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iForm® Installation Procedures ...... 2
Introduction ...... 2 Planning and Preparation...... 3 Tools and Materials...... 4 Handling and Storing Forms...... 5 Estimating ...... 5 Footings, Slabs, Shallow Frost Protected Footings and Grade Beams...... 11 Wall Layout ...... 15 Staging Materials for Jobsite Efficiency...... 16 iForm Course Placement ...... 17 Door and Window Openings...... 26 Utility Penetrations and Beam Pockets...... 31 Alignment, Bracing and Scaffolding...... 32 Intersecting “T” Walls...... 34 End Walls...... 35 Gable End Walls ...... 36 Radius Walls...... 36 Horizontal and Vertical Transition of Form Sizes...... 40 Four-Foot Foundation Walls ...... 40 Checklist Prior to Concrete Placement...... 43 Concrete Placement...... 44 Checklist After Concrete Placement ...... 52 Intermediate Floors ...... 52 Roof Connections...... 59 Electrical and Plumbing ...... 60 Interior and Exterior Finishes...... 61 Air and Vapor Retarder...... 70 Exterior Transition Area...... 70 Waterproofing ...... 71 HVAC and Indoor Air Quality...... 72 Termite Protection...... 74 Reward Ledge Form and xLerator® and tieKey® Anchor...... 76
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iForm® Installation Procedures
Introduction
Reward products are supplied through a nationwide network of independent distributors, dealers and builders. These installation procedures have been developed from the experience of building contractors nationwide who use our products. While these procedures are recommended guidelines that work best in general, there are other acceptable techniques that may work as well for specific situations.
Due to continued research and development, information contained in this manual may be added, deleted or revised. It is the responsibility of the user to make sure that they are using the most current information. Reward's website will always contain the most current information.
Reward Wall Systems has no control over the installation, choice of materials and applications used in the installation of our product; therefore, Reward assumes no responsibility or warranty expressed or implied beyond the physical characteristics of the Reward product.
*Any material or product that is applied in contact with the expanded polystyrene (EPS) foam plastic material of the iForm must be compatible. Petroleum, solvent, ketones, and esters based products are not compatible and will deteriorate the foam.
The details in this manual are generic and conceptual in nature. Reward Wall Systems, Inc. is not responsible for final design, construction and compatibility. iForm by Reward Wall Systems provides formwork for a solid continuous flat cast-in-place concrete wall. It is nominally 16" high, 48" long, and comes in the following widths: • 9" (228 mm) wide - 4" (102 mm) flat core • 11" (279 mm) wide - 6" (152 mm) flat core • 13" (330 mm) wide - 8" (203 mm) flat core • 15" (381 mm) wide - 10" (254 mm) flat core • 17" (432 mm) wide - 12" (305 mm) flat core
The size and shape of the iForm may vary by up to 0.75% of their specifications. iForm provides very strong formwork for placing concrete due to uniquely designed plastic form ties that maximize the concrete flow in the forms. The iForm tie is 1 ¼" (32 mm) wide and 6" (152 mm) on center and recessed ½" (12.7 mm). This makes applying all interior and exterior finishes easier than on similar forms. Additionally, the iForm's furring strip allows the acrylic finishes (stucco) to be applied without the problems associated with exposed steel or plastic furring strips.
It is important to note that if the forms or bundles of forms are to be stored outside for an extended period of time, EPS foam and plastic ties must be protected from UV degradation.
ADVICE AND ASSISTANCE can be obtained by contacting your local independent distributor, dealer or builder or the Reward Wall Systems, Inc. Technical Service Department, 800-468-6344, located at 9931 South 136th Street, Suite 100, Omaha, NE 68138-3936. Updated: April 2011 2 Release: K
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Planning and Preparation
Spending time planning and preparing in advance of all phases of the construction process will make for an efficient and successful project. To get started you should read and understand the plans, educate and provide information to the building official, estimate the materials, have the proper tools and materials available and provide the right size crew. Taking the time to execute right the first time will provide happy customers and higher profits for the project.
Specific items to consider when pre-planning for the project include storage of form bundles, access for concrete pump and trucks; establishing concrete delivery lead times; concrete and steel reinforcement requirements; construction of rough opening door and window bucks; coordination of concrete anchor bolts and embeds; coordination and layout of penetration sleeves; tool and material accessibility; and keeping a clean and accessible work site.
It is important to know and understand the local building code in your area. Building a relationship with the local building official and providing them with information before the project starts is another key to success. Reward has received building code compliance with all national model building codes and other local building codes as shown in the following evaluation reports.
United States ICC Evaluation Service ESR-1552 (IRC, IBC, UBC, BOCA, SBC) State of Wisconsin 200715-I Florida Product Approval FL 1743- R2 City of Los Angeles RR25418 City of New York MEA-116-03 Miami-Dade 08-0805.19
Canada Canada CCMC 13107-R ASTM- C578, E119 & E84
The International Residential Code (IRC) has adopted insulating concrete form prescriptive design for basement walls in section R404.4 and for above grade walls in section R611. Similarly, the Portland Cement Association and HUD have available prescriptive design prepared by the National Association of Home Builders Research Center. This document, PCA EB118, is titled The Prescriptive Method for Insulating Concrete Forms in Residential Construction. The PCA also has a document titled “PCA100-2007, Prescriptive Design of Exterior Concrete Walls for One and Two Family Dwellings.” ACI 332, Code Requirements for Residential Concrete is an additional prescriptive design guide.
Reward’s engineering section also has many design aides that can be utilized for the design of walls using the iForm.
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Any material or product that is applied in contact with the expanded polystyrene (EPS) foam plastic material of the iForm must be compatible. Petroleum, solvent, ketones, and esters based products are not compatible and will deteriorate the foam.
Tools and Materials
The following tools and materials are recommended for installing Reward forms. While not all of the tools and supplies listed are typically needed to construct Reward walls, they will enable a construction professional to handle almost any project.
Recommended Tools
Chalk line Sawzall String line Handsaw Rebar bender and cutter Keyhole saw Tape measure Utility knife Hammer Cordless drill 48" (1219 mm) Level Framing square Rebar "pigtail" twister Cutting pliers Hot knife Transit or laser Power saw Pliers Table or circular saw Permanent markers Concrete fastening system (i.e., Ramset) Extension cord Step ladder Concrete trowel Concrete vibrator - 1” (25.4 mm) or less diameter, low frequency, 1 hp motor max.
Materials
Reward iForms Anchor bolts (floor, top plate) Vertical and horizontal steel reinforcement Plumbing/electrical sleeves Concrete Various lumber sizes Rebar tie wire Low expansion spray foam Bar ties Fiber tape Bracing, alignment and scaffolding (with turnbuckle) Waterproofing material Nails OSB or plywood Coarse-thread screws - various lengths Reward’s light gauge metal starter track 2" & 3" (50.8 mm and 76.2 mm) 2 ½ x 2½ (63.5 x 63.5 mm) , 28 gauge Window and door buck material Waterproofing membrane Window and door buck anchors Transition area material
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Handling and Storing Forms
Reward iForms are delivered in bundles of different counts. They are packaged with corrugated trays on the bottom and top and wrapped with a clear plastic stretch wrap. The bundles are packaged in cubes for easy handling. Unloading the bundles can be accomplished manually by two people or with powered lifting equipment. Some use dollies to move bundles from location to location. In some cases conduit pipe or 2x4’s can be placed through the ends of the bundles and used as handles for two people to carry.
