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January/February 2014
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The Insulating Concrete Forms Magazine
2014 Industry Forecast
Unlimited Residential Winners
Trade Show Previews
Comparison Chart
$4.95
2 ICF BUILDER
January/February 2014 3
Inside This Issue
10
Features
10 Trade Show Report and Preview
20
22
26
A report on Greenbuild 2013, as well as what to expect at the International Builder Show and World of Concrete, both of which will be
held this year in Las Vegas, Nevada.
20 Project Profile: Best Development
While most ICF builders were struggling to survive the Great Recession, one Canadian builder built out a 76-home development in the
2008-2012 timeframe, selling nearly all of them at full price.
22 Comparison Chart and Explanation
The ICF Comparison Chart is back again, along with a list of EPS decking options. The charts are introduced by a concise, illustrated guide
to explain which form is best for your project.
26 Project Profiles: The Unlimited Residential Winners
These amazing custom homes—each with more than 10,000 sq. ft. of living space—are beautiful, functional and certified by LEED as
earth-friendly.
26 Casa Bella Verde
30 NY EcoLuxury Home
32 Silverleaf House
36 2013 ICF Market Report and 2014 Industry Forecast
As residential and commercial construction picks up, green building continues to boom. The ICF market is considerably different now than
it was 12 months ago.
40 A New Hope for Generic ICF Promotion
By Ross Monsour
Departments
6From the Mailbag
8As I See It: Pick Your Battles
12 Builder Awards
14 ICF News Roundup
42 New Products
44 Design Perspectives: Can ICFs Cost Less than Frame?
By Robert Klob
4 ICF BUILDER
On the Cover: Silverleaf Home,
built with Arxx ICF on the outskirts of
Scottsdale, Ariz., blends the timeless look
of Spanish Colonial with cutting-edge ecofriendly design. See story on p. 32 .
Photo by Michael Duerinckx
Advertising
Craig Shorts
ICF Builder Awards
Thank you for all the work you and your team did on the awards…We appreciate
the extra time and any stress that you and your team had because of completing
the awards. Thank you for the presentation last Wednesday. You did a great job at
describing all the projects! We are super grateful!
Sandy Esterle—Safe Harbor Design Build LLC
Thank you so much for creating such a wonderful opportunity for all of us to
showcase our projects. You have an incredible magazine, and we are so very honored
that our project was selected your first place winner. We are over the moon with pride
and excitement!
Briana Noelle—Casa Bella Verde
I want to thank you again for all that you do for the ICF industry. Also, thanks for
recognizing all the outstanding work that goes on in the industry by holding the awards
banquet every year, what a great time.
Rod Fetters—ICF Specialist
We were part of the winning team in the multi-family division. I must say, I had
a great time at the reception during the WOC a few weeks ago and met some very
interesting people.
Mike MacCormack—BMR Structural Engineering
September Issue
The latest issue is a giant. Congratulations… Rob Klob's article in the last ICF
Builder was a rude awakening for me. I was stimulated to the realization that the
key to reinforced concrete disaster-resistant houses will be in the residential codes,
not in selling virtues…The International Residential Building Code is an absolute
catastrophe for disaster-resistant houses. If tornadoes tell us anything, it is that no
wood-framed roof in the world, has ever, or will ever, survive a big wind. Reinforced
concrete roofs, properly designed, will absolutely do so. …As long as the code allows
destructible roof systems in the zones of tornadoes, hurricanes, firestorms and
earthquakes, the manufacturers of ICF roof planks may seldom see the opportunity
in the single family house market — probably one of the largest potential construction
markets out there.
Joe Warnes—CPM Engineering
craig@icfmag.com
Editorial Director
Clark Ricks
editor@icfmag.com
Circulation Manager
Monica Hall
subscribe@icfmag.com
Art Director
Jason Robinson
Webmaster
Brad Moulton
Contributing Editors
Robert Klob
Ian Giesler
Pieter Vanderwerf
Cameron Ware
Contributors
Briana Alhadeff
Bruce Anderson
Michael Duerinckx
Shelly Faye
Joe Hendricks
Ross Monsour
Nicholas Nikiforuk
Keven Stratton
Summit Publishing
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Mapleton, UT, 84664-3761
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Email the editor with your comments at editor@icfmag.com, or write to us at:
ICF Builder Magazine • 884 East 700 North • Mapleton, UT, 84664
Be sure to include your name, address, and a daytime telephone number. Letters may be edited
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stamped envelope.
6 ICF BUILDER
Volume 10 Number 1
ICF Builder magazine is published bi-monthly: January,
March, May, July, September, and November by Summit
Publishing, LLC, 884 East 700 North, Mapleton, UT, 846643761. Subscription price: $30 per year.
Copyright© 2013 by Summit Publishing. All rights reserved.
Printed in the USA. ICF Builder is a trademark of Summit
Publishing.
As I See It
by Clark Ricks
Pick Your Battles
The email was flaming. “I am frigging outraged,” it read, “and
am wondering why I have been busting my butt for a bunch of
industries showing the vision of a snail.” Fortunately, the vitriol was
not directed at me. Nor was it directed at ICFs. He was blasting the
concrete industry in general.
“Resilience” is the new buzzword, thanks to storms causing
billions of dollars of damage to the U.S. virtually every year.
Resilient construction was a big topic at the 2013 National
Hurricane Conference, and it’s going to be a big topic at the 2014
event being held in Orlando this April. Yet despite the more
than 100 exhibitors, not one is promoting concrete construction,
and that’s what has my friend so upset. (No one from this sector
exhibited or presented at the 2012 or 2013 shows either.)
“It is starkly interesting,” he writes, “that there were absolutely
zero exhibitors from the cement and concrete industry. Not a single
ICF company, not a single precast concrete company… or a single
cement- or concrete-related trade association.”
It’s obvious that the ICF industry does not have enough
resources to be everywhere at once. Nor does the larger concrete
8 ICF BUILDER
construction industry. It’s almost cliché that
in order to win a war, the fighter must “pick
his battles,” concentrating resources on those
he can win.
Can we transform building across the U.S. and Canada
overnight? Probably not. But this is no excuse for abandoning the
fight. We absolutely can make significant changes to the building
industry, especially in regions where ICFs already have a toe-hold.
(Look at school construction, for instance.) This issue provides the
most accurate look in years at where the industry really stands, and
the opportunities and challenges it faces. It also provides a close
look at how construction teams on three stunning ICF projects
created maximum publicity and broader acceptance for the entire
industry. If your client is looking for resiliency, sustainability, or
energy efficiency, make your stand. That’s a battle we can win.
Trade Show Corner
Greenbuild 2013
The annual Greenbuild tradeshow
took place Nov. 20-22, in Philadelphia, Pa.
It attracted about 25,000 attendees, with
room for 1,000 exhibitors.
Last May, Hanley Wood announced
that it had acquired the Greenbuild
Conference and Expo from the U.S.
Green Building Council (USGBC), and
this year’s show was significantly different
from the others. For instance, in past
years education sessions were the primary
focus of the event. But the new owners
dramatically increased access to the exhibit
hall this year, and made sure no competing
events were held for four consecutive hours
on Wednesday and Thursday.
In past years, ICFs have had a
heavy presence, but this year only three
manufacturers exhibited: Nudura, Amvic,
and LiteForm.
10 ICF BUILDER
Next year’s event is already scheduled
for late October in New Orleans.
Construct Canada
25
As this magazine was going to press,
Canada’s largest construction tradeshow
was getting underway at the Toronto
Convention Centre in Ontario, Canada.
Held Dec. 4-6, the 2013 event is anticipated
to be even more successful than last year’s
show, which attracted more than 25,000.
The 25th edition of Construct Canada
offers more exhibits, special features,
enlightening seminars and networking
opportunities for success.
More than 1,050 exhibits have
been reserved. Most of the major ICF
manufacturers are represented (Amvic,
Fox Blocks, Logix, Nudura, Plasti-Fab,
and Quad-Lock) as well as commercial
installers (Pro ICF) and makers of specialty
ICF products (Cosella, Soprema, etc.)
Construct Canada is held concurrently with Concrete Canada and the National
GreenBuilding Conference, and features
more than 200 presentations by 450 speakers delivering the very latest in technology,
best practices and applications for constructing all types of buildings.
World of Concrete Preview
World of Concrete 2014 will run
January 20-24, 2014 at the Las Vegas
Convention Center, which has hosted the
event since 2003. Organizers are expecting
the 2014 show to be slightly larger than the
2013 event, which attracted an estimated
55,000 attendees.
World of Concrete has several dozen
booths directly related to the ICF industry,
with form manufacturers, bracing, buck,
exterior finish and waterproofing companies all planning on setting up significant
exhibits. Most ICF-related booths are
located in the North Hall, including this
magazine, located at N2251. A few ICF
manufacturers are holding their annual
distributor meeting in conjunction with
the show, as well.
WOC offers a number of ICF-related
educational courses and events. The biggest,
of course, will be the presentation of the
ICF Builder Awards, which attracts over
300 of the most influential personalities in
the industry. Many of them claim it’s the
best networking opportunity of the year
(see story next page).
For more information about World of
Concrete 2014, visit www.worldofconcrete.com.
For more information about the ICF Builder Awards, visit www.builderawards.com.
IBS Preview
The National Association of Home
Builders’ (NAHB) International Builders’
Show is back in Nevada for 2014, running
February 4-6, 2014 at the Las Vegas
Convention Center. The show focuses on
residential homebuilding, with an emphasis
on high-end custom homes. Usually a
half-dozen of the largest ICF companies
exhibit, and this year is no exception.
Amvic, BuildBlock, Fox Blocks, LiteForm,
Logix, and Nudura have all reserved space,
along with many other names familiar to
readers of this magazine, such as Hambro.
As in previous years, IBS has built
a showhome to demonstrate the latest
building technologies. For the first time in
five years, no ICF technology is used in the
2014 New American Home.
The show also features a series of
educational seminars, including more
than a dozen on green building. However,
none are specifically geared
towards ICFs.
2013 ICF
Builder Awards
The biggest ICF event of the year is taking
place Wednesday, Jan 22nd in Las Vegas,
Nev. Held in conjunction with the World of
Concrete trade show, the ICF industry will
be honoring its best installers and builders
at the 9th annual ICF Builder Awards.
“This has become a can’t miss event,”
says Clark Ricks, organizer of the event.
“Industry executives, innovative builders,
and prospective customers gather from
literally across the globe to be at the
presentation. It’s the best opportunity to
come together, unwind, network, and learn
about what’s new in ICF construction.”
Attendees are eligible to win significant
door prizes, including an entire crate of
quality steel turnbuckle bracing courtesy of
Giraffe Brace.
As this issue goes to print, judges
are poring over the flood of entries that
represent the best of the best. The winners
were notified in early-December.
