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Durisol Insulated Concrete Wall Form
Coldham Architects LLC
Durisol: Insulated Concrete Form (ICF) WallForming System
Bruce Coldham, Coldham Architects, LLC — www.coldhamarchitects.com
Affordable Comfort. - Westford, MAOctober, 2003
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An explanation of the material andassemble of the wall system
Four project case examples
A discussion of the properties of thewall system
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Insulated Concrete Form (ICF) Material
• Shredded (recycled)“mineralized” woodmaterial
• Combined in acementitious slurryand pressed into a“wallform” block
• Mineral wool insulationplugs inserted into thecore
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Below grade foundation walls
Above grade walls
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First Course isset out preciselyon footing ……...by masons orcarpenters?
It is formwork, not abearing CMU wall.
• Use string line
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Wallform blocks aredry-stacked
Wood biscuits to align the interior face•.
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Door and window openings
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Cutting wallforms
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Steel reinforcing
• Steel reinforcingbars horizontallyand vertically
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Wall Form Shoring
• Prevent corner blowouts
• Prevent uplift andleaking of horizontaljoints — but this materialis much heavier thanEPS blocks
• Align and stabilize thetop course
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Fill core with concrete
• Pump placement — 3,000 psi and pea stone.
• We laid the wall forms to their full height andpoured the core in three lifts (circuits) in asingle pumping operation.
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Wall finishes …. and air barrier
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The wall form material acceptsmechanical fastening of wood and otherfurring materials using screw fasteners.
Exterior wall finishes
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Waterproofing ………….•.
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Supporting intermediate floors
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Supporting intermediate floors
Ledgers bolted to the concrete core through5” diameter shear connectors
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Lintels.. Header beams over rough openingsWallform create reinforcedconcrete lintels•.
Wrapped engineeredlumber beam ends inwallformed beampockets•.
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Accommodating electrical circuitry
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Materialproperties:
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A reliably well insulated masonry wall
Insulation value — R 8 to 20
Theoretical insulation value is achievable without requiringheroic oversight
Material properties:
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A non-combustible wall assemblyMaterial properties:
••Surface Burning (ASTM-E84)Surface Burning (ASTM-E84)
––Smoke Developed: 11Smoke Developed: 11
––Flame Spread Index: 0Flame Spread Index: 0
••UL/ULC (S101)UL/ULC (S101)
––4 hour rating4 hour rating
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The “breathability” of the wall system, particularly with a lime-based plaster applied to the interior walls, which maintains the wall’s moisture permeability. The exterior wall acts as something of a humidity reservoir with excess humidity taken up by the exterior walls and released back to the interior as interior RH levels diminish.
Air and vapor permeable — affording a vaporstorage potential
––Vapor PermeabilityVapor Permeability••20.5 (dry) - 26.5 (100%RH)20.5 (dry) - 26.5 (100%RH) ng ng / (Pa s m)/ (Pa s m)••14 (dry) - 18 (100%RH) perm - inch14 (dry) - 18 (100%RH) perm - inch
––Vapor Vapor PermeancePermeance••1.75 imperial perm for 81.75 imperial perm for 8”” block block••400 - 800400 - 800 ng ng/(Pa s m/(Pa s m22) per 50 mm) per 50 mm
Material properties:
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No capacity to "lift" moisture throughcapillary action — in thewallform material
… meaning that thewallform material is afree draining medium
Material properties:
No propensity tofreeze-thaw damage
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Completely non-biodegradable wall systemMaterial properties:
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Unable to support the growth ofmolds and mildew
Material properties:
The cementitious matrixis too alkaline
Not attractive totermites, but wallforminterstices appear toallow passage fortermites.
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Sound absorbent
sound attenuation propertiesespecially useful in largeinterior multi-use space.(Leave Durisol materialunfinished above 7’)
Material properties:
Noise reductioncoefficient — 0.70 to0.95
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The wall form seemsappropriate use of themixed hardwood forestproduce of the USnortheast, whichotherwise has limiteduse in building.
Material properties:
Regionally appropriate material ?
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Small, Timber Framed House — Francestown, NHCompleted: 2002Building Area: 1,500 s.f.Wall system cost: $11/ s.f.
Design requirements:
Robust, durable supportcomplement for a timberframe
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Concentrate the frameinvestment overhead — leta less expensive (and moresuitable) material be thewall
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In this instance, thewallforms were laid up on aconventional concretefoundation wall
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Great Barrington House — Gt. Barrington, MA
Design requirements:Interior floor flowscontinuous to the exterior.
Durable substrate forvegetated walls
Completed: 2001Building Area: 3,500 s.f.Wall system cost: $12/ s.f.
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2'-0" OVERHANG
HARDWOOD WINDOW SILL
3/4" PLYWOOD
5/8" GYPSUM WALLBOARD
5/8" GYPSUM BOARD OVER POLY. AIR / VAPOR MEMBRANE
2 X 10 WALL PLATES
EXTERIOR STUCCO
METAL ROOF
CONCRETE INFILL
WOOD ROOF TRUSSES @ 24" o.c.