The product consists of soft expanded polystyrene material and care should be taken when handling the forms to avoid breaking and cracking the forms, which could affect the performance of the product.
If form bundles are transported by open trailer, the bundles should be securely tied down with straps and positioned so that the wind travels through the open ends of the forms.
When unloading a new shipment of product, the quality and quantity of the product should be verified by signing the Bill of Lading. Contact Reward Wall Systems immediately in the unlikely event of any problems.
Bundles of forms should be stored in the same manner as they are shipped so that the forms are in upright direction and not on their sides.
If the form bundles are to be stored outside for an extended period of time, the forms must be protected from Ultraviolet (UV) rays and other weather elements. This is accomplished by covering and securing the bundles.
Estimating
Items to consider before estimating:
Ground soil conditions Floor and roof spans Design wind speed Fire ratings Seismic zone Building application Wall heights Below and/or above grade application Backfill heights Number of stories Interior and exterior finishes Brick ledge Availability and cost of concrete Waterproofing Footings Work site conditions Availability and cost of concrete Engineering requirements pump truck Number of corners, windows, doors, Special angles and curves
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Choosing the Correct iForm
Choosing the correct size form is based on structural, fire, and sound requirements. The wall must be engineered properly and meet building codes. The engineering can be done by having an engineer calculate the requirements or by using the prescriptive engineering tables in the Reward engineering section or the IRC building code or PCA’s Prescriptive Method for Insulating Concrete Forms in Residential Construction. When using the prescriptive tables, the project must fall within the design parameters of the respective tables. Each building has to support both lateral loads, consisting of wind, seismic, soil, axial loads, with both dead and live loads.
U.S. Patent # 6,920,384
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Calculating the Number of Reward iForms
Method 1
• Using a floor plan and working floor by floor, calculate the total lineal length of the walls to be built with iForm. Add up the number of corners. Multiply the number of corners by the figures shown here for each respective form.
Corner Form Multipliers, Lineal Feet (meters) of a Form
90º Corner Extended 90° Corner 45º Corner 9" 3.16 ft 4.16 ft 2.67 ft (228 mm) (0.963 m) (1.27 m) (0.8138 m) 11" 4.50 ft 2.67 ft N/A (279 mm) (1.37 m) (0.8138 m) 13" 4.83 ft 2.67 ft N/A (330 mm) (1.47 m) (0.8138 m) 15" 4.16 ft N/A N/A (384 mm) (1.27 m) 17" 5.5 ft N/A N/A (432 mm) (1.676 m)
• This total is the total lineal length of the corner forms. Subtract the total lineal length of the corners from the total lineal length of the walls, and divide by 4 if measuring in feet (or by 1.22 if measuring in meters) to determine the number of straight forms per course.
• To calculate the number of courses for the wall, divide the wall height by the height of the Reward form (16” or 406.4 mm). Always round up to the nearest full course.
• To calculate the number of straight forms needed, multiply the number of straight forms per course by the number of courses.
• To determine the total number of 90° corner forms needed, count the number of 90° corners in the building and multiply this number by the number of courses. Remember that the iForm is universal and the 90º corner form is both the left and right corner.
• To find the total number of 45° forms needed, count the number of 45° corners in the building and multiply by the number of courses.
• To find the total number of straight forms needed for the building, calculate the total square footage (m2) of all the window and door openings for openings greater than 4' x 5' (1219 x 1524 mm). Divide this number by 5.33 square feet (or 0.495 m2) and subtract the result from the total of straight forms determined above.
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• The ledge forms and taper top forms should be calculated separately. These forms are typically only used on one course and can be calculated by adding up the total lineal feet where these products are used and dividing by four. Be sure to subtract this quantity from the number of straight forms.
Method 2
• To determine the total wall area containing Reward iForms, subtract any window and door opening areas that are greater than 4'x5' (1219 x 1524 mm) from the total wall area.
• To determine the total number of 90° corner forms needed, count the number of 90° corners in the building. Determine the number of courses by dividing the total wall height divide the wall height by the height of the Reward form (16” or 406.4 mm). Multiply the number of courses by the number of 90° corners.
• To determine the total number of 45° corner forms needed, count the number of 45° corners in the building. Determine the number of courses by taking the total wall total wall height divided by the height of the Reward form (16” or 406.4 mm). Multiply the number of courses by the number of 45° corners.
• To find the total wall area of the 90° and 45° corner forms, multiply the number of corner forms by the figures shown here for each respective form.
Corner Form Multipliers, Area of Form
90º Corner Extended 90° Corner 45º Corner 9" 4.22 5.55 3.56 (228 mm) (0.392 m2) (0.516 m2) (0.331 m2) 11" 6.00 3.56 N/A (279 mm) (0.557 m2) (0.331 m2) 13" 6.44 3.56 N/A (330 mm) (0.598 m2) (0.331 m2) 15" 5.55 N/A N/A (384 mm) (0.516 m2) 17" 7.33 N/A N/A (432 mm) (0.680 m2)
• To determine the total area for straight forms, subtract the total wall area of the 90° and 45° corner forms from the total wall area of Reward forms.
• To find the total number of straight forms needed, divide the total area for straight forms by 5.33 ft2 (or 0.495 m2).
Method 2 is recommended only after the building professional has estimated and built a number of projects.
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Method 3
• Use Reward’s estimating program. A complimentary estimating program is available on the Reward Wall Systems website.
Estimating Additional Materials
Concrete
• The amount of concrete you need depends on the size of the form being used. See the tables below for the number of forms filled with one cubic yard of concrete.
Number of Forms Filled by One Cubic Yard of Concrete
Straight 90º Extended 45º Ledge Taper T-Form Corner 90° Corner Form Top Corner 9" (228 mm) 15.1 25.0 17.8 25.5 N/A N/A N/A 11" (279 mm) 10.0 N/A 11.3 16.5 7.67 8.26 8.4 (avg) 13" (330 mm) 7.5 N/A 8.1 12.2 6.11 6.5 N/A 15" (384 mm) 6.04 8.3 N/A N/A N/A N/A N/A 17" (432 mm) 5.06 N/A 5.0 N/A N/A N/A N/A
Number of Forms Filled by One Cubic Meter of Concrete
Straight 90º Extended 45º Ledge Taper T-Form Corner 90° Corner Form Top Corner 9" (228 mm) 19.7 32.7 23.3 33.4 N/A N/A N/A 11" (279 mm) 13.1 N/A 14.8 21.6 10.0 10.9 11.0 13" (330 mm) 9.8 N/A 10.6 16.0 8.0 8.5 N/A 15" (384 mm) 7.9 10.9 N/A N/A N/A N/A N/A 17" (432 mm) 6.6 N/A 6.5 N/A N/A N/A N/A
• To find the volume of concrete for the straight forms, simply divide the total number of straight forms calculated in the project by 15.1 yd3 (19.7 m3) if using the 9" iForm, 10.0 yd3 (13.1 m3) if using the 11" iForm, by 7.5 yd3 (9.8 m3) if using the 13" iForm, by 6.0 yd3 (7.9 m3) if using the 15" iForm and by 5.0 yd3 (6.6 m3) if using the 17" Form.