Platinum
Sponsor
Gold
Sponsor
Silver
Sponsor
12 ICF BUILDER
The award presentation will be held at
the same location as last year: Room N256
on the second floor just outside the north
exhibit hall. Recognizing the busy schedule
most show attendees have, the event will
begin immediately after the show floor
closes Wednesday.
The VIP reception begins at 4:30;
doors open to guests at 5 p.m. Complimentary drinks and hors d'oeuvres will be
served. The presentation will begin at 5:20
and will wrap up by 6:15.
“We want to make it convenient,
comfortable, and enjoyable for everyone
who wants to attend,” says Ricks. “We'll
conclude the presentation in plenty of
time for you to take your client—or
the new contact you just made—out
to dinner.”
For more information about
the ICF Builder Awards, visit
www.builderawards.com.
In The News
Fox Blocks ICF to Acquire Reward
Wall Systems
On November 15, Fox Blocks ICF—a
division of Airlite Plastics Co.—announced
that it has reached a deal to purchase “select
assets” from Reward Wall Systems. The
acquisition, which will be finalized in midFebruary, merges two of North America’s
leading brands of insulated concrete forms.
Terms were not disclosed.
Mike Kennaw, vice president of Fox
Blocks says, “This acquisition reflects Fox
Blocks’ commitment to the ICF market.
By gaining scale and volume, we hope
14 ICF BUILDER
to… expand our footprint in the North
America market at the same time that we
help expand the industry’s footprint in the
broader construction products market.”
He adds that the company “pursued
the acquisition opportunity as a way to
expand customer access to innovative green
building solutions.”
Reward Wall Systems is a pioneer in
the ICF industry, beginning operations in
1988. It was one of the first companies that
promoted ICFs to the heavy commercial
market, and has well established
relationships with contractors, design
professionals and owners. In the early years
of this century, most of North America’s
biggest, tallest, and most demanding ICF
projects were built with Reward.
Airlite Plastics and Reward Wall Systems, Inc. are both headquartered in Omaha, Nebraska where the companies have
enjoyed a long-standing business relationship. In fact, Airlite Plastics was introduced
to the ICF market as a contract molder for
Reward. They produced forms from 1996
until 2008 when Airlite began molding
their own Fox Blocks ICF product lineup.
“Reward has done an excellent job of
growing the residential and commercial
ICF market,” explains Brad Crosby,
president and CEO of Airlite Plastics
Co. “We're excited about the opportunity
to… combine the strength of two ICF
innovators and leaders."
The acquisition gives Fox Blocks
access to Reward’s “strong network of
ICF customers, developers, architects,
general contractors, residential contractors,
and construction supply distributors
throughout the U.S. and Canada.”
Ed Storm, who has served as president
of Reward Wall System, Inc. for the past 15
years, says of the merger, “This is a perfect
marriage. Airlite Plastics worked with
Reward for years and is intimately familiar
with the product line. Their expertise in
ICF design and self-manufacture together
with this expanded volume make for a
potent synergy that should be great for
existing and new ICF customers.”
While the deal won’t be formalized
until mid-February 2014, the companies
have started working together now to
develop and implement a plan that ensures
a seamless transition for customers and
employees.
Until the deal closes, Reward Wall
Systems will continue to exclusively handle
the sales and service of Reward products.
ICF Retrofit Shows Ingenuity
Installing a new foundation under
a home more than a century old is a
daunting task, but Logix ICFs combined
with fabric footings from Fab-Form made
the job much easier. In this case, not one,
but two “heritage homes” built in 1892
were renovated with additions to serve as a
seven-unit development.
The two older homes were nestled
tightly on a 50' by 132' lot in Vancouver, BC.
Josh Klein, project supervisor, explains,
"The lot width is only 50 feet wide, yet each
Heritage building measures over 21 feet,
not including roof overhangs. To excavate
for the new foundations, we carefully slid
each building to the south end to provide
sufficient space for the backhoe to operate."
He continues, "Once the foundations
were excavated, we slid the buildings back
to their original location, and built the new
insulated foundations underneath.”
The installer chose to “monopour”
the footings and foundation in a single
operation, even though wall heights
reached 15 feet. The boom operator had
only 16 inches of space between the top of
the forms and the bottom of the house.
For additional project details and
pictures, visit http://www.fab-form.com/
fastfootMp/ecoHeritage.php.
China Enters ICF Marketplace
After studying the North American
ICF market for years, Chinese manufacturers have begun offering ICF ancillary
products that closely parallel those already
on the market.
The products offered by one Shanghai manufacturer include a one-sided ICF
form—the other side is fiber-cement board
glued to the webs—a reuseable steel window
and door bracing system that copies a North
American version right down to the product
name and paint colors, and a steel turnbuckle bracing system that folds into the strongback, closely mimicking a popular ICF brace
currently manufactured in the U.S.
in foam do not significantly affect the
flammability of the building as a whole.
California Governor Jerry Brown
recently signed a law which directs the
California state fire marshal to consider
fire safety without the use of toxic flame
retardant chemicals.
"Excellent news that the state of
California recognizes the need to revise
out-dated flammability standards for
both furniture and building insulation,”
said Dr. Arlene Blum, of the UC Berkeley
chemistry department. Blum is a proponent
of banning HBDC. "These old standards
lead to the use of flame retardant chemicals
associated with health and environmental
harm, but we understand now that they
don't provide a fire safety benefit in many
cases, such as in insulation used below
grade and behind thermal barriers."
Dr. Vytenis Babrauskas, a leading fire
scientist, explains "The current practice of
ICC Rules Controversial Flame
Retardant OK
Earlier this fall, the International Code
Council has determined that flame retardants are to remain in foam insulation. The
ruling came during ICC’s public comment
hearings at their annual meeting in Atlantic
City, N.J., during the first week of October.
The flame retardant HDBC is used
to render EPS foam fireproof, but has
been shown to have long-term detrimental
effects on the environment. To complicate
matters, the only available alternative is not
yet available in commercial quantities.
The EIFS industry worked hard to
tamp down a growing movement to ban
the HBCD flame retardant, and the vote
on Oct. 4th proved them successful for
now. The vote on two proposals (RB 163
and RB 164) to ban flame retardants in the
International Residential Code failed on a
voice vote. About a dozen persons voted in
favor of the changes; the remainder, well
over 100, voted against.
Interestingly, a movement is underway
to remove HBDC from construction foams
without replacing it. Basically, proponents
of this approach argue that flame retardants
adding flame retardant chemicals to building insulation does not benefit fire safety
for most applications. Changing regulations to allow removal of such chemicals
will not diminish fire safety, but will be
highly beneficial for public health and the
environment. I congratulate the State of
California for taking this progressive step."
The law, AB 127, does not ban any
chemicals. “It simply asks the state fire
marshal to look into regulations, and make
changes that will give building insulation
manufacturers the choice to achieve fire safety without the use of toxic flame retardant
chemicals like HBCD,” explained Bill Allayaud, California Director of Government
Affairs Environmental Working Group.
Fox Blocks Begins Alaskan
Manufacturing
Fox Blocks, the Omaha-based manufacturer of Insulated Concrete Forms
(ICFs), has expanded its manufacturing to
Anchorage, Alaska. They have partnered
with an Insulfoam manufacturing facility
there to supply the Alaska construction
market with the full eight-inch-core product line-up (straight blocks, extended corners, Fox insulated window and door buck,
and HV clips). Additional product lines
will be added in 2014.
Fox Blocks are now manufactured
regionally in 12 other locations across the
U.S. and Canada.
“We have wanted to strengthen our
presence in Alaska for some time,” said
Mike Kennaw, vice president of sales. “We
feel the market potential for our products
in Alaska is significant.”
“Establishing in-state manufacturing
allows us to provide ICF products to
local dealers who then can supply their
contractor and builder customers,” he
continues. “Timely supply and a strong
product are keys to a quick efficient build.”
The regional sales manager for Alaska is
George Volker, who has more than a decade
of experience selling ICFs in the Northwest.
“Manufacturing Fox Blocks in Alaska
allows us to deliver ICF to our customers
faster and more efficiently.” says Volker. He
notes that in a cold climate like Alaska, not
only is energy efficiency important, but the
severe weather shortens the construction
season, so ICFs quick installation time is
also a considerable benefit.
Habitat for Humanity Uses ICF to
Rebuild Sandy Homes
In October, Fox Blocks ICF was used
on a major Habitat for Humanity project.
The project took place in Union Beach,
N.J., an area devastated by Superstorm
Sandy. The hurricane-strength storm
leveled entire neighborhoods—close to 270
houses were destroyed in this town alone.
After nine months, the area is starting to
rebuild, and Habitat spearheaded the effort
to rebuild the home of Elmer Lamberson.
This year marks Habitat for
Humanity’s 30th anniversary. The
organization has partnered with former
U.S. President Jimmy Carter to designate
certain jobs as “Jimmy & Rosalyn Carter’s
16 ICF BUILDER
Work Projects.” The Lamberson home is
one such project
Fox Blocks donated the Insulated Concrete Forms (ICF) and installation volunteers.
“Fox Blocks is honored to be a participant in the Union Beach Habitat project”,
said Brian Medford, Fox Blocks regional sales
representative. “We have been delivering Fox
Blocks to homes and aiding in the rebuilding in Union Beach for the last six months.
Having Jimmy and Rosalyn Carter on site
to rebuild the home of Mr. Lamberson will
boost awareness for the many more in need
and the fact that together businesses and the
community can rebuild a community.”
basement, over the last 20 years construction professionals have pushed the envelope
to the point that now Logix can build almost any kind of building you can think of.”
Concrete Associations Supports
Obama’s Sandy Strategy
Last fall, two concrete trade associations met with a representative of
President Obama’s Hurricane Sandy Rebuilding Task Force to discuss a possible
partnership between the federal government’s disaster rebuilding strategies and
the concrete industry’s goals for rebuilding
in the face of natural disasters.
The National Ready Mixed Concrete
Association (NRMCA) and the Portland
Cement Association (PCA) met in
September with the task force, a division
of the Department of Housing and Urban
Development (HUD).
During the meeting, NRMCA and
ICF High-Rises Reaching
New Records
The City of Waterloo, Ontario, Canada is a hotbed for ICF construction. This
summer, no fewer than 14 large commercial
ICF projects were underway, using a variety
of different brands. Located near Toronto,
the buildings range from hotels to offices,
and everything in between.
One of the most notable projects
finished recently is a high-performance
17-story student residence. The weightbearing ICF walls are built with Logix ICF.
Andy Lennox, VP of marketing reports
that Logix is also involved in building
another similarly sized student residence
building in the same city.
“When ICFs were introduced to
North America in the early 1990s they were
used primarily to build upgraded basements for custom homes,” he says. “While
Logix still remains a great way to build your
PCA outlined their strategies for resilient
construction which closely aligns with the
federal government’s strategies. NRMCA
presented details of legislation it initiated in
Congress, H.R. 2241, the Disaster Savings
and Resilient Construction Act of 2013, which
would provide tax incentives for building
owners and homeowners who rebuild using
resilient construction methods in the aftermath of federally declared disasters.
