Durisol: Insulated Concrete Form (ICF) Wall Forming System › lot_06 › design › DOWNLOADS › C... · 4" concrete slab 1" rigid insulation horizontal footing reinforcement 1/2"

Durisol Insulated Concrete Wall Form

Coldham Architects LLC

Durisol: Insulated Concrete Form (ICF) WallForming System

Bruce Coldham, Coldham Architects, LLC — www.coldhamarchitects.com

Affordable Comfort. - Westford, MAOctober, 2003


Coldham Architects LLC 2

An explanation of the material andassemble of the wall system

Four project case examples

A discussion of the properties of thewall system



Insulated Concrete Form (ICF) Material

• Shredded (recycled)“mineralized” woodmaterial

• Combined in acementitious slurryand pressed into a“wallform” block

• Mineral wool insulationplugs inserted into thecore



Below grade foundation walls

Above grade walls



First Course isset out preciselyon footing ……...by masons orcarpenters?

It is formwork, not abearing CMU wall.

• Use string line



Wallform blocks aredry-stacked

Wood biscuits to align the interior face•.



Door and window openings



Cutting wallforms



Steel reinforcing

• Steel reinforcingbars horizontallyand vertically



Wall Form Shoring

• Prevent corner blowouts

• Prevent uplift andleaking of horizontaljoints — but this materialis much heavier thanEPS blocks

• Align and stabilize thetop course



Fill core with concrete

• Pump placement — 3,000 psi and pea stone.

• We laid the wall forms to their full height andpoured the core in three lifts (circuits) in asingle pumping operation.



Wall finishes …. and air barrier



The wall form material acceptsmechanical fastening of wood and otherfurring materials using screw fasteners.

Exterior wall finishes



Waterproofing ………….•.



Supporting intermediate floors



Supporting intermediate floors

Ledgers bolted to the concrete core through5” diameter shear connectors



Lintels.. Header beams over rough openingsWallform create reinforcedconcrete lintels•.

Wrapped engineeredlumber beam ends inwallformed beampockets•.



Accommodating electrical circuitry



Materialproperties:



A reliably well insulated masonry wall

Insulation value — R 8 to 20

Theoretical insulation value is achievable without requiringheroic oversight

Material properties:



A non-combustible wall assemblyMaterial properties:

••Surface Burning (ASTM-E84)Surface Burning (ASTM-E84)

––Smoke Developed: 11Smoke Developed: 11

––Flame Spread Index: 0Flame Spread Index: 0

••UL/ULC (S101)UL/ULC (S101)

––4 hour rating4 hour rating



The “breathability” of the wall system, particularly with a lime-based plaster applied to the interior walls, which maintains the wall’s moisture permeability. The exterior wall acts as something of a humidity reservoir with excess humidity taken up by the exterior walls and released back to the interior as interior RH levels diminish.

Air and vapor permeable — affording a vaporstorage potential

––Vapor PermeabilityVapor Permeability••20.5 (dry) - 26.5 (100%RH)20.5 (dry) - 26.5 (100%RH) ng ng / (Pa s m)/ (Pa s m)••14 (dry) - 18 (100%RH) perm - inch14 (dry) - 18 (100%RH) perm - inch

––Vapor Vapor PermeancePermeance••1.75 imperial perm for 81.75 imperial perm for 8”” block block••400 - 800400 - 800 ng ng/(Pa s m/(Pa s m22) per 50 mm) per 50 mm




No capacity to "lift" moisture throughcapillary action — in thewallform material

… meaning that thewallform material is afree draining medium


No propensity tofreeze-thaw damage



Completely non-biodegradable wall systemMaterial properties:



Unable to support the growth ofmolds and mildew


The cementitious matrixis too alkaline

Not attractive totermites, but wallforminterstices appear toallow passage fortermites.



Sound absorbent

sound attenuation propertiesespecially useful in largeinterior multi-use space.(Leave Durisol materialunfinished above 7’)


Noise reductioncoefficient — 0.70 to0.95



The wall form seemsappropriate use of themixed hardwood forestproduce of the USnortheast, whichotherwise has limiteduse in building.


Regionally appropriate material ?



Small, Timber Framed House — Francestown, NHCompleted: 2002Building Area: 1,500 s.f.Wall system cost: $11/ s.f.

Design requirements:

Robust, durable supportcomplement for a timberframe



Concentrate the frameinvestment overhead — leta less expensive (and moresuitable) material be thewall





In this instance, thewallforms were laid up on aconventional concretefoundation wall



Great Barrington House — Gt. Barrington, MA

Design requirements:Interior floor flowscontinuous to the exterior.

Durable substrate forvegetated walls

Completed: 2001Building Area: 3,500 s.f.Wall system cost: $12/ s.f.



2'-0" OVERHANG

HARDWOOD WINDOW SILL

3/4" PLYWOOD

5/8" GYPSUM WALLBOARD

5/8" GYPSUM BOARD OVER POLY. AIR / VAPOR MEMBRANE

2 X 10 WALL PLATES

EXTERIOR STUCCO

METAL ROOF

CONCRETE INFILL

WOOD ROOF TRUSSES @ 24" o.c.