• To find the volume of concrete for the 90° corner iForms, divide the total number of 90° corner forms calculated in the project by 25.0 yd3 (32.7 m3) if using the 9" iForm, 11.3 yd3 (14.8 m3) if using the 11" iForm, by 8.1 yd3 (10.6 m3) if using the 13" iForm, by 8.3 yd3 (10.9 m3) if using the 15" iForm and by 5.0 yd3 (6.5 m3) if using the 17" iForm.
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• To find the volume of concrete for the 45° corner forms, divide the total number of 45° corner forms calculated in the project by 25.5 yd3 ( 33.4 m3) for the 9" iForm, 16.5 yd3 ( 21.6 m3)for the 11" iForm and 12.2 yd3 ( 16 m3) for the 13" iForm.
• To calculate the total volume of concrete needed for the project, add the volume of concrete for the straight iForms to the volume of concrete for the 90° and 45° corner iForms.
• Be sure to make sure that the extra concrete is included for any ledge forms or taper top forms.
• Add one yard of concrete loss from the pump truck. Concrete is priced by the cubic yard.
Reinforcement
• Reward walls contain both vertical and horizontal reinforcement. The engineer will determine the size and spacing of both the vertical and horizontal reinforcement. Calculate the total lineal feet (meters) of reinforcement for each size of specified reinforcement. Reinforcement is priced per lineal foot (meter) based on the size of reinforcement.
• The total lineal feet (meters) of vertical reinforcement is dependent on the spacing and wall height. To find the total amount of vertical rebar you will need, divide the total length of the wall by the vertical reinforcement spacing. Remember to include three verticals in each corner. Next, multiply this number by the wall height. Do this for each floor level. Keep in mind that below- grade and above-grade walls may have different size and spacing of reinforcement.
• The engineer will indicate how often to place the horizontal reinforcement. Multiply the number of courses that will have horizontal reinforcement by the total lineal feet (meters) of the floor plan to find the total lineal feet (meters) of horizontal reinforcement you will need.
• Add the total length of each size of both horizontal and vertical reinforcement together. Add a percentage (usually 60 times the diameter of the bar being used) to the total length of reinforcement to cover the required overlap.
• xLerator® reinforcement for the ledge form and taper top form is figured by one xLerator for every ledge form or taper top form.
Labor
• The number of man hours required is dependent on the efficiency, experience and size of the crew, number of corners, number of openings, site access, weather conditions and other details.
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Footings, Slabs, Shallow Frost Protected Footings and Grade Beams
The key to quick and accurate installation of Reward walls begins with properly installed footings or slabs. The footing or slab must be level, smooth and square to avoid additional costs and delays when installing the walls, and to ensure the walls are level. The footing or slab must be level within ¼" (6.35 mm) in all directions.
One method to compensate for uneven footings is to shoot a light gauge metal 90º track into the footing or slab. The metal track is used to keep the forms in line and also to adjust uneven footings by screwing the light gauge metal track to the forms after getting the first course of forms level.
The footings are constructed using grade stakes and usually wood formwork. Reward recommends using Form-A-Drain, which remains in place in lieu of wood formwork on projects where there is poor draining soil. This provides a self draining system to remove water.
The purpose of the footing is to transfer and distribute the building loads without exceeding the soil bearing capacities. The footings must be properly designed to carry the building loads as required by local code and engineering requirements. Properly designed footings must take into consideration the following: soil type, water table, frost depth, brick finish (if applicable), number of stories, and lateral and vertical loads. See the engineering section for soil bearing capacity and minimum width of footing table.
The only unique issue that must be considered when designing footings and slabs for a Reward building is the additional dead weight of the concrete wall. The 9" iForm is 50 psf (244.1 kg/m2), the 11" iForm is 75 psf (366.2 kg/m2), the 13" iForm is 100 psf (488.2 kg/m2), the 15" iForm is 125 psf (610.3 kg/m2), and the 17"iForm is 150 psf (732.4 kg/m2). when filled with concrete.
Foundation to Wall Connection
The foundation to wall connection is very important because it is what resists the shear force at the base of the wall to prevent the wall from deflecting inward.
Any of the following three methods can be used for the structural connections between the top of the foundation and the wall: • Ninety-degree bent vertical dowels into the foundation • Straight vertical dowels into the foundation • A keyway constructed on the top of the foundation
Of the three methods, the most common is installing vertical dowels into the foundation. Applications where there is very little shear force at the base of the wall may be able to eliminate the dowels or keyway and rely on the friction force between the wall and foundation. The foundation must be in compliance with the local building code and building code jurisdiction. Please see the engineering section for prescriptive vertical dowels tables.
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6" (152.4 mm) on center. Place three vertical dowels in the corners using the dimensions shown on the corner reinforcement detail found in the detail drawing section of this manual. From these three corner dowels, the succeeding dowels must be placed according to the design using a space sequence of 6" (152.4 mm) on center. The vertical dowel must have 3" (76.2 mm) of concrete cover between the soil and the bottom of the dowel. The quantity of dowels may vary from the quantity of vertical wall reinforcement, as these are two independent structural elements.
The dowels may be either cast-in-place with the placement of concrete for the footing or they can be installed later by drilling holes into the top of the footing and using an approved epoxy to secure the dowels into the footing. Be sure to mark the location of door openings to avoid the placement of dowels in these areas.
Stepped Footings
Due to sloping grade conditions, stepped footings may be required. They should be planned in 16” (406.4 mm) vertical height increments to avoid cutting forms, thereby reducing waste and labor. The iForm is designed so that it can be ripped in half creating an 8" (203.2 mm) form. The stepped footing can be constructed using an 8"(203.2 mm) vertical increment. The stepped footing should be a continuous footing.
Frost Protected Shallow Footing
A growing but yet relatively unknown type of design and construction for foundations is frost protected shallow foundations (FPSF). This type of construction lends itself very well to insulating concrete forms because it reduces construction costs, decreases excavation depths, disturbs less soil at the job site and it saves energy.
A FPSF is an alternative to deep conventional foundations. A foundation protected from frost heave because the foundation is insulated. Insulation is used to retard frost penetration below the
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foundation and to retard heat flow from beneath the foundation. This allows shallower footing depths, with no added risk of frost damage. In other words it is a foundation that does not extend to frost depth, but is protected from frost heave. This application is used in cold climates where there is seasonal ground freezing. Frost protected shallow foundations allows structurally sound foundations as shallow as 12" (304.8 mm) or 16" (406.4 mm).