The meeting among NRMCA, PCA
and the task force’s representative, Josh
Sawislak, concluded with recommendations that the government adopt the
FORTIFIED programs of the Institute
for Building and Home Safety (IBHS)
when rebuilding and that they support
a new NRMCA proposed LEED Pilot
Credit for Resilient Construction. That
credit emphasizes the concept that resiliency is a prerequisite to sustainability.
Massive “Gray Block” Project
Slated In Hawaii
An enormous 4,000-home development in Hawaii is approaching the final
planning stages, reports Dave West, CEO
of MillenniumBlok. His company makes
a screen-grid Insulated Concrete Block
(ICB) with a proprietary blend of Portland
cement and EPS bead. The resulting product is heavier and stronger than all-foam
ICFs, uses less concrete to fill, and is completely fire- termite- and disaster-resistant.
The building effort is financed
by a consortium of wealthy Japanese
investors. West plans on setting up both
a portable block manufacturing facility
and a temporary concrete batch plant
onsite to keep costs to the minimum.
He claims to have similar projects in the
early planning stages in Korea, China,
Israel, Africa, the Caribbean, and South
America. His company oversees the
construction of the “super shell,” from
manufacturing of the material to proper
installation of doors and windows.
Local contractors provide interior walls,
finishes, and utilities.
His U.S. operations, previously
headquartered in Panama City, Florida are
being relocated to Houston, Texas.
18 ICF BUILDER
Best Development
Additional photos can be viewed at www.icfmag.com.
Ravenscraig will stand out for years as a community of distinction where very
high standards were set and met and high value created for the customer.
Ravenscraig at Fleming Park
While most ICF builders were struggling to survive the Great Recession,
one ICF company in Canada built out
an entire 76-home development in the
2008-2011 timeframe, selling all of the
properties near full price.
Named Ravenscraig at Fleming Park,
the homes range from 2,600 to 4,500 sq. f.t,
and are built on a 25-acre site about 15 minutes from downtown Halifax. It is by far the largest single-family development built with ICF in
Atlantic Canada, and one of the three largest in North America.
The neighborhood is now home to 70 families who enjoy
“one of the nicest single-family subdivisions in the Halifax area.”
An article in the Chronicle-Herald, the regional newspaper, says the
homes “bring together superior architectural design and energysaving technology in a development that features more than 20
different styles of homes …all with energy-efficient, imaginative and
practical designs.” The article continues, “ICF construction means
more energy savings, as well as solid, sound-proof construction…
They’re an excellent example of not only top-rate construction —
but décor as well. The model home design features a loft overlooking
living room, while the finishes include upgraded walnut cabinets,
a glass tile backsplash, and engineered hardwood floors. The gas
fireplace and skylights make the living room feel modern and cozy.”
This is not the only press coverage the development received.
Polycorp, the general contractor and developer, has built several
20 ICF BUILDER
other large-scale ICF projects in the area,
and Ravenscraig garnered extensive local press as well as coverage from national
cement associations.
Mike Perrier Homes did the ICF
installation. This remarkable company
delivers top-notch ICF craftsmanship
despite the fact that all of the crew
members are deaf or severely hearing impaired. They knocked out
the ICF portion of each home in about 10 days, even though some
of the work took place through the cold winter months. In total,
they installed a total of 254,250 sq. ft. of Arxx ICF.
The homes are heated with in-floor radiant heat on a time-ofuse meter on an electric boiler to take advantage of reduced rates
on off-peak hours. Tubing is encased in 1.5” of lightweight concrete
topping over a regular wood-framed floor. Each home has five or
more zones each with its own programmable thermostat.
How was Polycorp able to be so successful at a time when many
of the best builders on the continent struggled to find work? It’s
true that Canada was not impacted as severely by the recession as
the U.S. market, but Polycorp also used a combination of strategic
planning, clever marketing, and plain hard work.
The site was effectively solid bedrock. To minimize blasting,
the street layout was designed to match natural topography and
minimize front porch height. They worked carefully with the city
to preserve mature trees, rock outcroppings and a natural stream
Project Statistics
Location: Halifax, Nova Scotia, Canada
Type: 76-home Residential Development
Size: 266,000 sq. ft. (floor)
ICF Use: 250,000 (all exterior walls)
Cost: $20 million
Total Construction: 5 years
ICF Start-to-Finish Time: 10 days per home
Construction Team
Owner: Polycorp Group
General Contractor: Polycorp Group
ICF Installer: Mike Perrier Homes
Form Distributor: Arxx Corp.
Architect: Michael Napier Architecture
Engineer: BMR Engineering
ICF System: Arxx
Fast Facts
First large-scale ICF development in the area
Designed to be “nicest single-family subdivision” in the area
Street layout designed to maximize natural topography and
minimize front porch height
Single family units range from 2,600 to 4,500 sq. ft.
In-floor hydronic heat encased in 1.5” lightweight concrete
topping
All homes sold except model home and two others, most at
full price
Extensive local press and coverage from national cement
associations
wall so visitors can see how ICF walls combine rebar, cement, and
foam. The home was also stocked with literature prepared by the
PCA promoting ICF technology. The website contains extensive
explanations of the advantages of ICF, video testimonials by
Ravenscraig homeowners extolling the virtues of ICF construction,
and even videos of ICF pours in the development.
Louis Lemoine, vice president at Polycorp, says, “This level
of marketing creates a very strong emotional connection between
our purchasers and the homes we build. By educating our
purchasers about the benefits of ICF it comes together, they can
see the difference for themselves and become quite excited about
the prospect of enjoying the comfort and security that comes with
living in an ICF home.”
By any measure, the community of Ravenscraig at Fleming
Park is a rousing success. Polycorp tackled a very challenging site
and through their tenacity, vision and sensitivity to the surrounding
community and existing terrain created a landmark achievement.
Lemoine says, “When we started, our larger homes started
at $459,000 and the smaller ones at $359,000. We just sold our
last large home on the park for $799,000 (full price) and we are
seeing resales in the $770,000 range on our larger homes and in
the $455,000 range on our smaller homes. These price increases
far outstrip average price increases in the area and we believe that
that is an indication of the market’s perception of these homes as
being of exceptional quality and value… Although the project took
a little longer to complete than we had anticipated, we have met and
exceeded our revenue projections for these homes.”
He continues, “Time and time again, our Ravenscraig
customers have told us that the main reason they bought [here]
was due to the advantages inherent with ICF wall construction.”
Photos courtesy Louis Lemoine
that flowed through the site. An old quarry bordering the property
was converted into a playground and soccer field, with the steep
slope on the upper portion used as a tobogganing hill in the winter.
Rather than aim for a specific demographic segment, the target
market for Ravenscraig was a mix of empty-nesters, mature families
with teenagers and young couples just starting families. About half
the homes have the master bedroom on the main floor, preferred by
empty-nesters. The other half are more traditional design. With 20
different floor plans and even more color schemes, it creates the feel
of an old-style, well-established neighborhood.
The model home/sales center features a mock-up ICF
Displays explaining ICF
construction were prominently
featured in model homes.
ICF Comparison Charts: A Usage Guide
The charts on the following pages are intended to help
architects, builders and homeowners understand some of the
basic features of every ICF currently on the market.
These charts are a good first step to ensuring you’ve chosen the
best form for the project. The table below contains technical data
for all the EPS flooring systems, while the chart on pp. 24-25 contains basic statistics for every significant ICF brand in North America. Finally, the chart on pg. 23 compares the other stay-in-place
concrete forming systems, such as composite cement-EPS blocks
and forms made with wood waste and non-insulating vinyl forms.
Keep in mind that while these charts are a great place to start
if you want to make an informed choice, it’s only a start. Call the
manufacturers, visit their websites, and sit down with the local
distributors. If you’re working with an experienced ICF installer,
strongly consider their recommended form system.
A Note on Cost:
Note that pricing is not included on any of the charts. While
cost is often the primary factor in selecting an ICF system, decision
makers should consider the following:
In performing block-to-block comparisons, recognize that form
size varies considerably. Most ICFs are 48” long by 16” high, but Nudura measures a full 96” long, while SmartBlock is only 40” by 10”.
The thickness of the foam sidewalls, which affects form strength,
insulation value, and amount of raw material needed, also varies.
Concrete costs should be considered as well. A nominal six-inch
22 ICF BUILDER
flat wall may actually measure anywhere from 5.5 to 6.75 inches.
Additionally, waffle- and screen-grid systems are still on the market,
so check the “Sq. Ft. per Cubic Yard of Concrete” column carefully.
Labor and freight are significant factors as well. The chart lists the
location of US and Canadian molding facilities to help estimate transportation costs. Note that panel systems (knockdown forms) ship flat
to reduce shipping, but require jobsite assembly. Reversible interlocks
and specialty forms can make installation go faster and reduce waste.
The best option is to ask for the “installed cost per square foot.”
Manufacturer Support:
Don’t underestimate the importance of manufacturer support,
especially if you’re new to the industry, or will be doing an DIY
installation. Local distributors can help answer questions, rent
bracing and other products, and provide immediate assistance if
you come up short on anything.
Training seminars are usually free, but if you want handson training, be sure to ask; a few companies offer classroom-only
instruction.
EPS Decking:
Over the last decade, EPS decking products have become increasingly popular. They’re used for decks, floors, sloped roofs, and even
tilt-up walls. The major differences between brands include whether
they’re custom-cut or modular, the amount of shoring requirements,
and how the utility chases and interior finishes are applied.
Alternative
Forming Systems
In addition to all-foam ICFs, several other stayin-place forming systems are on the market.
Polyurethane ICFs offer more rigidity,
strength, and R-Value per inch than EPS forms.
However, some forms use thinner sidewalls so
actual performance in the field is comparable. All
PU forms currently on the market are screengrid blocks.
Composite ICFs are made from a blend of
EPS and Portland cement. These blocks are termite-proof, fireproof, and will not melt or burn.
(A blowtorch applied for an hour to a two-inchthick piece caused temperature of the opposite
face to rise only 2 degrees). Nails and screws
hold wherever they are driven, making interior
and exterior finishes much easier to apply. Stuccos and plasters can be applied directly to the
block without mesh and without sheetrock and
still meet code. The forms can be shaped with
standard carpenter tools.
All are screen-grid blocks, meaning the
concrete forms a series of columns and beams
(usually every 16 inches on center). Because of
the screen-grid core, composite ICFs use only half
the concrete of all-foam flat-wall designs. They’re
considerably denser—and heavier—than their allfoam counterparts. That translates into less need
for bracing. They tolerate high-slump concrete and
enthusiastic vibration.
