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Insulating Concrete Forms for Residential Construction

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Insulating Concrete Forms for Residential Construction INSULATING CONCRETE FORMS FOR RESIDENTIAL CONSTRUCTION: DEMONSTRATION HOMES Prepared for: US Department of Housing and Urban Development Office of Policy Development and Research Washington, DC and The Portland Cement Association Skokie, Illinois Prepared by: NAHB Research Center, Inc. Upper Marlboro, Maryland May, 1997 NOTICE The U.S. Government does not endorse products or manufacturers. Trade or manufacturers names appear herein solely because they are considered essential to the subject of this report. The contents of this report are the views of the contractors and do not necessarily reflect the views or policies of the US Department of Housing and Urban Development or the U.S. Government. Foreword Recent material advances, technical developments, supply concerns, and economic uncertainty have prompted homebuilders to examine innovative framing materials and methods. Although such systems have existed for some time, builders often are hesitant to explore approaches that differ from their conventional practice. In many instances, their reluctance can be attributed to a lack of information about other systems. In response to heightened interest, the U.S. Department of Housing and Urban Development (HUD) commissioned a review of structural materials available for homebuilding. The results, Alternatives to Lumber and Plywood in Home Construction, were published in 1993 and included the identification of several promising materials. Publications released in 1994 and 1995-- Alternative Framing Materials in Residential Construction: Three Case Studies, and Steel Framed Residential Construction: Demonstration Homes--provided insight into the installed cost of several of these systems. HUD is continuing to research alternative structural materials. This report, Insulated Concrete Forms for Residential Construction: Demonstration Homes, provides builders with practical information based on actual experiences with these materials. The information presented here accurately describes the Insulated Concrete Form (ICF) framing process and the way these construction systems are incorporated into homebuilding. Insulated Concrete Forms plays a vital role in the Department' cooperative effort with the homebuilding and concrete industries to develop cost-effective, prescriptive methods of constructing ICF framed homes. We believe the report will guide builders in the use of this new technique, which promises to enhance housing affordability, and promote healthy competition through optimal use of all of our natural resources. Paul A. Leonard Deputy Assistant Secretary for Policy Development Acknowledgments This report was prepared by the NAHB Research Center under a cooperative agreement with the Portland Cement Association (PCA) and the US Department of Housing and Urban Development (HUD). The input and review provided by Lionel LeMay of PCA and William Freeborne of HUD contributed significantly to the successful development and execution of this project. This report was co-authored by Donald Carr, William Farkas, P.E., Matthew Pesce and Theresa Rosette. Technical support was provided by Geoffrey Gilg, James Lyons, Shawn McKee, and Albert van Overeem. Mark Nowak provided technical review. Julie Kostro provided administrative assistance. NAHB Research Center would like to thank the following builders for their participation in demonstrating the use of insulating concrete forms in their homes: Dominion Building Group Virginia Beach, VA John Weaver Custom Homes Austin, TX Gary Niles Homes Sioux City, IA Romak & Associates Chestertown, MD NAHB Research Center would like to thank the following Insulating Concrete Form manufacturers for their contributions to this project: American Polysteel Albuquerque, NM I.C.E. Block? Building Systems, Inc. New Carlisle, OH Lite-Form, Inc. Sioux City, IA Reddi-Form, Inc. Oakland, NJ TABLE OF CONTENTS LIST OF FIGURES, TABLES, AND PHOTOS ...............................................................................................v EXECUTIVE SUMMARY ...............................................................................................................................ix SECTION I Purpose, Scope and Overview of Insulating Concrete Forms INTRODUCTION.............................................................................................................................................1 INSULATING CONCRETE FORMS...............................................................................................................3 General ................................................................................................................................................3 Builder Issues For ICF Construction ...................................................................................................6 Potential ICF Advantages to Home Purchasers...................................................................................7 BUILDING CODES..........................................................................................................................................9 General ................................................................................................................................................9 Fire Code Considerations ....................................................................................................................10 Termite Protection Issues ....................................................................................................................10 Moisture Control .................................................................................................................................11 Seismic Resistance ..............................................................................................................................12 Wind Resistance..................................................................................................................................12 TYPICAL CONSTRUCTION PRACTICES ....................................................................................................13 General ................................................................................................................................................13 Concrete Design Requirements ...........................................................................................................13 Variations Due to Climate ...................................................................................................................13 Foundations ........................................................................................................................................13 Comparisons to Wood Framing...........................................................................................................14 Pre-Construction Planning.............................................................................................................14 Utilities ..........................................................................................................................................15 Openings for Doors and Windows.................................................................................................15 Corner Details................................................................................................................................16 Floor Joists and Bracing ................................................................................................................16 Finished Surfaces...........................................................................................................................16 THERMAL OVERVIEW AND ANALYSIS....................................................................................................19 Cost Comparisons................................................................................................................................19 Thermal Resistance .............................................................................................................................19 Infiltration............................................................................................................................................23 Infrared Thermography - Resolution and Physics ...............................................................................23 Peak and Annual Energy Consumption Analysis.................................................................................23 SECTION II Demonstration Home Construction Process INTRODUCTION.............................................................................................................................................27 SITE PROFILES ...............................................................................................................................................29 DEMONSTRATION HOME #1 - VIRGINIA BEACH, VIRGINIA ...............................................................31 ICF Product Summary.........................................................................................................................33 Construction Summary ........................................................................................................................34 Cost Summary .....................................................................................................................................42 Builder Comments...............................................................................................................................43 Homeowner
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