Shallow frost protected footings is a good choice for these applications:
• Slab on grade – reduces the excavation and foundation depths • Walk-out basements – especially where there is a significant changes in grade • Unvented crawlspaces • Elderly, physically disabled buildings because slab on grade reduces steps inside and outside and long ramps • Building additions • Light commercial construction • Apartments – The Fair Housing Act requires apartment buildings to have wheelchair accessible ground floors, so slab-on-grade construction is becoming more common for apartments.
FPSF was recognized in the 2000 International Residential Code, the 1995 CABO One and Two Family Dwelling Code, the 1988 International One and Two Family Dwelling Code, and in various state and local building codes.
The design of the FPSF is a function of the type of building. There are different requirements for heated buildings with slab-on-grade, heated buildings and unheated buildings. The design steps, generally speaking, consist of: • Selecting the site’s design Air Freezing Index • Determining the insulation R-value, dimensions and footing depth based upon the Air Freezing Index • Determining insulation types, thickness and protection.
When installing FPSF you must make sure allowable bearing capacity of the undisturbed soil supporting the foundation is greater than the structural loads imposed by the building; assuring that the site is graded to drain surface water away from the building; making sure that fill materials are compacted properly; and providing termite protection where needed.
FPSF should not be used in permafrost foundation design.
Reward recommends the following reference materials for more information: • The Design Guide for Frost-Protected Shallow Foundations, 2nd Edition. NAHB Research Center, 800-638-8556 • The Design and Construction of Frost-Protected Shallow Foundations, SEI/ASCE 32- 01. American Society of Civil Engineers, (ASCE)
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Grade Beams and Caissons or Piles
Some geographical areas of the country have soil conditions that are not conducive to the installation of footings as the foundation. Footings require soils with adequate bearing capacity to support the building loads. When the soils near the surface do not have this capacity, or in areas where there are expansive soils, grade beams may be necessary to transfer the building loads to the soils. This is accomplished by installing caissons or piles down through the weaker soil and bridging them with grade beams from pile to pile. In expansive soils, void forms are placed beneath the grade beams so that the soil can expand without putting pressure on the foundation.
The iForm can be designed and utilized as both the grade beam and the wall. See the grade beam detail in the detail drawing section.
Install the void forms to the height shown on the plans. The width of the void form is determined by the size of the iForm being used. The void form should be 3" (76.2 mm) narrower than the iForm. For example, if an 11" iForm (279.4 mm) is being installed the void form should be 8" (203.2 mm) wide.
Level the soil between the caissons to the height determined on the plans. Be sure the soil is smooth and free from big clumps of dirt. Bring in fill sand if necessary to smooth out the soil between the caissons.
The layout of the void form is accomplished similar to the layout of the foundation by running string lines to the dimensions of the building. Cut the void form to fit around the caissons or piles while making sure the void form is flush with the top of the caisson.
After placing the void forms between the caissons, install a 2x wood runner that is the same height as the void form on both sides of the void form. When the iForm is stacked on top of the void form, the iForm will need to be flush on both sides of the 2x. Next, place stakes on both sides of the 2x form to keep the void form in line with the string line. Do not attach the stakes to the 2x forms yet.
Stack the iForm on top of the two 2x’s and void material starting in the corners and working your way to the center just as you would on footings or a slab. After stacking the first course place the horizontal rebar into the iForm. Mark on the wall where the bracing, door and window openings will be installed in the wall.
Cut 7/16" (11.1 mm) or 5/8" (15.8 mm) plywood or OSB strips into 6 inch by 4 foot (152.4 x 1219.2 mm) strips. Using 1 5/8" (41.2 mm) course thread screws, fasten the strips of plywood to the 2 x lumber and iForm between the stakes and the bracing locations on both sides of the wall. This will keep the void form and the iForm together as one unit.
After installing the plywood or OSB strips, secure the stakes to the 2x lumber making sure the wall is in line with the string line. Finally, the successive courses are stacked the same as you would if you where building on footings or a slab. Follow the same bracing procedures as if you where building on a slab or footing.
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Wall Layout
A little time spent on the layout can greatly increase installation productivity. The Reward iForm is an innovative and universal block designed for maximum efficiency. The interlock is a tooth style system designed on 1" (25.4 mm) increments. In order for blocks installed in successive courses to lock down to one another, blocks must be cut in 1" (25.4 mm) increments directly to the side of each tooth and not cut through a tooth. Reward has incorporated recessed cut lines on 1" (25.4 mm) increments in the proper cutting locations on the forms. The forms should be cut on the line and cut square to the line.
The interlocking system of the Reward iForm provides the block with the unique ability to be flipped (the forms have no top or bottom). There is only one corner form; turned one way it is a right hand corner, simply flip it over and it is a left hand corner. When determining the exact wall height required, the block may have to be ripped. When ripped in half, both halves of the block can be used. Since the interlocking teeth are removed on one side of the form when ripping the form in half, the half form should be installed with the smooth side on top of the foundation or the smooth side at the very top of the wall.
Universal and Reversible 90º Corner and Straight iForms, “cut away” to show ties
Keep most materials and tools outside the footing area when laying out the building.
The wall layout must be in accordance with the plans and specifications. Some methods used to make sure the layout is square include: • Using a string line and verifying equal diagonal dimensions • Performing calculations using the Pythagorean Theorem (A² + B² = C²) • the 3-4-5 triangle principle • Using surveying equipment such as a transit or Total Station
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After the corners have been determined, chalk lines are snapped on the footing or slab using the dimensions on the plans. The outside face of the iForm should line up with the outside dimensions of the overall building dimensions on the plans. Metal track or batten boards are used to provide both horizontal and vertical layout requirements.
After the building is laid out, the door opening locations and dimension should be marked on the foundation to help in later stages of installation.
Staging Materials for Jobsite Efficiency
After laying out the building, it is best to organize the jobsite for efficiency. On most projects it is best to work on the inside perimeter of the building. Therefore, most of the equipment and materials should be placed six to eight feet from the inside of the footing or slab area so that it will not interfere with the bracing and alignment system. Bundles of forms should be spread out along the inside perimeter.
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Window and door bucks, iForms, rebar, bracing and alignment systems, scaffold planks, ladders and necessary tools can all be placed inside the perimeter of construction.
Protect the interlocking teeth on the forms from snow, ice and UV rays by keeping the tops of the forms covered, and keep the site clean and accessible.
iForm Course Placement
First Course
First, be sure the top of the footing or slab is clean and free of dirt and debris. As the forms are stacked keep the cavity free of debris as well. Taking time to determine the most effective layout pattern for stacking the forms on the first course will save unnecessary time cutting forms on successive courses.
Use guide boards or tracks or else glue the first course to the footing to maintain the alignment of the first course along the layout. Either of these techniques can also be used to level the first course if the footing is uneven.
When setting the first course, start at the corners and work inward towards the center of the wall and into an area of a large opening (beneath a window or in a door opening). Place the forms tightly end- to-end along the chalk line Where the two wall sections meet, it is likely that you will have to install a cut form. During the process of splicing cut forms, it is possible to disturb the uniformity of the alternating pattern of teeth and spaces on the forms. The cut forms could create a situation where two adjacent forms have teeth and spaces right next to each other rather than diagonal from each other. When this happens, the interlocking teeth on the lower course will interfere with the interlock on the course above it. Be sure, when stacking the forms, that the furring strips or ties line up from course to course.