However, a 48”x16” block of this type weighs
nearly 50 lbs. and larger ones need to be craned
into place. A new company has been added to this
category this year, Millennium Blok, which has
octagonal cores.
Insulated Concrete Blocks (ICBs): Made
from wood fiber and cement, these blocks
mimic concrete masonry units in size, weight,
and shape. Unlike CMU, though, they do have
some insulating value, and finishes attach directly
to the block without furring.
Vinyl Forms: Installed as vertical planks,
these are a viable alternative only when the form
is intended to serve as a final finish. Insulation
can be added to one side of the cavity of the wall
if needed.
2013 Industry
Comparison Chart
Regional Manufacturers
Major Manufacturers
BuildBlock Building Systems
Fox Blocks
IntegraSpec ICF
Logix Insulated Concrete Forms
(866) 222-2575 www.buildblock.com
(877) 369-2562 www.foxblocks.com
(800) 382-9102 www.integraspec.com
(888) 415-6449 www.logixicf.com
AL, AZ, CA, CO, FL, ID, IN, MA,
MN, MO, NC, WI +CAN
AZ, AK, NC, FL, MA, NE, ID, CA,
CO, AB, MB, NB, QC, CAY
AK, GA, MA, NV, MO, QC, INT’L
BC, AB, MB, ON
CA, HI, KS, MA, MN, TN
NUDURA Corp.
(705) 726-9499 www.nudura.com
GA, QC
Plasti-Fab
(888) 446-5377 www.advantageicf.com
AB, ON
PolyCrete
(450) 670-7624 www.polycrete.com
VA
48
Arxx Edge
48
Arxx Steel (waffle)
48
Spacing
Arxx Prime
(P)lastic (S)teel (E)PS
16
48
(P)anel (B)lock (H)inge
48
Wall Type
(S)creen (W)affle (F)lat
AB, CO, GA, ID, QC, AK, MO,
SD, PA, WI
Amvic
Amvic 3.30+
SF per CY(6” core)
(800) 293-3210 www.arxx.com
AK, ID, MN, MO, NC, ON, UT, MX
Form Name
Core Sizes
ARXX Building Products Inc.
(877) 470-9991 www.amvicsystem.com
Manufacturing
Locations
Height
Amvic
Contact Info
Ties
Dimensions
Length
Manufacturer
Form Specs
4-12
53
F
B
P
6, 8
53
F
B
P
6, 8
52
F
B
P
8
53
F
P
P
8
72
W
B
S
12
16
4-12
12,
16.75 4-10
16 4-20+
16
6-8
Arxx Steel
48
24
6-8
54
F
B
S
6
BuildBlock
48
16
4-12
54
F
B
P
6
BuildLock
48
16
4-12
54
F
P
P
6
GlobalBlock
48
16
4-6
85
S
B
E
12
Fox Blocks
48
16
4-12
53
F
B
P
8
Fox 1440
48
16
4-24
53
F
P
P
8
iForm
48
16
4-12
53
F
B
P
6
eForm
48
16
5.5,
7.5
56
F
B
P
6
IntegraSpec ICF
48
54
F
P
P
8
Logix Pro
48
12.25 4-12+
16
4-12+
54
F
B
P
8
Logix KD
48
16
4-12+
54
F
P,B
P
8
Logix XRV
48
16
4-12+
54
F
P,B
P
8
Nudura ICF Series
96
18
4-12+
54
F
H, P
P
8
Nudura One Series
96
18
4-12+
51
F
P
P
8
Nudura Plus Series
96
18
4-12+
54
F
H, P
P
8
Advantage ICF
48
16.5
6, 8
53
F
B
P
8
PolyCrete Big Block
96
24
6-10
56
F
H
S
12
Flex 850
96
12
6-12
56
F
P
S
12
Quad-Lock
48
12
4-28+
56
F
P
P
12
Quad-Lock FS
48
12
4-28+
56
F
P
P
12
Quad-Lock PLUS
48
12
4-28+
56
F
P
P
12
Quad-Lock Building Systems
(888) 711-5625 www.quadlock.com
BC, GA, AUS, ENG
QPX3
48
12
4-28+
56
F
P
P
12
Superform Products Ltd.
(877) 227-0964 www.superformicf.ca
AB
Superform
48
12
4-8
48
F
B
P
6
Cellox, LLC
(608) 524-2316 www.celblox.com
WI
CelBlox
48
16
4-12
52
F
H
P
8
CIW Manufacturing
(800) 214-5199 www.ciwmanufacturing.com
ON
Consulwal
48
16
4,6,8
65
W
B
S
8
Smartblock SF10
40
10
6.5
55.5
S
B
E
10
Conform Global
(800) 266-3676 www.smartblock.com
UT, ID
Smartblock 12VWF
40
12
4-20+
53
F
P
P
4-6
HercuTech
(800) 289-3139 www.hercutech.com
AZ
HercuWall
24
96
3,4
125
S
B
E
12
NY, VA, GA, FL, TX, MN, SD, IN,
WA, AK, AB
Hobbs Vertical ICF 8, 16
Any
6
100
W, F
P
P
8,16
96
4-12
50
F
B
P
8
HOBBS Building Systems
(866) 904-9255 www.hobbsverticalicf.com
Hi-Tech Building Systems Corp.
(905) 738-0567 www.armopanel.com
LiteForm Technologies
(800) 551-3313 www.liteform.com
Mikey Block Co
(520) 623-3023 www.mikeyblock.com
ReddiForm
(800) 734-8268 www.reddiform.com
Reddi-Wall Inc.
(586) 752-9161 www.reddi-wall.com
Standard ICF Corp
(507) 396-3802 www.standardicf.net
TF System
(800) 360-4634 www.tfsystem.com
WI
ON
ARMOPANEL
48
8
4-24
53
F
P
P
8
FlexxBlock
48
12,16
4-12
53
F
B,H
P
6
AZ
Mikey Block
48
12
12
91
S
B
E
12
NY, ID, FL, IRE, PR, THAI
ReddiForm
48
12
6,
80
S
B
E
9.5
MI
Reddi-Wall
60
12
6
75
S
P, B
E
10
MN, NE, MA
Standard ICF
48
16
7
56
F
B
P
12
TF System
12
ANY
4-24
F
P
P, S
12
NE, SD, ND, VA
LiteForm 48, 96
Every effort has been made to ensure this information is complete and accurate at the time of printing. However, this chart is not adequate for the purposes of making construction decisions. ICF Builder Magazine is not liable for any errors or omissions in the data. Any c
Major manufacturers are considered to those with both ICCEF and DCMC approvals.
24 ICF BUILDER
54
2.5
Y
Y
N/A
58
Varies
4
54
2.63
3
54
4
3
3-4+
57
2.5
2-4+
56
2.75
2-4+
56
2.75
Reversible
Brickledge
Y
Y
Y
Y
Y
Y
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
M
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Exposed ties on one or both sides
Y
M
Y
Y
M
Y
Y
Y
Y
Y
Y
2.5 inch foam
T&G
M
Y
Y
M
Y
Y
Y
Y
Y
Tongue & Groove Interlock
T&G
M
Y
Y
M
Y
Y
Y
Y
Y
Steel Ties
Y
M
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
M
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
2.5
Y
Y
Y
M
Y
Y
M
Y
54
2.5
Y
Y
Y
Y
Y
44
1.88
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
3, 9
Y
Y
Y
Y
Y
Y
Y
Y
Y
2-4+
56
4-8
4
52
2.63
Y
4
55+
2.63
4
55+
2-6
3
50+
2.63
3
54
1.75
T&G
3
54
2.5
T&G
4
55+
2.25
Y
4
55+
Y
4
55+
2.25,
4.25
4.2510.25
Y
4
55+
3.2
3
55
2.75
4
54
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
M
Y
Y
M
M
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Tilt-up and retrofit applications
Y
Y
Y
Y
Y
Y
Y
Y
Y
Brickledge reinforcement, Reinforced corner tie, ICF masonry
anchor, Certified to ASTM E2634 Standard,
Insert panels available
Y
Y
Y
Y
Y
Y
Full form float/independent panel system
Y
Y
Y
Y
Y
Y
Available with termite resistant or NEOPOR foam
Y
Y
Y
Y
Y
Y
Y
Knockdown Line, Integrates with LOGIX Pro
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Widest variety of block shapes and sizes
Y
Y
Y
Y
Y
Y
Y
Foam on one side only
Y
Y
Y
Y
Y
Y
Y
Y
Y
Continuous concrete brickledge
Resists 1,600 lbs/sf lateral pressure
Y
Y
Y
Y
Y
M
Y
Y
M
M
Y
Y
M
Y
Y
M
M
M
M
M
Y
Y
Y
M
M
M
M
M
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
ISO 9001 & 14001 certified
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
2.5
Y
Y
M
Y
Y
Y
P
Y
Y
Y
Y
Y
M
Y
2
Y
Y
Y
Y
1.8
Y
Y
M
M
M
M
M
Y
Y
4
56+
2.13
Y
Y
M
M
M
Y
M
Y
Y
Y
Y
Y
N
N
Y
Y
Y
Y
Y
Y
N/A
Y
N
N
Y
Varies
N/A
Y
Y
Y
Y
2.0
4
53
2.0
4
53
2.0
55
Varies
2
52
2
55
2.1
3
50
Y
Y
Y
Y
Y
M
Y
Y
Y
Y
Y
Y
Y
Y
2.5
M
T&G
2.5-4
N/A
Y
Y
Y
Y
Locking hinge, US owned and operated.
Allows interlocking different thicknesses at corners.
Y
Y
Delivered as pre-engineered, panelized kit
Available in flat and contour wall options. Engineered by project
T-Panels, Integral Footing panels
Y
Y
Y
Y
55
30
Y
Y
52+
3
Y
Extended corners, full height furring strips
Y
2
50+
Furring strips optional
Y
2
2
Termite resistant block available in Florida only
All products connect and interchange
Y
6, 8
Y
Home Plans
3-4
M
M
On-Sirte Rep
Y
Y
Y
Training Class
Y
Y
Y
Video/DVD
2.5
Y
M
Y
Manufacturer Support
Installation Manual
54
Comments
City of NY
3-4
12
City of LA
2.5
Miami-Dade
Varies
51+
Y
Florida
51+
4+
Y
Wisconsin
4+
Y
ICC-ES
51+
Y
Code Approvals
End Caps
4
Y
Y
Taper Top
51+
Y
Y
Radius
4
Y
M
45°Corner
50
90° Corners
3
2.5,
3.3
2.5,
3.25
2.52.625
2.5
T-Blocks
Sidewall Thickness
50
Interlocking
Sound Attenuation
3
Height Adjusters
Fire Rating (Hours)
Building Considerations
CCMC
Performance
Data
P
M
M
Y
Y
Y
Y
M
P
Continuous furring strips
Y
Y
M
Y
Y
M
Y
Y
M
M
M
Y
Y
M
M
Y
Y
Y
M
Y
Cores are 5.5 inches 12” O.C.
