A few months ago we met a group of architects and designers that attended our Green Building Enclosure Design Conference in Minnesota, and since then asked us to host the Iowa Chapter American Institute of Building Design monthly education seminar. So we set up shop upstairs in our office and were able to give our two newest presentations, hands on product demos, and they were able to meet our engineer (Kelvin D), our product application specialist (Darryl U), and our architectural presenter (John O).

New Advanced Insulated Concrete Form Education

These are the two other presentations we gave them, all which go deeper into specifically designing with insulated concrete forms and the science to WHY building with ICFs improves a building’s performance.

Design and Construction using Insulating Concrete Forms (ICF)

Summary: Attendee with become familiar with the basic concepts of using ICFs in the construction and design of a building, including installation techniques, structural performance comparisons, and explaining common details in regards to connections, penetrations, utilizes, finishes and waterproofing. AIA: 1 HSW and SD

Building Performance with Insulated Concrete Forms (ICF)

Summary: Attendee will learn how the inclusion of ICFs affects the performance of a facility, with an emphasis on thermal and moisture issues. Topics will cover air quality and condensation principles of ICFs versus traditional construction, introductions on specific energy modeling tools and familiarization of how finishes can affect the performance and life cycle costs of the facility. AIA: 1 HSW and SD

New ICF Professionals

After a couple hours in our office the Iowa chapter of the AIBD is now more familiar with ICF, how to design with them and how to better incorporate them in their current designs. If you and your firms would like to be educated in how to expands your expertise and being able to confidently offer your clients the access to insulating concrete forms call us and lets get it scheduled.

If you are looking more for an intro course to ICFs find our basic course online for free at AEC Daily.

A metal lath is fastened directly to the Reward formwork to hold the stone to the wall and withstand the dead weight.  The lath is fastened to plastic furring strips that are located every 6 inches on center.  The 1 ¼” wide furring strips are embedded into the EPS foam plastic panel and are recessed ½” from the foam face.  They are marked on the foam panel for location.

Reward recommends a sharp pointed, corrosion resistant course thread screw.  Typically a #6 to #10 screw approximately 1 ¼” to 1 ½ inches in length is common.  A screw with a lath washer is recommended to ensure that the lath is fully secured.  Nails or staples are not recommended.

Reward has tested different fasteners for both direct withdraw and also for lateral resistance from the plastic furring flanges (see fastener test results).  The direct withdrawal value is used to calculate the fastener spacing to withstand lateral loads from wind pressure and seismic loads.  The lateral resistance test result is used to calculate the fastener schedule to withstand gravity dead loads such as the self weight of the stone.  The ½” recess distance was included in the test.

The test results in the Reward test summary report are all shown as ultimate loads.  A safety factor must be applied to each of these ultimate values for designing the fastener schedule to withstand the project specific design criteria.  The Reward ICC ES evaluation report, ESR-1552, lists a select few of the tested fasteners.  The values in the ESR-1552 report are allowable loads and already include the safety factor.

Once the screw to be used for attaching the metal lath is determined, the fastener schedule must be determined utilizing the tested direct withdrawal and lateral tests.  Consult the design architect or structural engineer for applying these tested values to the project’s design criteria.

For example, if the design wind and seismic load is 25 psf and the allowable direct withdrawal of the screw is 50 pounds.  The fastener spacing should be no greater than 2.0 square feet.  Similarly, if the dead weight of the manufactured stone is 15 psf and the allowable lateral value of the screw is 45 pounds, than the maximum fastener spacing is every 3.0 square feet.

The steps beyond the lath attachment to the Reward ICF wall are the same according to the manufactured adhered concrete masonry veneer’s manufacturer’s requirements.  Follow the stone veneer manufacturer’s installation procedures.

Avoiding Drywall Joint Cracks

It is very important to fasten drywall properly and to control and monitor the interior humidity and temperature once the Reward ICF walls are stacked, the concrete is placed, and the building envelope is enclosed.

New construction has new materials and the materials typically have some amount of moisture. The Reward ICF wall also has fresh concrete that is going through the curing process. As the moisture from the concrete wall and new materials vaporize, it increases the humidity levels inside the building’s shell.

Controlling Humidity and Temperature

When the drywall is fastened to the interior walls it is critical to control and monitor the humidity level and keep the interior at a constant temperature. If the humidity is not controlled under certain conditions, the water vapor exiting the ICF concrete wall could eventually lead to drywall cracking along the drywall joints. The drywall joint is a weak link consisting of drywall joint compound and joint tape. Moisture can potentially cause the drywall to swell leading to joint cracking.

If the humidity and temperature is not controlled properly after the building is enclosed both before and after occupancy, the moisture can lead to drywall cracks.

It is recommended to control and monitor the humidity and temperature both during construction after the building is enclosed and after occupancy. Moisture will continue to evaporate for up to the first 12 months of occupancy. If the humidity is not controlled it could lead to condensation on windows and moisture creating problems with different materials.

Fastening the Drywall

Typically the drywall is hung horizontally with the longer side (i.e. 8’ or 12’) of the drywall running horizontal and the short side (4’) running vertical.  There are two types of joints – a butt joint and a tapered joint.  The drywall edges are tapered on the long sides (i.e. 8’ or 12’) and the drywall edges are square cut on the short sides (4’).  Therefore the taper joint runs horizontally and the butt joint runs vertically.

The drywall must be attached to the Reward ICF wall using a #6 or greater sharp point course thread drywall screw spaced as required by the applicable code but no greater than 30 inches apart both horizontally and vertically.