Use a common splice at the location of the cut iForm. Be sure the seam of the common splice runs from the bottom to the top of the wall. A common splice will always be in the same location within the length of a wall. Brace the seam with plywood or other supporting material. Flip the corners on every other course to be sure the forms are stacked in a running bond pattern. The iForm that is cut to create the common splice in the first course will be cut the sameCut Line for For Common Splice courses 3, 5, 7, etc. The form cut to create the common splice in the second course will be the same for courses 4, 6, 8, etc. Locating the splice in the openings for the windows and doors will reduce the number of splices needed to just those above or below the opening and reduce bracing requirements. Updated: April 2011 17 Release: K
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When setting the first course, it is important to run the forms through all window and door openings (they will be cut out later). This will ensure that the interlock will work above the openings. Also set all of the corners so that the long end of the return runs in the same direction. This facilitates a running bond.
Tie all corner forms to the form next to it using wire hooks, or tape around the corners using 3" (76.2 mm) wide fiber-reinforced tape. Overlap the form next to the corner form by approximately 12" (304.8). When using tape apply two lengths of tape to each block about one-third of the way down from the top and one-third of the way up from the bottom of the form. Do this on every course. Corner bracing is recommended to keep the corner plumb and to provide supplemental bracing. The design of the interlock helps ensure that the corners will be stacked plumb if the footing is level.
When installing cut forms, always use a cut form with a minimum of two plastic tie inserts remaining in the form. Continue stacking along theCut perimeter Line For Common of the wall Splice until the first course is complete. Verify the dimensions.
Run the forms past any door and low window openings, so that the plan dimensions can be verified and the interlock pattern is ensured. Always place horizontal steel reinforcement in the first course of the forms before continuing on to the second course.
Second Course Be sure ties line up
After the first course is completely in place, start the second course working from the original corner toward the same direction as the first course was stacked. Be sure to seat each form to each subsequent form firmly. Use your hands to pound each form down so that the interlocking teeth are fully snug. This will minimize interlocking settling during concrete placement. Remember to use the ability of the forms to flip, and install the corner forms in alternating directions (i.e. "left" and "right" hand corner). This will create a 12" (304.8 mm) stagger of the vertical form joints and a running bond pattern. Supplemental bracing is required if the vertical running bond joint between two courses of blocks is closer than 6" (152.4 mm).
Run the second course through all window and door openings just like for the first course. Once the second course is in place, the interlock design of the iForm will create a "self-leveling" effect with the footings within ¼" (6.35 mm) of level. The blocks will be resting on any high spots and bridging any low spots. At this time secure the blocks to the footing or slab using Reward’s light- gauge metal starter track or 2x board fastened to the footing or slab and screwed to the forms. You may also use another method of your choice.
After the blocks have been secured to the footing or slab, cut the blocks out at the door openings and any window openings that fall in the first two courses, and install the bucks. Courses 1, 3, 5, 7, etc. should be identical and courses 2, 4, 6, 8, etc. should be identical.
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Instead of using a tape measure to measure the length of a cut piece, utilize the tie markings and marked, one-inch increments (25.4 mm) on the iForm. To cut your form to fit exactly, simply look at the course you are duplicating (duplicating course 2 with course 4, for example), count the number ties and on which line the form is cut. With a little practice this method is much faster and more accurate than a tape measure. For example, a 24” (609.6 mm) piece would be 4 ties and cut on the third recessed line. Use a marker to show the cut measurements on the cut forms of each course. These cut forms will repeat themselves throughout the remaining height of the wall, and this will speed construction.
There is no need to glue or use vertical wire hooks for each course. To be on the safe side, though, the first and second courses can be glued or vertically hooked together and the top course glued or vertically hooked down. Also, use vertical wire hooks to secure the course below and above the ledge form. Aside from any unusual areas, any additional securing will have absolutely no impact on the form's performance.
Locating the special or common splice cuts of blocks along the sides of door or window openings will greatly reduce the number of times they occur. These common splice cuts are not needed above the openings for the doors or above and below the openings for the windows.
Successive Courses
Successive courses should be placed in the same manner as the first two courses. For example, courses 1, 3, 5, etc. will be the same and courses 2, 4, 6, etc. will be the same.
Continue to firmly pound the forms in place with your hand so that they seat firmly with the pervious course. Always use a form with a minimum of two plastic tie inserts. After each course place the necessary horizontal rebar in the rebar chairs of the iForm. The horizontal rebar should be spaced at a maximum of 48" (1219 mm) on center and in the bottom and top courses.
As each course is placed continue to check the wall to make sure it is straight, plumb and square. Also keep checking the building dimensions for accuracy. The alignment and bracing system should be installed at some point between the second and fourth courses of forms. See the alignment, bracing and scaffolding section in the Reward manual.
Set a string line at each plumb and square corner and adjust the walls to the string line to ensure that the entire wall between corners is straight. Place a string line at the top course set ¾" (19 mm) off the wall to check for straightness. Then run a ¾” (19 mm) thick piece of wood between the wall and the string.
Protect the interlock tooth design during the concrete pour if continuing upwards with a second pour and from snow and ice. Follow the bracing and alignment procedures discussed in the alignment, bracing and scaffolding section.
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Cutting Special Angles for Corners
The Reward 9", 11" and 13" iForm product line offers a pre-molded 45-degree corner form. Each 45-degree corner form has return lengths of 22" (559 mm) and 10" (254 mm).
For any other angled corner the iForm straight can be cut at any angle to create any desired corner. Also if you are in a pinch without any 45-degree or 90-degree pre-molded corners, the iForm straight can be mitered to create those corners as well.
The special angles for corners can be cut and installed by using the table and details below for the respective desired angle and form size. Measure and mark on the form the specified dimensions for the angle. Using a saw make the diagonal cut on the form.
Imperial Measurement
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Metric Measurement
Steel Reinforcement
The design of the iForm plastic tie allows the horizontal reinforcement to be placed in different positions within the form and "snapped" into a loose fit position. The various positions allow the reinforced concrete wall to be designed efficiently by structural engineers and the loose fit rebar chairs help in the installation of straight walls without bows when the rebar is not perfectly straight. Remember to overlap the rebar the proper dimension according to the table on following pages.
The iForm can accommodate structural design applications that may require a double curtain of horizontal and vertical reinforcement.
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The requirements for steel reinforcement must adhere to ACI 318 (CAN CSA 23.2) and follow the structural engineer's specifications, Reward Wall Systems’ prescriptive reinforcement tables found in the engineering section or the Prescriptive Method for Insulating Concrete Forms in Residential Construction (EB118) produced by HUD, the National Association of Home Builders Research Center and the Portland Cement Association, section R404.4 and R611 of the IRC building code, or PCA 100, ACI 332 (see earlier sections). Note that the Prescriptive Method for Insulating Concrete Forms in Residential Construction has been incorporated into the national model building codes as referenced in Reward's evaluation reports. The steel reinforcement must meet the requirements of ASTM A615. Steel reinforcement is available in common strengths of 40,000 psi (275.8 MPa) - grade 40, and 60,000 psi (413.7 MPa) - grade 60. Whenever and wherever possible always specify grade 60. Never use “no-grade” steel reinforcement. Besides the strength of steel reinforcement, the correct size, spacing and position in the wall must be specified and installed.