Continuous horizontal attachment/online estimates
Y
Y
P
P
Modified flatwall maximizes efficiency, insulation and durability
Y
P
Vertical Panels give option of steel or plastic ties. XPS
foam option.
copying, redistribution or republication of this chart, or the content thereof, is strictly prohibited.
Unlimited Residential — Winner (Tie)
Perched on a bluff overlooking the foothills of the Sierra Nevada, this home
used an astonishing 60,000 sq. ft. of ICFs in every conceivable application.
Situated on the foothills of the Sierra Nevada in Northern California, Casa Bella
Verde is a magnificent example of energy
efficiency, sustainability, and design ingenuity. More than that, it showcases how
ICF technology can be used in an astounding array of construction situations. The
main home and attached guest house have
a combined 9,000 sq. ft. of conditioned
floor space. Yet the homes used more than
30,000 sq. ft. of ICF wall forms, and an additional 30,000 sq. ft. of ICF forms in landscaping, pool construction, and other uses.
An additional 15,000 sq. ft. of Insul-Deck
EPS decking was also installed.
26 ICF BUILDER
Photos courtesy Nicholas Nikiforuk
Casa Bella Verde
“We tried to apply ICF technology
to every application of the project building process,” says Nicholas Nikiforuk, the
IntegraSpec executive that supplied forms,
trained installers, and oversaw the con-
struction process. “We created new uses for
standard ICF components and found ways
they could help solve design issues.
Construction began with a semicircular rain cistern built from ICF and foam
decking. Then the infinity edge pool was
stacked—all 3500 sq. ft. suspended 18 feet
above ground and built out of ICF and
EPS decking. The pool steps, hot tub, even
stools at the swim-up bar were made from
ICF. At each end, a three-tiered waterfall
(also of ICF) cycles water into the pool
The massive curved walls run 180
feet long on radius of 66’ 5” and 73’6”. The
others have radii of about three, four, seven,
Elevated skywalks (right) cistern (left) and even the suspended swimming pool, hot tub, and steps (below) were all formed with ICF.
and eight feet. Depending on the amount
of curvature, the inner panel was either
shortened by a few inches every 12 feet, or
miter-cut into pieces and strapped together
with H-Clips.
By the time of the first pour, the project
had already acquired a local reputation. In
addition to the local inspector, CEMEX had
sent 14 executives from their national headquarters in El Dorado Hills to observe. Nikiforuk had ordered 155 yards of 5” slump, to
be reduced to a 9” slump onsite with a superplasticizer. He recalls, “It was a cold, pouring
rain. I wanted to demonstrate the strength of
the system so I began filling the 12-foot high
walls to the top in one lift. I had one helper
walk the scaffolding with me to screed off the
top of the wall. As the walls were filling, the
inspector followed the concrete flow and verified that we were achieving 20 feet of uninterrupted flow. Passing this first test with the
inspector and the concrete mix supplier was
a major hurdle that was overcome. This technique was going to save us time and money,
as we still had 1,700 cubic yards ahead of us.”
Video of this pour is available on the
Casa Bella Verde website.
The list of creative ICF use on this
project boggles the mind. A 40-foot skybridge connecting the main living quarters
to the guest house is all ICF. Two 14 ft. wide
sliding glass doors disappear into a pocket
wall allowing a seamless transition from
the inside to the outside. They required an
ICF lintel of more than 28 feet. The second
floor of the main house (built with InsulDeck) cantilevers 14 feet out over the pool
deck on two sides. The master bedroom
has a 10-foot cantilever. To maintain stiffness on these overhangs, the ICF flooring
system required additional EPS that increased the depth of the ribs from 7 inches
to 18 and 24 inches as required.
As the rainy season gave way to summer, weather became more of a concern.
Some days reached 114 degrees at the jobsite. Sunglasses and frequent water breaks
became mandatory.
As the home progressed, its reputation
spread further. Nikiforuk says, “We’ve
had visitors from all the western states, as
well as Iowa, New York, Kentucky, Ohio,
Michigan, Colorado, Florida, Georgia and
Maryland. We’ve also educated foreign
visitors from Canada, England, Egypt,
Mexico, Switzerland, and Germany.
Not all those visitors were satisfied
with a simple tour. The Casa Bella Verde
project was used as a training site for contractors and individuals wanting advanced
ICF training. “We had as many as 12 people
at a time assembling walls, installing bracing and assisting on pour day,” says Nikiforuk. These “trainer crews” changed weekly.
“Making sure the installation was correct, taking time to demonstrate and giving
tours took time out of the construction
progress,” Nikiforuk admits, “but the idea
of teaching newcomers was more important to us.”
He adds that in addition to the onsite
education, the construction and design
team has also given lectures and seminars
to building inspectors, county engineers,
concrete manufactures, contractors and
material suppliers.
It is directly responsible for at least
nine other homes being built with ICF.
Casa Bella Verde is notable for more
than just ICF training and creativity,
though. The residence is a near-zero energy
design, with LED lighting and onsite
wastewater treatment. The paperwork for
LEED certification has been submitted,
and the preliminary report states it easily
qualifies for LEED-Platinum status.
The house is heated and cooled by a
geothermal exchange system which consists
of four heat exchangers and ten 300-footdeep ground loop wells. On the rooftop, 95
Dozens of ICF contractors learned
advanced installation techniques (left) on
this project. The finished home is a LEEDPlatinum-certified green home (below).
Project Statistics
photovoltaic solar panels provide power to
the home. Excess power is sold back to the
utility grid.
To date there has been zero energy cost
for heating and cooling, and the structure’s
thermal mass has been performing as
designed. “Once all the systems are fine
tuned and adjusted, we anticipate being at
net zero for energy consumption for the
entire property,” reports Briana Alhadeff,
owner of the home.
Consuming about 1,800 yards of
concrete, Casa Bella Verde is a showcase
of resilient construction. It was designed
to withstand earthquakes, tornados, fire,
termite infestation and water penetration.
The exterior finish is stucco and the
outdoor deck areas are slate and travertine.
It’s stunning architecturally, too. Every
window was situated to capture views of the
surrounding hills. Walking through the custom-designed, swing-glass front door, visitors enter a 26-foot-high grand foyer. Two
floor-to-ceiling windows look out over the
infinity-edge pool with a backdrop of the Sierra Nevada mountain range. At the base of
28 ICF BUILDER
the windows a magnificent curved stair case
leads to an ICF catwalk to the second floor.
National magazines have written
articles on Casa Bella Verde, including
Innovative Home, GB &D magazine,
Concrete Homes, Residential Systems, and
Walls and Ceilings magazine. The Casa
Bella Verde website has had thousands of
inquiries and hits, and the construction
newsletter had more than 400 subscribers.
Casa Bella Verde’s role as an ambassador for the industry isn’t finished yet. All
exterior walls have thermal sensors imbedded in the concrete tracking core, outside
and inside temperatures, data which will
be used by future designers and engineers.
And the home will continue to be available
for occasional tours.
Says Nikiforuk, “We worked hard
to demonstrate the potential of ICF
technology as a standalone product that can
perform all of the functions of conventional
building materials and more. Casa Bella
Verde demonstrates that when building
with ICF materials, the only limitation is
your imagination.”
Location: Pilot Hill, Calif.
Type: Private Residence
Size: 9,000 sq. ft. (conditioned)
ICF Use: 60,000+ sq. ft. (all
exterior walls, most interior walls
+ landscaping)
Cost: $3.6 million
Total Construction: 43 months
ICF installation time: 29 months
Construction Team
Owner: B. Alhadeff
General Contractor: KD
Construction Management
ICF Installer: California ICF/
West Coast ICF
ICF Distributor: IntegraSpec
Designer: B. Alhadeff
Engineer: DG Engineering
ICF System: Walls by IntegraSpec/
Floors by Insul-Deck
Fast Facts
ICFs used in every conceivable
application, including swimming
pool, retaining/privacy walls,
water features, elevator, cistern,
floor slabs, stairs, and skywalk
Provided advanced training for
dozens, including at least 12
custom builder crews, numerous
design professionals, and visitors
from 16 states and 7 foreign
countries.
Multiple large-radius walls, 40-foot
suspended ICF skywalk, wall
heights to 26 feet, lintels span
16 feet
Near-zero energy design, with
geothermal heating/cooling,
LED lighting, onsite wastewater
treatment. Qualifies for LEEDPlatinum status
Major feature-length articles in 5
magazines
Project website has thousands of
unique visitors
400 subscribers to project
newsletter
Thermal sensors in wall provide
real-world feedback
Used 1,855 cu. yds. of concrete
IntegraSpec
®
“The User Friendly ICF”
Click on thumbnails above for a full slide show
Visit www.integraspec.com/downloads.htm to view all slide shows
Visit us at the World of Concrete – Booth N163 | Jan 21st -24th
Numerous International Patents
1-800-382-9102 | www.integraspec.com
Unlimited Residential — Winner (Tie)
This project demonstrates the remarkable ability to
tackle virtually any construction challenge, including
radius walls, unusual angles, and intersections.
NY EcoLuxury Home
Inspired by a recent trip to Europe, the owners of this home
wanted to build a residence to last for many generations. Like the
grand homes of Europe, it would be architecturally impressive, but
they also wanted to build in a sustainable and ecofriendly manner,
and have the home be as efficient as possible. They quickly realized
that wood-frame construction techniques would be inadequate.
Insulated Concrete Forms (ICF), on the other hand, could
provide the durability and energy-efficiency they desired and could
confirm to virtually any architectural style. So the project team went
the World of Concrete show in January 2011 to look at the major
ICF systems and ended up selecting Quad-Lock. This system has the
ability to easily shift thermal mass to the inside
face of the walls, and can resolve design intricacies onsite using the basic components—no
specialty parts required.
With that decision made, they got to work
finalizing plans, and soon had blueprints for a
remarkable dream home to be situated on the
banks of a small pond in upstate New York.
Construction challenges were consider-
30 ICF BUILDER
able, beginning with the scope of the project. Nearly every wall was
built with ICF. Multiple wall thicknesses and intersections were
common, as were radius walls, unusual angles, and large archways.
To further complicate things, the schedule was fast-tracked
and incredibly tight from the beginning. The owners wanted it
completed as quickly as possible, while insisting on the highest
level of craftsmanship and enough technology to qualify for LEED
Platinum certification.
“For the size and scope of what they were trying to accomplish
with sustainability and ultimately the LEED Platinum for Homes
certification, this was a major challenge,” says one member of the
design team.
The local Quad-Lock distributor selfperformed the ICF work. They brought an
experienced crew with the focus, drive, and
knowledge to ensure an error-free installation.
They kept up with the aggressive time
schedule despite the daunting challenges.
For instance, the entire roof structure
and several other areas were timber-framed.