1 X 3 FURRING @ 16" o.c.
SELECT PINE TRUSS RAFTER
VENT ROOFING FELT
MINERAL WOOL INSULATION INSERT - 80mm
3/4" C.D.X OR OSB ROOF SHEATHING
1 X 4 WOOD BASEBOARD
1 X 6 WHITE CEDAR T&G BOARDS
5/4" X 2" WHITE CEDAR
DURISOL BLOCK - 300 mm THICK
#4 HORIZONTAL FOOTING REINFORCEMENT
#4 DOWEL BAR
9" X 20" CONCRETE STRIP FOOTING
1 X 3 WOOD SILL APRON
DAMP-PROOF MEMBRANE
WINDOW BLOCK
1/2" DIA. ANCHOR BOLT @ 48" o.c.
1" RIGID INSULATION
SEAL AIR / VAPOR MEMBRANE TO WALL PLATE
4" CONCRETE SLAB
6" FOOTING DRAIN
WATERPROOFING(BELOW GRADE)
#4 BAR VERTICAL REINFORCING
#4 BAR HORIZONTAL REINFORCING
1/2" DIA. ANCHOR BOLT @ 16" o.c.
9 1/2" TJI JOISTS
3/4" SUB-FLOOR
2" CONCRETE TOPPING SLAB (FINISH FLOOR)
5/4" X 14" WOOD FRIEZE BOARD
R-40 (12") BLOWN-IN CELLULOSE INSULATION
4" CONCRETE SLAB
1" RIGID INSULATION
HORIZONTAL FOOTING REINFORCEMENT
1/2" DIA. ANCHOR BOLT @ 16" O.C.
DOWEL BAR
1 1/2" RIGID INSULATION THERMAL BREAK
5/8" GYPSUM WALLBOARD
HORIZONTAL REINFORCING
WATERPROOFING(BELOW GRADE)
CONCRETE STRIP FOOTING
6" FOOTING DRAIN
VERTICAL REINFORCING
1 X 4 WOOD BASEBOARD
2 X 3 STRAPPING
DAMP-PROOF MEMBRANE
2" CONCRETE TOPPING SLAB (FINISH FLOOR)3/4" SUB-FLOOR
9 1/2" TJI JOISTS
S.I.P. - 5 1/2" RIGIDINSULATION (EPS) W/1/2" STRESSED SKIN OSB,BOTH SIDES
4" CONCRETE SLAB
1" RIGID INSULATION
HORIZONTAL FOOTING REINFORCEMENT
1/2" DIA. ANCHOR BOLT @ 16" O.C.
DOWEL BAR
1 1/2" RIGID INSULATION THERMAL BREAK
HORIZONTAL REINFORCING
WATERPROOFING(BELOW GRADE)
CONCRETE STRIP FOOTING
6" FOOTING DRAIN
VERTICAL REINFORCING
DAMP-PROOF MEMBRANE
2" CONCRETE TOPPING SLAB (FINISH FLOOR)3/4" SUB-FLOOR
9 1/2" TJI JOISTS
WOOD SHINGLES OVER BUILDING WRAP MEMBRANE
1 X 4 WOOD BASEBOARD
5/8" GYPSUM WALLBOARD
2X6 WALL PLATESWOOD SHINGLES OVER BUILDING WRAP MEMBRANE
WOOD FRAMEWALL - 2X6 @ 24" O.C. W/ 1/2" OSB SHEATHING
7" CELLULOSE INSULATION
2X6 WALL PLATES
ELEV. MALE - 96'-8" FEMALE - 99'-1" T.R. - 99'-4"
ELEV. MALE - 105'-3" FEMALE - 107'-8" T.R. - 107'-11"
Great Barrington House — Gt. Barrington, MA
Wall system design options:
Durisol I.C.F.
Conventionalstud frame onconc. foundationwall
S.I. P. on conc.foundation wall
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Wholefood farm store — Ghent, NYCompleted: 2003Building Area: 9,000 s.f.Wall system cost: $16/ s.f.
Design requirements:Rodent exclusionSound absorption
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Wholefood farm store — Ghent, NY
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Wholefood farm store — Ghent, NY
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Wholefood farm store — Ghent, NY
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Wholefood farm store — Ghent, NY
Cement substitution— ’Gran Cement’
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Vipassana Meditation Center — Shelburne, MA
Design requirements:
Durability — “ abuilding that wouldlast 100’s of years”
Completed: Project abandonedBuilding Area: 30,000 s.f.
Non-combustibility —a large building in anisolated setting
Multiple accessibility— many on-gradeexits and entries
Conform to a slopingsite
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Vipassana Meditation Center — Shelburne, MA
Design opportunity:
Use the insulatedmass of the structuralenclosure to carry thebuilding whilst theheating system isentirely serving theDHW need.
The space heating and theDHW loads were similar inmagnitude.Therefore a 50% reduction inheating system capacity waspossible.
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The Durisol Corporationwww.durisol.com
www.coldhamarchitects.com
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Material Properties
• Modulus of Elasticity (ASTM C513)
– E=1500 MPa compression
• Modulus of Rupture (ASTM C293)
– 1.0 to 3.0 MPa
• Ultimate Compression Strength (ASTM C513)
– 1.5 to 3.0 MPa
• Shear Strength: > 0.2 MPa
• Durisol to Concrete Bond: > 0.6 MPa
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Great Barrington House — Gt. Barrington, MA