The reinforced concrete wall must adhere to local code, regulations and environmental conditions.
Lap Splices Lap splices may be either contact lap splices or non-contact splices. Both of the splices require a lap according to the table below. Contact lap splices must be secured together. Non-contact lap splices can be separated by the smaller of 1/5 the lap length or 8 bar diameters and not greater than 6" (152.4 mm). The tables below provide dimensions for lap splices for different bar sizes.
Minimum Lap Splice Lengths (Contact and Non-Contact) Concrete Compressive Strength = 2,500 psi (17.5 MPa)
#3 (3/8”) #4 (1/2”) #5 (5/8”) #6 (3/4”) Yield Strength of (9.53 mm) (12.7 mm) (15.9 mm) (19.1 mm) Steel Reinforcement 10 M 15 M 20 M 40,000 psi, 40 Db 15” 20” 25” 30” (300 MPa) (381 mm) (508 mm) (635 mm) (762 mm)
60,000 psi, 60 Db 23” 30” 38” 45” (400 MPa) (584 mm) (762 mm) (965 mm) (1143 mm)
#7 (7/8”) #8 (1”) Yield Strength of (22.2 mm) (25.4 mm) Steel Reinforcement 25 M 40,000 psi, 50 Db 44” 50” (300 MPa) (1118 mm) (1270 mm)
60,000 psi, 75 Db 66” 75” (400 MPa) (1676 mm) (1905 mm)
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Maximum Non-Contact Lap Splice Separation
#3 (3/8”) #4 (1/2”) #5 (5/8”) #6 (3/4”) #7 (7/8”) #8 (1”) Bar Size (9.53 mm) (12.7 mm) (15.9 mm) (19.1 mm) (22.2 mm) (25.4 mm) 10 M 15 M 20 M 25 M Non-Contact 3” 4” 5” 6” 6” 6” Separation (76 mm) (102 mm) (127 mm) (152 mm) (152 mm) (152 mm)
The iForm product is formwork for a steel reinforced solid monolithic cast-in-place concrete wall. The structural adequacy is based upon the design of the steel reinforced concrete wall. The formwork offers no structural value after the concrete is placed.
Steel reinforcement is usually necessary in the concrete wall to add strength for resisting tension and bending forces. The steel reinforcement also will help minimize concrete cracking and control temperature and shrinkage cracking. The concrete formed by the iForm is very strong for compressive forces but weak when tension or bending forces are applied. Installing the proper size, spacing and placement of steel reinforcement in the concrete wall allows the concrete to resist these forces due to wind, backfill and seismic loads. In order to gain maximum efficiency of the reinforcement, the rebar is placed in the portion of the wall that will be loaded in tension.
The steel reinforcement must be installed so it is secure when the concrete is placed. This can be accomplished by using steel wire ties, plastic or electrical “zip” ties or restraining the bar within the iForm rebar chairs between horizontal rebar and PVC rings. Any combination of these methods may also be used to secure the rebar in place.
Horizontal Reinforcement
Horizontal reinforcement is placed into the loose-fit, two-deep rebar chairs as the courses of iForm are stacked. The loose-fit design helps keep bows out of the wall caused by crooked or bent rebar. The two-deep rebar chair allows two horizontal pieces of rebar to be contact lap spliced together and eliminates the need for tying horizontal rebar. All contact lap splices must overlap according to the dimensions in the preceding table. The design of the Reward iForm ensures that all horizontal reinforcement will have the required ¾" (19 mm) clear concrete cover. The iForm can accommodate structural design applications that may require a double curtain of horizontal and vertical reinforcement. If proper placement of the reinforcement is maintained during the placement of concrete, the rebar does not need to be tied together.
Typically the horizontal rebar is staggered from side to side using alternating rebar chairs in the different courses of iForm. Continue to stagger the horizontal reinforcement, as the subsequent courses are stacked. This method allows the vertical steel reinforcement to be
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inserted between the staggered horizontal reinforcement thus holding the vertical reinforcement bar in position. In order to take full design advantage of the 11", 13", 15", and 17" iForm below grade and Reward's below grade reinforcement tables, the stagger method should not be used. See the off- center vertical rebar position found in the detail section.
An alternative method is to place two horizontal reinforcement bars in the bottom and top courses leaving an open rebar chair in between the two horizontal bars. The vertical reinforcement can be inserted between the two horizontal bars in the top and bottom courses. When using this method, insert other horizontal rebar in subsequent courses as required by the design.
Always place a horizontal rebar in the bottom course and in the top course of every Reward wall.
For ease of construction, it is desirable to design and construct the wall with horizontal reinforcement spaced 16 inches (406 mm) on center. For column tie reinforcement the tie cage or confinement is most easily constructed when designed at 8 or 16 inches (203 or 406 mm) on center.
Vertical Reinforcement
The placement and location of the vertical reinforcement within the Reward iForm is critical to the strength of the Reward walls. The vertical reinforcement is most easily placed after the iForm is stacked.
The most efficient method of placing vertical reinforcement consists of the following four steps: • Cut it to the proper length. • Place it between the staggered horizontal reinforcement. • Insert it into a drilled hole in the footing or slab or into a PVC ring placed over the vertical dowel in the footing or slab. • Tie it to the top horizontal rebar with wire or plastic ties after the last course is placed.
An alternate method is to cut the vertical rebar into two or three equal lengths relative to the wall height. The lengths are cut so that an average person can lift the iForm over the vertical rebar. As the walls are being stacked, the vertical reinforcement is placed between the staggered horizontal rebar and tied, at the bottom to the vertical dowel and at the top to the horizontal rebar, with wire or plastic ties.
Vertical steel reinforcement must be placed in each corner. ACI 318 (CAN CSA A23.3) requires two #5 vertical rebars to be placed on each side of each door and window opening.
Always extend the vertical rebar 40 times the bar diameter beyond the first concrete pour if the walls will be continuing upward, or place a vertical lap bar into the first concrete pour. This will add structural integrity to the cold joint. If using a vertical lap bar, terminate the vertical bar 2" (50.8 mm) below the pour.
The vertical reinforcement in the iForm must maintain a ¾" (19 mm) clear concrete cover.
For ease of construction, it is desirable to design and construct the wall with a vertical reinforcement schedule on a 6 inch increment -6”, 12”, 18”, 24”, 30”, 36”, 42” or 48” (152.4 mm increment – 152, 304, 457, 609, 762, 914, 1066, or 1219 mm).
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11" iForm 13" iForm Steel Reinforcement Placement Steel Reinforcement Placement
Outside Inside Outside Inside Outside Inside Outside Inside
15" iForm 17" iForm Steel Reinforcement Placement Steel Reinforcement Placement
Reference CAD details: 2-01, 2-02, 2-03, 2-05.