To meet deadlines, these had to be ordered long before the ICF
structure was begun, so the placement of every wall and window
had to be absolutely perfect to fit to the pre-built timber sections.
Other challenges included a huge radius wall for the feature
staircase, three different octagonal rooms, and eight archways that
had to be within 1/8” of design to fit the jambs, cut from reclaimed
timber with a CNC machine. When the massive timber sections
finally arrived, they fit perfectly.
Floors were made from the Quad-Deck EPS floor system,
which allow for long spans, in-floor heating, and a thermal/sound
barrier between upper and lower floors.
Obviously, a project of this type attracts attention, and the
builders willingly showed literally hundreds of construction
professionals the advantages of ICF. Over the course of the project,
more than 100 college and graduate students toured the site. It
has exposed over 200 contractors to a new concept of sustainable
building which they can take to future projects in the region.
A Quad-Lock representative says, “These students and
contractors have been shown how ICFs are not only the most
precise way to build for energy-efficiency, sustainability, safety
and healthy living, but that this should and can be the mainstream
building methodology.
From the beginning, the owners wanted a LEED Platinum
for Homes rating. ICFs played a major role in this. The inside face
of the ICF wall used a regular 2¼” panel. All exterior faces used
an additional Xtra Panel to total 6¼” of foam between the outside
environment and the concrete core of the wall.
The radiant in-floor heat is coupled with five geothermal
units, as well as a bank of solar panels for maximum efficiency. The
home uses only 17% of the energy compared to an average house
its size. The home uses so many sustainable technologies that it is
reportedly the highest-scoring LEED for Homes project to date.
The score was so impressive that when it was certified LEEDPlatinum by the U.S. Green Building Council in 2012, USGBC president Rick Fedrizzi personally presented the award. As part of the certification, the owners have committed to five years of energy tracking.
“I think in the construction industry we need owners and
developers that are not afraid to reach beyond what was thought
possible and raise the bar to push the industry forward,” says the
principal architect. “When you step back and see the home and how
well it performs, it has completely shattered the notion that a large
home beyond a certain square footage can or could ever be green.
During construction, dozens of tour groups and hundreds of ICF
professionals were educated about how ICFs are a solid choice
for sustainable, resilient construction.
This project is the highest scoring LEED for Homes project in the
World and has proven that no matter what the square footage, any
home can be green and sustainable. The hope is that others will
continue to push the envelope and strive to raise the bar past where
this team has set it.”
Radiant hydronic heat and ICF foam reduce energy bills dramatically—about 16% of what a frame home this size would be.
Project Statistics
Location: Upstate New York
Type: Private Residence
Size: Undisclosed
ICF Use: 19,600 sq. ft. (All exterior and interior walls) +
8,600 sq. ft. of decking
Cost: Undisclosed
ICF Start-to-Finish Time: 85 days
Construction Team
ICF Installer: Homes American Made
ICF System: Walls by Quad-Lock/ Floors by Quad-Deck
Fast Facts
Lifespan to be “multi-generational”
Multiple radius walls, unusual wall intersections, and large
archways
Tight, fast-tracked schedule
Certified LEED Platinum;
Highest scoring “LEED-Homes” project in the world
ICF training site for 100 college-level construction students
About 200 contractors were exposed to ICF technology
through this project
Unlimited Residential — Runner-Up
This Spanish Colonial home is a masterpiece
of architecture and sustainability.
Silverleaf House
32 ICF BUILDER
Photos by Michael Duerinckx
Silverleaf House, is one of the most stunning examples of
Spanish Colonial architecture in a state known for outstanding
examples of this style. ICFs accommodated the design far better
than most systems. It was perfect for building long thick walls, with
deep recesses at window and door openings. The rigid foam was
the perfect substrate for a cement stucco finish, while the concrete
core at the center of the wall easily supported the heavy tile roof.
Additionally, ICFs could accommodate the balconies, columned
colonnades and arched arcades this home has in abundance.
Surprisingly though, this isn’t why the homeowner chose ICF.
He states, “My wife used to tease me during the construction process because I would repeatedly go up to a wall and hit it with the
palm of my hand and comment ‘I just love that solid sound.’ The
thick walls give a sense of durability even to the casual observer.
When I took into consideration the superior sound and thermal
benefits, there was no question that ICF would offset any incremental cost or time of construction. The advantages of this system
were the key differentiating factor between [the winning] builder’s
proposal and the others that were proposing conventional frame
construction. Now the home is finished, it has only confirmed we
made the right decision.”
Built in an exclusive gated community in the hills surrounding
Scottsdale, Arizona, the massive 11,700 sq. ft. home could have
been extremely expensive to heat and cool. Temperatures in the area
range from 120 degrees in the summer to well below freezing in the
winter. ICF was ideal for accommodating such fluctuations.
The builder, Joe Hendricks of Hendricks Construction,
acted as general contractor and self-performed the ICF install.
And it was a massive undertaking. Already familiar with the Arxx
brand, it was selected as the block of choice for all 11,000 sq. ft.
of exterior wall. Dozens of corners and varying wall heights also
presented challenges. Walls rose to 26 feet—in some cases without
intervening floors—and they were penetrated by more than 30
arched openings. Many of these contained a tapered, chamfered or
Dozens of corners and more than 30 arched openings required
expert ICF installers to ensure a precision build.
Plants displaced at the construction site were moved to an
onsite nursery and replanted as part of the final landscaping.
flared edge, and were up to 12 feet in diameter. Hendricks solved
this daunting task by getting a local metal shop to fabricate the
custom arches, then built the rest of the bucks onsite.
In order to meet aggressive deadlines, Hendricks had his
interior framing crews working at the same time the exterior ICF
walls went up. Site access was extremely limited, as little as five feet
in some places, so a tower crane was used to distribute construction
material to the different trades.
Throughout the entire build, earth-friendly construction practices were paramount. Of the 2.5 acre site, only one acre was allowed to be disturbed. The remainder has been set aside as a wildlife corridor. Within that one acre, crews carefully transplanted all
of the major plantlife before any earthwork began. The displaced
plants, including palo verde, ironwood, saguaro, ocotillo, and barrel
cactus, were cared for at an onsite nursery until they were replanted
as part of the final landscaping.
The exterior finish incorporates 15,000 bricks recycled from
turn-of-the-last-century manufacturing facilities.
The final product is breathtaking. Hendricks turned it over
to the proud owners only 18 months after the footings went in.
He says, “It’s been a privilege to be involved with this home. This
residence will be here long after wood-framed homes have reached
their life expectancy. In an area of extreme weather and temperature,
and at a time of dramatically rising energy prices, this home will
more than payback its owner in longevity, comfort and security, not
to mention pride of ownership.”
34 ICF BUILDER
Project Statistics
Location: Scottsdale, Ariz.
Type: Private Residence-Net Zero Energy Home
Size: 11,700 sq. ft.
ICF Use: 11,000 sq. ft. (All exterior walls)
Cost: $3.2 Million
Total Construction: 585 Days
ICF Start-to-Finish Time: 38 Days
Construction Team
Owner: Undisclosed
ICF Installer/General Contractor: Hendricks
Construction, LLC
Distributor: Southwest Wall Systems
Architect: Rains Design
Engineer: Sinclair Engineering
ICF System: Arxx
Fast Facts
ICFs chosen for strength, efficiency, and match to
architectural style
Sustainable construction practices
All displaced plants saved and transplanted in
final landscaping
Exterior finish uses 15,000 recycled century-old bricks
Dozens of corners, multiple wall heights
Wall heights to 26 feet without intervening floors
30+ arches, many of which are tapered, chamfered, or flared
2013
Market Report
and Forecast
As 2013 comes to a close, it appears that the year has not been
as positive for the ICF industry as many had hoped. More than
six years have passed since the bottom fell out of the construction
market, and despite the best efforts of the world’s leading
economists, the recovery has been relatively modest.
Despite that, the ICF market continues to evolve, and wellmanaged companies are solidifying market share and positioning
themselves for the strong growth that inevitably lies ahead.
Regulatory Changes
A few events that occurred this year will affect the shape of the
ICF industry for years to come.
The Portland Cement Association (PCA) recently updated
the engineering standards it recommends for ICF walls in the
residential sector. Titled 2012 PCA 100 - Above Ground Concrete
Construction, this language will ultimately be incorporated into
the International Code Council (ICC) by way of the American
National Standards Institute (ANSI).
The new standard provides a basic engineering reference for
the design and construction of concrete footings, foundation walls,
and above-grade walls. PCA 100 also includes updated tables that
match recommendations from ACI (American Concrete Institute)
and ASCE (American Society of Civil Engineers).
New energy codes in the U.S. and Canada significantly
increase the amount of insulation required in Northern
climates, and make ICF construction more cost competitive.
(For more information, see Energy Codes and ICFs in the May
issue of this magazine.) Ken Williams, a longtime ICF executive
now working for Fox Blocks says, “ The changes to Canadian
codes are creating incredible opportunities for ICFs,” he says,
“In Manitoba and Saskatchewan, nine out of ten foundations
are being formed with ICFs, and nearly one in ten is using ICFs
all the way to the roof.”
“They’re calling for better insulation in Canada and in the U.S.,
and they’re going to keep doing that for at least the next five years,”
says Gary Brown, vice-president marketing at Amvic Systems.
“Across Canada, it’s now R-22 for ICF and R-27 for traditional
construction. That’s the new minimum.”
36 ICF BUILDER
Green Building shows no signs of slowing it’s meteoric
growth. LEED is the largest green building certification system
in North America, and latest iteration—LEED v4—puts even
more emphasis on energy savings, an area where ICFs have
always performed strongest. Additionally, certified buildings
now have to track actual energy usage for five years, which
should demonstrate how ICF walls actually perform compared
to other alternatives.
"In LEED v4 we're turning on the light," says Rick Fedrizzi,
CEO of the U.S. Green Building Council. "If you claim to be the
best, if you claim to be healthier, prove it. Our world has put real
data on building performance at our fingertips so we can understand
and compare green building projects.”
Finally, a string of high-profile natural disasters—Superstorm
Sandy and dozens of Midwest tornadoes—have kept disaster
resistant building methods in the spotlight. “Resilience” is quickly
becoming the new buzzword in the design community. Obviously,
ICFs outperform frame buildings in this area as well.
Internal Changes
Within the industry, consolidation continues, with large
companies gaining market share at the expense of small, regional
manufacturers. The biggest, most recent sign of this was the
announcement in November that Fox Blocks, the rapidly growing
ICF brand based out of Omaha, Nebraska, was purchasing the
assets of Reward Wall Systems. (See story on p.14 of this issue.)
Reward pioneered commercial ICF construction, and has sold one
of the most popular form line-ups for decades. For now, Fox Blocks
will continue offering both the iForm and the eForm, although once
the sale is finalized in February, that may change.
