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.

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Finished Insulated Concrete Form Ledge Corner

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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.

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

We visited the theater last week with Chris P of Construction Supply Centers.  They are progressing quite nicely now.  The various aspects of finish work are well underway and it’s really starting to look like a theater now.  Tim Boos, Project Manager with Warfel Construction said they had had some delays with the weather and were expecting to be ready to open the before the first week in June.

When walking through the individual theaters there is a unique “quietness” to them which is easily attributed to the mass of the insulating concrete forms walls.  There was no need for any sort of spray foam on the walls dividing the individual theaters because of the use of Reward’s iForm.  We would presume that was a significant savings in terms of labor and materials for the owners.  The painters were in, touching up the main corridors and lobby area and there were contractors setting the big decorative columns in the main lobby. There’s a nice restaurant area in the front which will be an excellent convenience for the patrons of the theater.

We are looking forward to visiting the theater when it’s completed and excited for the Frank Theatre’s upcoming Grand Opening.   Here are some follow up pictures with the exterior getting closer to completion, taken back in January.

1. Concrete Mix for ICF
2. Placement of Concrete for ICF
3. Consolidation in ICF

Concrete Consolidation

The concrete placed into the Reward walls needs to be consolidated.  Consolidation is required to prevent voids, prevent honeycombing and to ensure that there is solid contact made between the concrete and the steel reinforcement.  It is important to consolidate the concrete during each concrete lift.  Consolidation can be accomplished by using internal vibration.

We do not recommend other types of consolidation as they are not as effective and the iForm can handle internal vibration.  The Reward iForm has plastic webs 6 inches on center making the form very strong for concrete placement and consolidation.  Additionally with the webs 6 inches on center, there is less EPS foam area being supported by each webs making the form strong during concrete placement and consolidation. This results in a very consistent flat wall with no pillowing or bulging at the horizontal and vertical seams that is typical with forms that have ties 8” or greater on center.

Internal Vibration

This is the best method for consolidating the concrete.  A light-duty pencil with a maximum 1″ diameter head size, the lowest frequency or revolutions per minute, a lower motor size of 3/4 to 1 maximum horsepower and the shaft length to meet the wall height vibrator is recommended. The head can be either the squared headed or round head. Darryl U prefers the square head vibrator. The concrete should be stung on each lift and in such a manner that the multiple lifts should be boned together. This can be accomplished by internally stinging thru the current lift and just into the previous lift by a few inches 6” approximately, thus bonding the two together.

Do not use an internal vibrator unless it meets these guidelines.  Consolidation using internal vibration method should be done with care to avoid placing excessive internal pressure on the forms.

In order to achieve the best results when using an internal vibrator, it is important to place the head of the vibrator into the concrete fast and remove it slowly from the concrete.  This will do the best job of removing the entrapped air from the fresh concrete.  Once the head is in the fresh concrete it should be moved slowly but consistently through the concrete.

Around areas of high reinforcement concentration special attention should be given to ensure proper consolidation of the concrete. The rule of thumb for stinging concrete is steady and deliberate when stabbing into the concrete and withdrawing at approximately 1’ per second. The rate of withdraw of the vibrator is also determined by the release of entrapped air in the concrete. and loosen the amounts of congestion inside the form at any given area. Caution should be taken so the vibrator doesn’t touch the sides of the forms. The frequency and amplitude will determine the spacing between the insertions and the rate of withdraw also.

In summary, all three of these aspects must be monitored for each pour. Internal vibration is a must to ensure that the concrete inside of the form work be consolidated to achieve structurally sound walls. These are only guide lines as experience will play into the methods of good technique of internal vibration.

One thing to stress. The most important element of all three is the proper concrete mix. If the mix shows up at job-site at a level not specified…REFUSE the concrete and send it back.

Insulated Concrete Form Concrete Placement

The concrete should be placed in 4′-0″ lifts to ensure proper concrete consolidation.  Typically if there is more than one concrete pour per project, the walls are poured a story at a time.  Concrete is placed in 4′-0″ lifts using several passes around the perimeter of the building plan until either the top of the wall is reached or until the first pour is completed.  Concrete should be placed below every window opening through the opening left in the sill of the window buck.

Most Reward builders have found that an overhead boom pump truck is the most efficient method to place the concrete in the Reward walls.  With the overhead boom pump truck it is important to slow the velocity of the concrete by reducing the diameter of the hose to 3″ near the end of the line.

During placement, the ICF contractor must keep a close eye all the time on how the concrete is flowing through the forms and around rebar.  Be sure the concrete is not getting hung up on rebar or any embedments.

During cold and hot weather, the concrete mix may need to be adjusted to modify its flowability and the rate of concrete placement may also need to be adjusted.

Next post we will cover the actual concrete consolidation and use of internal vibrators with insulating concrete forms.