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Door and Window Openings
Window and door openings are accommodated by building and installing metal, wooden or vinyl bucks. The inside dimensions of the buck are constructed so that the inside measurements agree with the rough opening dimensions provided by the window and door manufacturer. Remember that the thickness of the buck material must be accounted for when determining the rough opening dimensions. The buck provides the fastening surface for installing the windows and doors while holding back concrete during placement. Some installations may be constructed by placing a temporary buck in the wall, removing it after placing the concrete and then fastening the windows and doors directly to the concrete.
The buck's location in the wall is preplanned and installed into the wall as the iForms are being stacked. The remaining forms are then stacked around the installed bucks. It is recommended to leave a 1/16" (1.6 mm) gap for every course below the top of the buck. For example, six courses stacked to the top of the buck would need about a 3/8” (9.5 mm) gap to ensure there is no crowning or block separation on each side of the buck. This gap compensates for slight settling of the forms when the concrete is placed. A ¼" (6.3 mm) gap should also be allowed on the sides of each buck.
Regular dimensional wood should not be in direct contact with the concrete. If regular dimensional lumber is used as bucks or sill plates, a moisture resistant barrier must be placed between the buck and the concrete in accordance with the International Residential Code (IRC), Section R319.1.
Otherwise pressure treated lumber is used for the bucks and sill plates. Since CCA treated lumber is no longer available and has been replaced by ACQ treated lumber, extra care must be taken in fastening the ACQ lumber to the concrete. One can not really tell the difference between the CCA lumber and the ACQ lumber by eyesight. To be sure what kind of treated lumber you own, look at the inspection mark or tag on the end of the lumber.
Section R319.3 of the IRC requires that fasteners used with pressure-preservative treated wood or ACQ be hot-dipped galvanized, stainless steel, silicon bronze or copper. One cannot use the same metal fasteners with ACQ lumber as with CCA lumber. ACQ lumber will corrode ordinary galvanized fasteners. Consult with the manufacturer or supplier of fasteners to be sure that you are using the properly coated fastener.
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The buck is built so that the top (header) rests on the sides (jamb) and the bottom (sill) fits between the two sides. Placing the bottom between the sides keeps the bottom of the buck from pushing inward when concrete is filling the sides. The buck must be built so that it is level, plumb, square and straight to ensure that the window and doors will be fastened into the buck without any adjustments. This is accomplished by horizontally and vertically bracing inside the buck every 2 feet (610 mm) from side to side, top to bottom and by placing a diagonal brace across the corners of the buck. The sides of the bucks should be braced and aligned to ensure that they are plumb. The buck is aligned to the iForm by fastening 1"x 4" wood to the perimeter of the buck.
At the bottom of window bucks there must be a means for placing and consolidating the concrete below the buck. This can be accomplished by making the sill out of two 2 x 4’s, which creates an opening in the bottom of the buck. The concrete is troweled flush with the openings in the sill of the buck.
Another method for providing this gap is accomplished by drilling holes in the bottom of the buck with a hole saw. When using the V-Buck product, the holes are drilled using a hole saw in reverse mode. Side flanges or leg braces on each side of the bucks that extend down to the floor, ground or slab are recommended.
Every side of the buck must be anchored to the concrete wall with concrete fasteners, large nails, spikes or anchors. All anchors must be recessed into the buck so it will not interfere with the window and door installation. Anchors must be ACQ lumber approved.
Proper lintel reinforcement must be placed directly above the openings to resist the loads over the doors and windows. Refer to the engineering section for proper lintel design above window and door openings.
In order to expedite the construction of the Reward walls, Reward recommends that the window and door bucks be built at the shop prior to stacking the forms, or whenever weather interferes with regular construction, rather than at the job site.
Wood Buck Methods
There are three main methods of constructing wood door and window bucks. The first one is to run the wood buck all the way across the width of the Reward insulating concrete form, the second is to inset or recess the buck into the cavity of the form and the third is to use plywood in combination with 2x cleats.
Method 1
This method is probably the most common method used by contractors. The 2x buck is placed so that the ends are flush with the inside and outside face of the ICF wall. Depending upon the form width, the 2x will vary in size. Some form sizes require taking a large width 2x and ripping it to the form dimension.
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Method 2
This method may be utilized for projects that will have a stucco exterior finish or when thermal breaks is a concern. The 2x material is placed flush into the cavity of the form. The buck is held into place using long screws with EIFS- type washers.
Method 3
This method may be used to save on the cost of the buck due to the higher costs of lumber. It also provides a wider flange around the opening to fasten to. A 2x6 ripped in half is fastened to a ¾ (19 mm) inch pressure treated plywood.
Vinyl Buck
The vinyl buck is made specifically for ICFs. Choose the correct thickness of vinyl buck that corresponds to the iForm thickness.
Cut the vinyl buck to the dimensions of the rough opening. Insert the corner connectors into the vinyl buck slots on the outside of the four corners. Assemble the vinyl buck on the head first, followed by the sill and finally the jambs. The vinyl buck has flanges on the interior and exterior sides of the iForm. It must be firmly seated all around the door or window openings.
Open concrete placement holes in the sill of the vinyl buck by either using a hole saw run in reverse mode in the field or ordering the vinyl buck with the holes pre-drilled. As with the wood bucks, the vinyl bucks must be braced every two feet both horizontally and vertically within the opening and braced for square.
The vinyl buck has a fin molded into the backside that is designed to anchor the vinyl buck to the concrete wall.
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Custom Metal Frames
The Reward Wall Systems NoricF4™ Custom Metal ICF Frame (CMF) is a fully integrated metal door and window buck frame for ICF construction. This is a two-in-one product consisting of both the “block out” buck to stop the concrete around the openings and also the frame for the door or window. It is a pre-welded and pre-assembled fabricated CMF that fits any ICF form size and is shipped direct to the jobsite. The combination of the 2-in-1 product and the pre-welded and pre- assembled product saves many tasks that save time and money on a project. The NoricF4 is a customized buck frame that is available with many options to meet the specifications of any project. It is manufactured with 14 gauge steel for all the exterior components and 16 gauge steel for the interior components. The frame is designed and made to snugly fit around the EPS foam thickness of the ICF product. An integrated 85-degree flange is designed into the product that will capture the concrete core of the ICF wall and structurally embed the NoricF4 to the concrete wall. The product also consists of a drywall return that can be made on one or two sides of the frame to suit any thickness of drywall.
Uses or Applications The NoricF4 is primarily a commercial buck frame that is typically used on schools, churches, hotels, theaters, retail, institutional and office projects. It may be also used for some residential applications as well.
Door The NoricF4 door buck frame is custom designed and can be ordered to meet any door and hardware manufacturer or type or size. The NoricF4 is fabricated with the strike plate and hinge preps already in place at any location according to the project’s specifications. The standard NoricF4 will include a patented door weather strip seal. The patented door seal is easily and quickly installed by hand with no tools. It provides a superior weather stripping and can be easily replaced. It can also be made without the patented seal.
Window The NoricF4 window is custom designed to any window opening size. The standard NoricF4 will consist of smooth window head and jambs. The NoricF4 sill will have an integrated open concrete placement and consolidation opening. A sill filler plate is available that caps the sill opening after concrete placement.