Small, regional ICF companies are becoming fewer in number.
After an unprecedented drop in construction, and a non-recovery
that has stretched on years longer than anyone expected, even wellmanaged companies are on the ropes. A few of those I spoke with
compiling the comparison chart (pp.24-25) reported they were
distributing forms on an “extremely limited basis” only, and careful
observers will note the demise of at least three brands from the
“regional manufacturer” section of the chart.
Another recent trend with long-term implications involves
the effort to ban HBCD, the chemical used to make EPS foam fire
resistant. This issue is far from resolved. An alternative chemical
was developed by Dow, and should be available in commercial
quantities by next year. The EPS Industry Alliance (EPS-IA),
which includes the remnants of the old ICF Association, has led
the fight to keep HBCD in foam, and so far they appear to be
successful, primarily because there’s no viable alternative. The
state of California, however, has begun investigating whether
HBCD-free foam is acceptable for construction. This move, and
the development of a less-harmful chemical from Dow, may lead to
molders discontinuing HBCD.
Residential Sector
Residential ICF construction is up slightly from last year. That
matches the general trend reported by the National Association
of Home Builders (NAHB), the U.S. Census Bureau, and the
National Association of Realtors (NAR).
Lawrence Yun, chief economist for the NAR, reported
in November that “the supply of new homes has languished
at historically low levels.” For most of the late ‘90s and early
‘00s, builders cranked out more than a million homes per year.
At the top of the bubble in 2007, they built 1.7 million homes.
The bubble burst and hit rock bottom in early 2009, when
they averaged 27% of normal production. And since then,
they’ve never built more than a half-million homes per year.
The U.S. Census Bureau estimates that they’ll close out
2013 near 600,000 single-family units, right about where
they predicted.
Yun points out, though, that the long-term average is 1.5
million units a year, so there’s considerable pent-up demand.
Unfortunately, strict lending standards, a poor job market, and
abundant distressed properties will keep home sales down for the
near term.
Yun anticipates a slightly stronger job growth and more lenient
mortgage-qualification standards, leading to an 18.5% increase in
newly built homes. However, he cautions that if the Federal Reserve
reduces their $85 billion per month loan purchasing program—
known as QE3—next year, interest rates will rise dramatically and
tamp down any increase in home sales.
He adds that uncertainty about how lawmakers will address the
federal budget and debt limit may also reduce construction growth.
Yun’s forecast is in line with other housing economists. NAHB
chief economist David Crowe predicts growth for the next two years.
His organization includes multifamily housing as part of
their residential numbers, so they don’t match Yun’s single-family
predictions exactly. NAHB is forecasting 924,000 total housing
by year end. About two-thirds (629,000) are single family homes.
That’s up 18% from 783,000 units in 2012.
Crowe predicts single-family home starts will rise 30% next
year to 826,000 and finally surpass the one million mark in 2015.
For comparison, before the current recession, the last time America
built fewer than one million homes was in 1992.
“Housing has been growing at two, three and four times the
rate of the rest of the economy in recent months,” says Crowe. “The
cards are in play for a decent and fairly strong recovery in 2014 and
particularly in 2015.”
38 ICF BUILDER
One of the ICF industry’s latest
accomplishments is the successful completion of this 22-story
hi-rise in downtown Waterloo,
just west of Toronto.
He says twenty-something
adults who had moved back in
with their parents or doubled
up with roommates are starting
to buy places of their own, and
households across the nation
have increased their savings and
shed debt, making it easier for
them to qualify to buy a home.
NAHB estimates that multifamily starts were up 20% percent
in 2013 to 296,000 units and will rise an additional 10% to 326,000
units in 2013.
Commercial Sector
Commercial ICF construction turned in a stronger-than-expected showing, driven primarily by three regional markets: the Appalachians, the Southwestern US, and the Kitchener/Waterloo area
west of Toronto, Ontario. Companies that were established in these
areas with strong heavy commercial credentials and good installer relationships did very well. Those that were unable to win jobs in these
three key regions were largely shut out from the commercial market.
Growth in the Ohio River Valley and the larger Appalachian
region is being driven by the education sector. School boards
across Kentucky and now Ohio are insisting on all new schools
being built with ICF. Most of these jobs use more than 50,000
sq. ft. of ICF each, and there are literally dozens on the drawing
board or under construction. Much credit goes to Nudura for
opening up the education market, and to the special class of ICF
installers capable of making these dreams a reality. Heavy-gauge
steel window and door assemblies are becoming the buck material
of choice on these jobs.
It appears that ICF schools are beginning to spread beyond
that specific region. One ICF distributor in Texas reports he bid on
five ICF schools earlier this year—and was awarded the contract on
four of them.
In Arizona, heavy commercial use is driven by the Catholic
Diocese of Phoenix, which has commissioned more than a
dozen massive ICF projects, and has at least that many more on
the drawing board. This has raised the visibility of ICFs in the
marketplace, and now fire stations, emergency call centers, and
other municipal buildings are also being specc’d as ICF.
The Toronto area has always been something of a hotbed for
ICF construction, and the epicenter right now is Waterloo. Within
a few downtown blocks, more than seventy massive ICF buildings
have been erected, using at least eight different brands. Like the
church and school buildings, the Waterloo projects were built for
owners that will be the long-term occupants of the building, so
reduced energy and maintenance costs were important.
Over the next 12 months, the PCA expects a modest 8%
growth in overall commercial construction. Ed Sullivan, PCA
chief economist, says growth in U.S. construction markets
could be dampened by congressional drama that erodes
consumer confidence and hinders recovery. “Each time the
political circus on Capitol Hill addresses extensions of the
debt limit, budget approvals or the fiscal cliff, it harms the
burgeoning economic momentum.”
A New Hope for Generic
ICF Promotion
by Ross Monsour
ICF companies’ marketing efforts have been particularly successful
in Waterloo, Ontario. Every building in this picture is built with ICF.
Photos courtesy Ross Monsour/RMCAO
Insulating Concrete Form technology has been around for more
than forty years and has provided an alternative innovative
technology for builders and contractors to provide an product
that meets the demands of today’s consumer.
The challenge has always been penetration into a market that is
not known for fast change or adoption of new technologies. Historically, the construction industry has been slow to adopt any new technology, but generally the more affordable the option, the faster it is
adopted. Past examples, such as gypsum board or heat recovery ventilators, took about seventeen years to become widely used. This is a rule
of thumb for most changes that are made in the construction industry.
In examining the history of the ICF industry it would seem
that it has taken longer than the rule of thumb explained above.
That’s partially because at the time of ICF’s initial foray into the
market, it was a relatively expensive option compared to the
methods of construction used by traditional builders.
In the late ‘80s when the price of lumber started to fluctuate,
builders—who operate on small margins—began to look for ways
to deliver homes under the original estimate despite the highly variable lumber prices. This opened the door for alternate technologies
such as ICF to provide a cost-effective solution. The primary components of the system (concrete and EPS foam) were much more
stable in terms of pricing. It also provided builders with flexibility
for design decisions and therefore additional cost efficiencies.
In order for the ICF industry to grow, there needed to be a
focus on marketing and sales which began through trade shows and
contractor training, even selling to the do-it-yourselfer. The larger
concrete and cement industries also recognized the huge benefit
that would be achieved with the expansion of this technology into
the marketplace. In the 1990s, the Portland Cement Association
(PCA) partnered with the infant ICF industry helping them establish the Insulating Concrete Forming Association (ICFA). They
jointly developed several programs from marketing, training, codes
and standards. The main purpose was to run marketing collectively
from an industry perspective rather than as individual company.
The association also helped benchmark the industry, to know
40 ICF BUILDER
where it stands in terms of government lobbying, research resources,
market penetration and forecasting. The ICFA conducted surveys
of its members in order to track and address the above issues. The
PCA eventually withdrew direct support of ICFA, and a combination of circumstances resulted in the ICFA closing it’s doors in 2008.
Since that time there have been several attempts to bring the
industry together. ICF Builder magazine has been at the forefront
of this effort with their annual ICF Builder Awards banquet. They
provide a venue for the ICF contractor industry to connect and
exchange views and stories.
The EPS Alliance has offered a home for ICF manufacturers
within their structure. In Canada, the Ready Mixed Concrete Association of Ontario (RMCAO) established a technical group of ten
ICF manufacturers that deals with issues related to codes and standards and recently developed a National ICF standard for Canada.
With the success of this group, the Canadian Ready Mixed
Concrete Association (CRMCA) has created an ICF marketing
group run by the RMCAO and the British Columbia Ready
Mixed Concrete Association (BCRMCA). This group is still in its
infancy but was created for several reasons. First, the need to have
the industry working together never went away. In fact, the need is
stronger than ever. Second, the ICF manufacturers that developed
the Canadian standard have seen the advantages of working as an
industry, and the next natural step is to apply this to marketing.
The following ICF manufacturers are involved in the marketing
group; Arxx, Amvic , Advantage (Plasti-Fab), Fox Blocks (Airlite
Plastics), Logix, Nudura, Quad-Lock, Reward, and Superform.
The first task was to identify the market that would be most
beneficial to the ICF manufacturers with the limited resources
of the collective group. The company representatives selected the
three- to eight-story market, which has seen unprecedented growth
in a specific area of Ontario. In the cities of Kitchener and Waterloo,
there have been over 70 of these ICF buildings built in the last eight
years. The latest one is 25 stories high.
They also identified a need to benchmark where the industry
is in terms of size in North America, and how that compares to the
past few years. This data will give the group the ability to measure
the success of the marketing program they will implement over
the next couple of years. The group also set targets for where the
industry would like to be in five years.
The group set to work to try and identify the reasons for the
uptick in the ICF high rise market. We are seeing several reasons for
this growth specific to the Kitchener/Waterloo region. The majority of the buildings we are seeing are student residences, and because
the developers are also the long-term owners, they recognized the
benefits of reduced energy and maintenance costs for these buildings. Also, ICFs provide faster construction schedules, which better
matches the required time frame for construction of these buildings, usually the school year.
Other owner/developer buildings such as hotels, schools and
senior residences also recognize these same two benefits and have
likewise become growth markets. The Canadian ICF group will
attempt to develop a marketing program around the characteristics
of selection identified in the next phase of this industry led initiative.
The push for energy efficiency in housing and buildings will also
continue to generate opportunities for the ICF industry. Canadian
codes and standards are pushing the envelope, and ICF is recognized as
a more effective R-Value. With the new codes, competing systems must
take into account thermal bridging, finally creating a level playing field
for ICF systems after years of bias. The promotion of net-zero housing
will also assist in ICF being recognized as one of the most cost-effective
and efficient methods of achieving energy efficiency.
Challenges still exist. For instance, getting regulatory building
evaluation tools to properly model the effects of thermal mass from
an ICF has been problematic. If resolved, this will go a long way to
recognizing the actual field effects which we all know exist from
experience over the years.