The horizontal tapered joint can be fastened up to every 6 inches on center and should not exceed 30 inches on center.  Reward recommends a maximum fastening spacing of 24 inches on center equal distance across each 48 inch long form.  This places two fasteners horizontally along each ICF form.

The vertical butt joint should be placed either equal distance over the 1 ¼” wide plastic furring strip or at midpoint between two plastic furring strips.  Avoid having one sheet of drywall extending past a plastic furring strip more than the other sheet of drywall.  Preferably Reward recommends using two screws spaced equal distance per each 16” height course of Reward ICF forms.  In addition to fastening the drywall with screws, it is recommended to run either a bead of glue or spot glue using a compatible glue along each side of the butt joint within an inch or two of each drywall edge.

Control Joints

Gypsum wallboard is subject to some form of movement induced by changes in moisture and temperature just like any other building product.  Control joints are necessary in walls to relieve the stresses that occur from this movement.  Control joints are added to prevent cracking in gypsum wallboard due to movement.  Control joints should be incorporated in 30 foot intervals.  ASTM C 840 and GA-216 are two standards where the requirements for control joints are addressed.

Summary of ICF Movie Theater

This 13-plex movie theater was completed in about 10 months. The 13-Plex was able to stay on schedule and was ready in time for the scheduled Grand Opening. STC testing was done on-site to show the soundproofing properties that the owner was looking for.

Features and Facts:

• 210,000 total square feet
• 72,000 square feet of ICF wall
• 36-foot above grade walls
• ICF exterior and demising walls
• 13″ insulated concrete forms with ledge form- iForm
• Brick and TAFS exterior
• ICF Distributor: Construction Supply Center
• Architect: ADW Architects
• General Contractor: Warfel Construction
• ICF Installer: Rubright Construction

There you have it folks! We have a couple more theaters around the country we have done and have a few more in the works as well. Be sure to check out our insulating concrete form gallery of projects to see the versatility of Reward ICF wall systems!

If you are looking to start building with ICFs or already have ICF construction in mind, we offer on site consultation and field training, along with an education course to get you and your team familiar with insulated concrete forms.

Onsite Training

Reward Wall Systems, Inc requires all new customers who are building with insulating concrete form for the first time to sign up for onsite training. When it comes time to build your ICF project, an experienced Reward building consultant (if you’re lucky it will be Darryl U!) will come directly to you jobsite for up t three days to offer guidance and advice for you and your crew. The Reward trainer is prepared to show you all the steps for correctly and efficiently installing forms and placing concrete.

Cost

The standard onsite training package has a small nominal fee for a three day session. This fee is to cover costs for our ICF trainer’s travel and food expenses. All training can be customized to meet varying needs, based on the scope of the project. Whether you prefer onsite help with the footings to the ceiling, or just want an onsite specialist on hand for the initial concrete pour- our trainers are ready help.

What is included?

Pre-construction consultation - Once you have scheduled your training, the Reward trainer will call you to be sure you have the proper tools and that the site is prepared to make the best use of his time upon arrival. Discussion will be made on if there are any specific areas of attention for our trainer to prepare for.

Onsite training - The Reward trainer will teach you and your crew proper and efficient installation techniques throughout the wall installation process including:

• Stacking forms
• Reinforcement
• Bracing
• Aligning
• Door and window buck placement
• Placement of concrete

Post-Construction follow up – After the jobsite training has been completed, the Reward trainer and all of our support staff will be available to answer further questions by telephone and e-mail until your project is finished.

ICF Training Benefits

This valuable service will shorten your crew’s learning curve for installing ICF walls. Installation experience and expertise are necessary to be a successful user of insulated concrete forms. Your trainer can show you installation techniques and shortcuts that will save you time and money in the field. The trainers shared experience and skills will help you to avoid costly mistake and ensure your first project goes up smoothly.

At Reward Wall Systems, we don’t just sell you the insulating concrete forms and walk away. Through our Solid Support program we provide you with the tools you need to be successful. Reward also offers a comprehensive technical manual, AutoCAD drawings, ICF BIM objects, and estimating software in addition to technical support that is always just a phone call away.

Call us at 800-468-6344 to get a quote on your customized onsite training package.

ICF Construction- Inside Ledge Corner

Line up the ties and allow for room to make a cut

Draw 45 degree angle from the ledge and draw cut lines

Make the Cut

For the perpendicular Ledge Form that will connect the corner- measure the 45 degree to the outside corner apex. Next, make a square cross cut on the outside panel at the inside core wall.

Once corner is cut you will have to remove the teeth directly in the corner, so a 90 degree can fit snugly on top.

No need to dig out the corbel or bend xLerator as concrete will flow correctly and ledge will be properly reinforced

And Congratulations you have completed the Mitering an ICF Ledge Corner Tutorial. If you have any questions leave us a comment or give us a call!

xLerator Ledge Reinforcement

The xLerator is used to reinforce the ledge form and must be cut and bent to form 90 degrees.

1. Cut the tab that sticks out from the spreader bar on the corbel side & eliminate about 1 ½”.
2. Jump over that spreader bar on the same side as you just cut and cut between the cross piece you save and the next cross bar removing approximately 5” of material.

Bend the cross piece  45 degrees. See detail 6-05 in the Reward ICF Product Manual for further description.

Repeat those steps on another xLerator, on the opposite side so they fit nicely on top of each other and provide reinforcement everywhere there is concrete.

icf

Finished Insulated Concrete Form Ledge Corner

icf

So our final post on the ICF Corner Ledge series we be showing how to do the inside miter cut for insulated concrete form ledge corner walls!

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 next post on our Mitering a Ledge Form Series part IV 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)

Miss a couple steps? Start from the beginning!

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.