manual where you can see all of the research and testing done on our product lines:
Insulating Concrete Forms and Cold Weather Concrete Part I
Insulating Concrete Forms and Cold Weather Concrete Part II
Insulating Concrete Forms and Cold Weather Concrete Part III
ICFs and Cold Weather Concrete Part III
December 10th, 2009 | From the Field, Lets Get Technical!
So far we have discussed the basics of using insulating concrete forms in cold weather, as well as broke down the main reactions and ideal temperatures for concrete to cure properly. Now we’ll go over how the insulating properties effect the minimum temperature concrete can be placed at. Also we’ll summarize some tips to result in strong concrete during cold weather.
Insulating Concrete Forms in sub-freezing temperatures
In order to keep the concrete at the desired temperature for the protection period, the concrete must be covered or insulated. This is where ICF construction in cold climates becomes an obvious benefit. The R-value of one panel of Reward iForm EPS is R-10. Assuming a cement content of 500 pounds per cubic yard and a wall thickness of 6 inches and interpolating from the graph below for R-10, the minimum ambient temperature for placing concrete would be around 10º F.
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Thermal resistance (R) of insulation required to maintain the concrete surface temperature of walls and slabs aboveground at 50º F or above for 3 days. Concrete temperature as placed 50º F. Maximum wind velocity: 15 mph.
Thermal resistance (R) of insulation required to maintain the concrete surface temperature of walls and slabs aboveground at 50º F or above for 3 days. Concrete temperature as placed 50º F. Maximum wind velocity: 15 mph.
Insulating Concrete Forms
Using ICF construction in cold weather means that vulnerable corners and edges are consistently covered and protected. Forms are left in place to keep moisture and heat contained for an extended period of time, improving the curing condition of the concrete. Additionally, the consistent insulation from ICFs allows for even heat distribution.
Not only is it important to insulate the top of the Reward ICF wall after concrete placement in cold weather, there are three other areas to be concerned with. These include footings, bulkheads and embedment steel. Placing concrete on top of a cold footing and around cold steel embedments can affect the concrete temperatures in those local areas. Precautions should be considered or taken for these areas. Bulkheads, much like the top of the ICF wall must be insulated as well.
Tips for strong concrete
• Keep forms covered before concrete placement if any precipitation is expected. This will prevent snow and ice from forming inside the cavity of the ICFs.
• Cover the top course after concrete placement in order to contain the heat produced and to insulate the top of the concrete wall. Rigid or batt insulation blankets of R-10 or greater work well for both covering the forms before concrete placement and for insulating the top of the wall after concrete placement.
• Work closely with a local ready mix supplier to determine concrete mix requirements for the specific project and climate.
• Do not rush a concrete pour late in the day or if bad weather is approaching. This can lead to problems.
CMU vs. ICFs during Cold Weather
Next week we will highlight a specific ICF school job we were at about a week ago, where they used CMU for a portion of the building and ICFs for the other. The pictures will tell the story.
insulating concrete forms
ICFs and Cold Weather Concreting Series Part II
December 8th, 2009 | From the Field, Lets Get Technical!
For Part two of our Cold Weather Concrete for ICFs series there are some key areas that effect chemical reactions when concrete cures.
Heat of Hydration
Concrete generates heat as it hydrates through a chemical reaction of the cement reacting to the water. The heat generated is affected by the dimensions or mass of the concrete, the air temperature, the initial concrete temperature, the water-cement ratio, the cement composition, the amount of cement and admixtures. The heat of hydration sometimes generates enough heat to provide adequate curing in cold weather.
Concrete Mixture
Concrete mixtures may be adjusted in cold weather to accelerate the curing time by using one or a combination of 1) Type III Portland cement – high-early strength cement; 2) additional Portland cement of 100 to 200 pounds per cubic yard; 3) chemical accelerators such as a maximum of 2% by weight of calcium chloride and 4) air-entrained concrete to help the concrete absorb stresses due to ice formation.
Temperature of Concrete
The recommended temperature of the concrete as mixed and as placed should be not less than what is shown in the table below. Mixing concrete to temperatures higher than 70º F can have adverse effects of shrinkage and cracking.
In order to get the proper concrete mix temperature you are trying to achieve, the aggregate, cement and water temperatures must be known and accounted for.
The concrete should be placed into the forms before the concrete temperature drops below 55º F as indicated in the table above. That temperature should be maintained for the duration of the protection period indicated in the table below. This maintains durability against exposure to freezing and thawing.
For Thursday we’ll address how the insulation effects the temperature of the concrete and explain exactly why ICFs are ideal for cold weather applications.
ICFs and Cold Weather Concrete Series
December 3rd, 2009 | From the Field, Lets Get Technical!
Since we are heading into the winter months now, we receive stories and pictures from guys in the field on how wonderful it is to build with ICFs during the winter months. If certain precautions are taken when building with insulating concrete forms (ICFs), concrete can be placed properly throughout the winter months even in cold climates.
ACI 306 is the standard used for placing concrete in cold weather. ACI 306 defines cold weather as a period when for more than 3 successive days the mean daily temperature drops below 40º Fahrenheit (F). Normal concreting can resume once the ambient temperature is above 50º F for more than half a day. Fresh concrete that begins to freeze can reduce the strength gain and its durability.