A couple of Canadian studies have tried to identify the impacts
of the thermal mass in both a high rise situation and a year-long
modeling on two sections of an ICF wall. The intent was to try to
determine an equivalent R-value to be used in the design and sizing
of the mechanical systems.
Field monitoring has also been increasing over the last couple
of years, and has generally validated the thermal mass impact.
Education and training from the industry perspective will remain
one of the last major obstacles to move the ICF industry into the
forefront of construction.
One other challenge: Until the ICF industry has an industrydriven training protocol that is recognized by building authorities,
this will limit ICF’s growth in the market.
The industry’s willingness to sit down and discuss the future
with the CRMCA, represents a return to the days when recognition
of the ICF industry working together will bring ICF to the top of contractors', developers', architects', consumers' and governments' minds.
Ross Monsour is director of marketing for the Ready Mixed
Concrete Association of Ontario, and coordinates the efforts of the ICF
technical and marketing committees referenced above.
New Products
Watkins 45-degree ICF Hanger
RP Watkins is now marketing a
45-degree truss bracket for floor joists and
roof trusses.
The Watkins Hanger can dramatically reduce the cost of multistory ICF
construction by eliminating rims boards,
anchor bolts, rim joist hangers, and the
truss hangers to attach to them.
Now, the company is proud to offer
a 45-degree bracket. The bracket’s design
creates and instant true 45-degree angle
to set the truss. Unlike some competing
systems, the Watkins Hanger design offers a full bearing base. The
hangers are pre-slotted to make it easier to place screws in tight
angle spaces.
Last year, the company opened two manufacturing locations in
Canada to ensure product ordering is now easier than ever before.
To order, or for additional info, visit www.watkinshanger.com,
or stop by their booth at World of Concrete, N2013.
Polyurethane ICF on the Market
U-Blocks are a polyurethane ICF that combine high R-values
with easy installation and economical prices.
The superior tensile strength of U-Blocks' polyurethane makes
installation easier because U-Blocks walls hold concrete without
the additional strapping and plywood reinforcement that many
polystyrene ICFs require. U-Blocks walls have been poured at over
12 feet in a single pour without any blowouts.
“Installation is so simple it even lends itself to do-it-yourselfers,”
said Dan Jensen, president of U-Blocks, Inc.
U-Blocks are available in two sizes. The smaller blocks have a
5” concrete core while the larger blocks have an 8” core. Adjusted
(whole-wall) insulation values range from R-24 to R-49. Nominal
values for the form are between R-56 and R-84.
The closed-cell polyurethane in U-Blocks is termite resistant,
has the highest Class 1 fire rating and is ideal for coastal areas
because the salt air does not deteriorate polyurethane. U-Blocks
do not contain CFCs, HCFCs or other gases harmful to the
environment.
For more information visit www.U-Blocks.com or call
801-899-9678.
42 ICF BUILDER
Polycrete “Split Block”
Polycrete now offers “split
blocks” with different height wall
panels on each side of the form.
Their Big Block lineup has been
available in heights of 12, 18, and
24 inches for some time. Now,
installers can mix and match
panel heights on each block.
If, for instance, the job has
a slab turning down into an ICF
footing, it calls for a 24-inch
height on the outside of the wall and 12 inches on the inside, the
installer doesn’t need to make the modification in the field. It can be
ordered from the plant with that configuration.
This capability is available with any concrete core width from
5-1/2” to 24” and all three different heights that can be mixed and
matched on the same block.
For more information visit www.PolycreteUSA.com or call
800-570-4313.
Better Acrylic Stucco Basecoat
Earlier this year, Parex USA began offering new basecoats and
adhesive for use with EPS foam.
The first, 121 Cool Base, is a premium white EIFS basecoat
and adhesive. It’s 30% percent cooler than typical products,
which means less suction and hydration when the final finish is
applied. That translates to better coverage and faster and easier
finish application.
The second product is named 121 Dry HI; the last two
letters stand for high impact. It’s a high performance basecoat
and adhesive fortified with a unique blend of raw materials for
increased impact and puncture resistance. With standard 4.5 oz.
mesh, it withstands 88 inch-lbs. of force, compared to 36 in-lb.
of impact resistance regular Parex products achieve. With thicker
mesh, 121 Dry HI can withstand impacts in excess of 160 in-lbs.
It’s ideal for ground floors and other areas where greater impact
resistance is required. The product is also formulated for enhanced
workability and application.
Both 121 Cool Base and 121 Dry HI are shipped in 50-pound
bags. Coverage, mixing instructions and limitations can be found in
the Product Data Sheet at www.parex.com.
Can ICFs be Cheaper than Frame?
How much more does it cost to build
with ICFs? Two percent more? Five percent? Ten percent? Pick a percentage that
suits your needs.
We have all used them, and unfortunately these percentages have historically
been true. It’s also unfortunate that these
percentages have scared away many customers before they even got started with
their plans.
This battle over the true cost of ICFs
has been waged since the dawn of our industry. With the technology and manufacturing advances over the past few years,
what is the current cost of ICFs? Is it possible that ICFs can be incorporated in a design where it is actually less expensive than
frame structures? The simple answer is yes.
I know what you are thinking. Either A, I am off my rocker; or B, "sure, a
simple home with only 4 walls and no aesthetic character". But what if I were to tell
you that a 6,000-sq.-ft. custom ICF home
could be 5% less expensive than its wood
frame counterpart? Now you must be really
thinking that option A is the right answer.
But it’s true. Let me give you an actual, realworld example of a recent home I designed.
About two years ago, I was approached by a battalion chief for a local fire
department to design a new home for him
and his wife. Many of the new fire stations
in the area were being built with ICFs and
they really liked the idea of using them for
their new home.
We started on his design and worked
thru his family’s needs, wants and dreams.
When the design was done, the home was
nearly 6,000 square feet of livable space
and about 10,000 sq. ft. under roof. It was
a wonderful design with lots of character
plus ample living and entertaining space.
44 ICF BUILDER
Being in Arizona, the design integrated
outdoor living spaces as well.
The design called for nearly 7,000 sq.
ft. of ICF walls reaching 12 feet high. The
design also included 42 corners plus several
angles, curves and T intersections. This
home was going to utilize the full product
line-up from many manufacturers.
Also in that design were over 30 windows and eight exterior doors. Three of
the doors were multi-panel sliders that
spanned between 12 and 18 feet. This
home exemplified the potential of indoor/
outdoor living.
They loved the design but were concerned about the budget. So, when we had
the conceptual design worked out, we put it
out for preliminary bid to ensure the design
was within their budget.
The bids were very competitive and
in the end, came in at pretty close to their
budget. Then, as has happened to all of us,
a framing contractor dropped a bombshell.
He said that he could cut the budget by “at
least $40,000” (5%) if we changed from
ICF to 2x6 construction.
The owners wanted a sit-down with
me. I used the normal pitch to save the ICF.
I reminded them that it was the same 5%
higher that I told them in the beginning. I
fought long and hard to keep ICFs in the
design. I explained about insulation, structural integrity, and in the end even played
the fire card thinking it would be something the fireman owner could relate to.
After many meetings and emails the
owners decided that $40k could pay for a
lot of electric bills. They wanted to change.
My job is to give the best service to my
clients (even when I don’t agree with their decisions). After all it is their house and their
money. To my dismay, the design was changed
by Robert J. Klob
to 2x6 frame construction; ICF was out.
We then commenced with the structural engineering portion of the process.
Remember all those doors and windows I
mentioned previously? They became a thorn
in the engineer’s side as he was designing
his shear walls & bracing in the now wood
framed exterior walls. The owners were adamant. All of the openings must stay.
With concrete, it’s not a big deal to
have an 18-foot-wide by 9-foot-tall opening with only 24 inches of wall at each
end. With wood, it’s not so easy. So, back
to the famous framer with our shear panel
concerns. His solution was to use Simpson
Strong-Wall®. He said that he had used
them before and they were "not too expensive" and easy to install. The engineer told
the owner that based on his experience;
they were neither easy nor cheap.
The problem was that there were 13
panels that would be required. Again, the
owner didn't want to modify the design
and the framer said that his price would be
"about" the same. We proceeded.
At all of the Strong-Wall® locations
the anchoring and footings can be quite
large. When combined with some of the
increased wind loads in the current building codes due to past storms, it further exacerbates the problem. Four of the panels
required a footing that was 9' long x 5' wide
x 30" deep with substantial rebar. That is
112 cubic feet, or over 4 cubic yards of concrete for each footing.
We were too far in to go back now
and the owners didn’t want to hear about
any more problems, they just wanted to get
started on the construction.
Well, the concrete was installed for all
these wonderful new footings at an additional cost of about $25k. The 2x6 frame
walls went up with the Strong-Wall panels.
The contractor’s “not too expensive” panels
added $18k+. Then there was the additional required sheathing, bracing, beams,
posts, footings, labor—and since they still
wanted a very energy efficient home— expansive foam insulation. That added another $42,000 that was not allocated in the
original budget.
I wish I had a nickel for every time the
general contractors and the owner said that
we should have never switched from ICF.
There were so many delays, additional expenses and unnecessary stress that it made
the process very difficult for the owners,
both at home and on their budget.
Because of the options the owner
wanted and the requirements to meet code
for the frame construction, the actual cost
turned out to be $45,000 greater than the
ICF design would have been. So for this
home, the owners would have saved over
5% on the overall build cost by using ICFs
instead of wood frame. This savings does
not take into consideration monthly savings
from maintenance and utility expenses.
The home was completed recently and
they do love the design, so I guess I did my
job. It is a nice home and one I am proud of.
But I know it could have been so much better.
I have recently kept two customers
from switching to frame just by telling them
this story. Hopefully this will help you and
your customers learn from the mistakes
of others and expose some of the hidden
fees that exterior wood frame construction
brings. Few things are worse than regretting your choices during the building of
your dream home. Every time you walk in
the front door, or open that electric bill, or
make the mortgage payment, you will be reminded of them.
Ad Index
Robert J. Klob is President of Robert
Klob Designs, Inc., a full service residential design firm specializing in ICF design
and consulting throughout the U.S., Mexico and the Caribbean. He can be reached
at www.rkdzns.com, 866-584-2474 or
robk@rkdzns.com.
Giraffe5
Amvic3,37
BuildBlock19
Canam-HambroIBC
DMX13
Ecospan7
EproBC
European Windows
18
EZ Breathe
17
Fab-Form38
Fox Blocks
FC,11
Hilltop42
ICF Builder Awards
ICF Builder Magazine
35,42
45
Inexo18
IntegraSpec29
Lavann ICF Hangers
43
Lite-Deck41
Logix39
MTE Consultants
14
Nudura9
Oztec IFC
Pre-Buck12
Quad-Lock16
Sider-Oxydro8
Superform43
U-Blocks15
World of Concrete
46
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