1 X 3 FURRING @ 16" o.c.

SELECT PINE TRUSS RAFTER

VENT ROOFING FELT

MINERAL WOOL INSULATION INSERT - 80mm

3/4" C.D.X OR OSB ROOF SHEATHING

1 X 4 WOOD BASEBOARD

1 X 6 WHITE CEDAR T&G BOARDS

5/4" X 2" WHITE CEDAR

DURISOL BLOCK - 300 mm THICK

#4 HORIZONTAL FOOTING REINFORCEMENT

#4 DOWEL BAR

9" X 20" CONCRETE STRIP FOOTING

1 X 3 WOOD SILL APRON

DAMP-PROOF MEMBRANE

WINDOW BLOCK

1/2" DIA. ANCHOR BOLT @ 48" o.c.

1" RIGID INSULATION

SEAL AIR / VAPOR MEMBRANE TO WALL PLATE

4" CONCRETE SLAB

6" FOOTING DRAIN

WATERPROOFING(BELOW GRADE)

#4 BAR VERTICAL REINFORCING

#4 BAR HORIZONTAL REINFORCING

1/2" DIA. ANCHOR BOLT @ 16" o.c.

9 1/2" TJI JOISTS

3/4" SUB-FLOOR

2" CONCRETE TOPPING SLAB (FINISH FLOOR)

5/4" X 14" WOOD FRIEZE BOARD

R-40 (12") BLOWN-IN CELLULOSE INSULATION

4" CONCRETE SLAB

1" RIGID INSULATION

HORIZONTAL FOOTING REINFORCEMENT

1/2" DIA. ANCHOR BOLT @ 16" O.C.

DOWEL BAR

1 1/2" RIGID INSULATION THERMAL BREAK


HORIZONTAL REINFORCING


CONCRETE STRIP FOOTING

6" FOOTING DRAIN

VERTICAL REINFORCING


2 X 3 STRAPPING

DAMP-PROOF MEMBRANE

2" CONCRETE TOPPING SLAB (FINISH FLOOR)3/4" SUB-FLOOR

9 1/2" TJI JOISTS

S.I.P. - 5 1/2" RIGIDINSULATION (EPS) W/1/2" STRESSED SKIN OSB,BOTH SIDES

4" CONCRETE SLAB

1" RIGID INSULATION

HORIZONTAL FOOTING REINFORCEMENT

1/2" DIA. ANCHOR BOLT @ 16" O.C.

DOWEL BAR

1 1/2" RIGID INSULATION THERMAL BREAK

HORIZONTAL REINFORCING


CONCRETE STRIP FOOTING

6" FOOTING DRAIN

VERTICAL REINFORCING

DAMP-PROOF MEMBRANE

2" CONCRETE TOPPING SLAB (FINISH FLOOR)3/4" SUB-FLOOR

9 1/2" TJI JOISTS

WOOD SHINGLES OVER BUILDING WRAP MEMBRANE



2X6 WALL PLATESWOOD SHINGLES OVER BUILDING WRAP MEMBRANE

WOOD FRAMEWALL - 2X6 @ 24" O.C. W/ 1/2" OSB SHEATHING

7" CELLULOSE INSULATION

2X6 WALL PLATES

ELEV. MALE - 96'-8" FEMALE - 99'-1" T.R. - 99'-4"

ELEV. MALE - 105'-3" FEMALE - 107'-8" T.R. - 107'-11"


Wall system design options:

Durisol I.C.F.

Conventionalstud frame onconc. foundationwall

S.I. P. on conc.foundation wall



Wholefood farm store — Ghent, NYCompleted: 2003Building Area: 9,000 s.f.Wall system cost: $16/ s.f.

Design requirements:Rodent exclusionSound absorption



Wholefood farm store — Ghent, NY










Cement substitution— ’Gran Cement’



Vipassana Meditation Center — Shelburne, MA

Design requirements:

Durability — “ abuilding that wouldlast 100’s of years”

Completed: Project abandonedBuilding Area: 30,000 s.f.

Non-combustibility —a large building in anisolated setting

Multiple accessibility— many on-gradeexits and entries

Conform to a slopingsite



Vipassana Meditation Center — Shelburne, MA

Design opportunity:

Use the insulatedmass of the structuralenclosure to carry thebuilding whilst theheating system isentirely serving theDHW need.

The space heating and theDHW loads were similar inmagnitude.Therefore a 50% reduction inheating system capacity waspossible.



The Durisol Corporationwww.durisol.com

[email protected]

www.coldhamarchitects.com



Material Properties

• Modulus of Elasticity (ASTM C513)

– E=1500 MPa compression

• Modulus of Rupture (ASTM C293)

– 1.0 to 3.0 MPa

• Ultimate Compression Strength (ASTM C513)

– 1.5 to 3.0 MPa

• Shear Strength: > 0.2 MPa

• Durisol to Concrete Bond: > 0.6 MPa




Documents

Durisol: Insulated Concrete Form (ICF) Wall Forming System › lot_06 › design › DOWNLOADS › C... · 4" concrete slab 1" rigid insulation horizontal footing reinforcement 1/2"