The next few posts in this series will look a cold weather concreting form a technical standpoint, showing pictures and proejct examples in the field, and will highlight the extra steps needed to do CMU construction during cold weather.
Cold Weather Concreting
The concrete mixture and its temperature must be adapted to the construction procedure during cold weather. This means making preparations to protect the concrete’s temperature from the cold air. The insulating concrete forms, reinforcing steel and concrete embedments must be clear of snow and ice when the concrete is placed.
Concrete strength gain is a function of the temperature at which it cures. Typical concrete compressive strengths are based upon the concrete curing at an ideal temperature of 72º F the entire 28 days. Temperatures higher than 72º F will shorten the curing time and temperatures lower than 72º F will increase the curing time. Concrete gains very little strength at low temperatures.
The concrete must be protected against freezing effects until the degree of saturation of the concrete has been sufficiently reduced by the process of hydration. This time corresponds to the time that it takes the concrete to attain a compressive strength of 500 psi. During normal temperatures, this time is usually within the first 24 hours of concrete placement. Significant strength loss of up to 50% can occur if concrete is frozen shortly after placement or before it reaches a strength of 500 psi.
Yes that it snow, not a white sand beach. This is an Air Force Base Reward did a few years ago in Alaska.
For Tuesday we will talk about the chemical reactions and properties of concrete that play a role curing concrete in cold weather.
Project Showcase: Waterside Concrete Curing Time
November 24th, 2009 | From the Field, Lets Get Technical!, Project Showcase, Unique Applications
As a followup to the previous post I wanted to highlight some additional in the field research Parks ICF Wall Systems was able to do to verify the notion that insulated concrete cures faster than exposed concrete with freezing cold temperatures outside.
During the Waterside Towers project, Parks ICF participated in a study that helped scientifically prove that concrete curing times are greatly accelerated in cold weather when placed in ICF forms versus when left exposed. The field tests showed the concrete reached the required 2,000 psi compressive strength in just 2 days versus 4-5 days with exposed concrete. Mr. Petersburg of Shield Engineering worked hand-in-hand with us on the project as a third-party engineering representative as we continued with sample testing on each floor before the flooring system was placed. Through this testing, Parks ICF was able to accelerate the project schedule by 10 to 15 days and help keep the other crews continuing with minimal down time.
“The incredible thing about working with ICF wall systems was its workability in cold temperatures and inclement weather. Working through what turned out to be one of the coldest and wettest winters in recent memory, we’ve experienced minimal lost days versus a potential of several weeks or months with traditional construction methods.” -Ted Kuerschen, Project Manager, Waterside Condos
“One of the great benefits we found working with ICF, especially in the winter, is that weather does not slow down construction as it does on standard job sites. Rain and snow did not affect placement of ICF block or of concrete. Being insulated with the foam, the concrete was able to retain its temperature even on the coldest of days of placement. Both laboratory and field cured cylinders were cast during the construction process. It was found that standard field cured cylinders broke considerably lower than core samples obtained from the poured wall. The strength of ICF cured test cylinders, giving a more realistic indication of on-site conditions, were more closely correlated to the laboratory cured specimens.” -Nathan Petersburg, Shield Engineering
Project Showcase: Waterside at Norris Lakes
November 19th, 2009 | Marketing, Project Showcase
Waterside Towers at Norris Lakes
Waterside Towers at Norris Lakes is one of the more recent projects that have been completed, especially of this size and significance. It was a sizable project, unique not just for the building materials and the location, set in in a peaceful getaway spot, but unique for the construction techniques and concrete testing the builder, Parks ICF Wall Systems, LLC performed.
The Waterside Towers, located North of Knoxville, Tennessee, presented many architectural challenges that were overcome by the strength properties of Reward ICFs. Designed to withstand seismic loads, the Waterside Towers utilized ICFs to provide extreme strength and resistance to environmental changes such as earthquakes and high winds that develop on the adjacent lake. The architect also used the noise reduction properties of ICFs for the interior unit, separation walls in order to keep noisy neighbors silent to condo owners. ICFs were also used in the elevator shaft to reduce noise transmission to the adjacent units.
Cold Weather Challenges Met
One of the greatest challenges faced by the crews of Parks ICF, on this project, was the weather. Having begun the project in October, their crews worked through the cold winter months to finish the tower in just over 3 months. The temperature dropped to just 22 degrees Fahrenheit during the project. Through the use of concrete accelerators and extensive compressing strength testing, our crews were able to finish ahead of schedule. (More on testing measures of concrete in later posts)
Waterside Towers Impact on Environment
Parks ICF Wall Systems, LLC is dedicated to protecting the environment and reducing the environmental impact of construction. The fragile ecosystems and undeveloped woodlands surrounding the Waterside at Norris Lake, sustains many different types of wildlife that can be greatly impacted by traditional construction methods. The profitability of the Waterside Towers depends on the the surrounding environment to bring in customers and tenants to the multi-hundred thousand dollar condos. Reward ICFs helped to minimize the effects on the environment and thus increase profitability. Also, in order to reduce emissions, the Towers minimized the size of their HVAC systems because of the energy efficiency of the ICF.