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Temporary Bucks
Temporary bucks are typically used in commercial construction. The doors and windows are attached directly to the concrete after the temporary bucks are removed. The temporary bucks can be made from either light gauge metal or wood. They are made in a “U” shape to fit the iForm thickness on the project.
Radius Top Openings
Arches above windows and doors can easily be installed by using plywood or Masonite.
Using plywood or OSB, creates a template with the height and radius dimensions for the radius top. Mark the radius outline on the iForm wall using the template. Cut the iForms to this radius, and then construct the sides and bottom buck pieces, leaving openings for concrete placement in the bottom buck piece.
The arched top buck is constructed using plywood or Masonite with small 2x pieces of wood used as stiffeners around the arch. Install the bottom, then the sides and finally the radius top buck in order.
Steel Reinforcement for Door and Window Openings
The lintel must be designed to support applied live and dead loads from roofs, floors and the weight of the concrete in the wall above the opening.
Reward provides prescriptive design lintel reinforcement tables in the engineering section. These tables are for uniform loads above the openings, and they do not consider concentrated loads over the openings. A local engineer is necessary for lintel design that does not meet the design parameters for these tables. Specific lintel reinforcement placement is addressed in this section.
The bottom lintel horizontal reinforcement bar should be placed across the top of the door and window buck before stacking the iForm across the top of the opening. This will provide easy access to the bottom rebar. This horizontal bar should be placed no lower than 1 ½" (38 mm) and no higher than 3 ½" (89 mm) above the buck.
Top and bottom lintel bars must extend 47 bar diameters past the opening for bar sizes up to a #6 (20 M). If there is a corner before 47 bar diameters, continue the bar around the corner. If shear reinforcement or stirrups are required, the spacing is critical and they are placed evenly across the opening.
Door and Window Installation
Please refer to the door and window details found in the library of iForm details. These details show door and window installation for the head, jamb and sill along with different exterior finishes.
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Utility Penetrations and Beam Pockets
Utility access ports must be planned and positioned into the Reward iForm wall prior to placement of concrete. These ports will allow access between the outside and inside of the solid reinforced concrete wall to accommodate incoming dryer vents, exhaust ducts, electrical, gas, sprinkler, telephone, cable TV or water lines or pipes.
An access port is accomplished by permanently installing a PVC or steel sleeve into the wall large enough to carry the required utility. An imprint of the sleeve is made on the wall and the EPS foam is removed using a long blade keyhole saw. When the sleeve is inserted into the opening, it should be positioned slightly higher on the inside face of the wall. It is very important to remember to seal with a 15-minute fire stop sealant and caulk around all access ports to avoid the intrusion of water. If the opening is in a location that requires cutting a plastic tie insert, be sure to add additional form support to this area.
If the penetration opening gets too wide, the penetration should be reinforced similarly to a door and window opening.
Beam pockets may be required for a floor beam. A pocket is created before placing concrete by using lumber. The beam pocket size and location is marked on the iForm wall. A keyhole saw is then used to cut the 2 ½” (63.5 mm) of EPS foam away following the marked dimensions. Some tolerance should be allowed for beam adjustment. It is very important that this pocket is created before placing concrete.
Many times it is recommended to have the beam bear on a bearing plate that is anchored to the concrete wall. Be sure to provide room in the pocket for these items.
A beam pocket can be installed right after concrete placement by cutting out the foam and wet concrete before it hardens. The obvious key to this option is remembering to do this before the concrete hardens. When this method is used, the exact location and size of the pocket must be marked on the wall prior to concrete placement.
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Alignment, Bracing and Scaffolding
It is critical to properly brace and align the wall to ensure level, plumb and straight Reward walls. Reward recommends using the Reward rBase II system. This system is sold by Reward and includes steel or an aluminum strongbacks, diagonal turnbuckle brace, platform bracket and guardrail post assembly. This type of system will provide the means to brace and align the Reward wall as well as the means for building efficiently, safely and professionally. This system is engineered and OSHA compliant.
If the Reward rBase II is not available other commercial or wood bracing can be used. Generally it is recommended to use adjustable bracing with a turnbuckle to easily make minor adjustments with little effort.
The maximum spacing of the bracing and alignment system is 6 feet (1.8 m). The bracing and alignment system should start within 2 feet (0.6 m) of each corner. Place the alignment system on either side of the door and window openings and attach the strongback to the iForm using #10 coarse threaded screws after a minimum of three courses of forms are placed. Fasten a #10 screw to each course of iForm. The diagonal turnbuckle brace must be securely fastened at approximately 45- degrees or staked to the floor, ground or slab. Typically the bracing and alignment systems are placed on one side of the wall (usually interior side) during construction.
Whenever a very long or tall wall is being constructed, it is recommended to place sufficient bracing on the opposite side of the wall that is braced at 6' (1.8 m) spacing. Installers must remember that the taller and longer the walls are the more wind they can pick up like a sail. Wind can blow from any direction and if the wall is only braced on one side, there is a chance the forms could be blown down.
Check to make sure that the wall is plumb and straight before, during and after concrete placement using a level and a string line. Corner bracing is recommended to keep the corners plumb.
The ICFs may compress when concrete is placed. The rate of compression is usually 1/16" (1.6 mm) per course of blocks. It is important to attach the strongback to fit loose to allow for this compression. When using the Reward rBase II, install the screws in the slots in the strongback near the top of the slot to allow the blocks to compress down when placing concrete.
Bulkhead and intersecting walls must be braced near the bottom, mid-point and top of the wall. These areas have greater concrete pressures during concrete placement.
Scaffolding, guardrail posts and toe boards are required by OSHA once the installer's feet exceed 6 feet (1.8 m) in height above the ground. Do not remove the bracing and alignment system until the concrete in the wall has cured sufficiently.
Users are responsible to review and apply the requirements of federal, state and local code and regulations.
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Tall Walls Traditional scaffolding systems can be rented and used for tall walls in combination with the Reward scaffolding extension brace.
Additional Form Support
Additional iForm support is required for the following applications: • When there is more than 3 inches (76.2 mm) beyond a plastic tie support • When a common splice or vertical joint is on consecutive courses • Around door and window openings, corners, intersecting “T” walls, radius walls, and end or bulkhead walls.
Bracing and Securing Corners
Use corner bracing if a corner, door or window is within 12 feet (3.65 m) of any particular corner. Except for corner bracing use, up to, a maximum spacing of 6 feet (1.83 m) for bracing along the lengths of the walls. The first course of forms should be secured and leveled by using one of several methods. The following methods may be used:
1. Reward’s starter track, a 90º bent light-gauge metal tracking fastened to the footing or slab and to the first course of forms 2. Use of low expanding spray foam glue to glue the first course of the footing or slab 3. 2 x wood runners
Each course of forms should use one of the following methods at every corner to keep the corners from separating:
1. On the inside cavity of the forms, use a horizontally placed wire hook to secure the corner form to the adjacent straight form by hooking the plastic ties together. 2. Use fiber-strapping tape on the outside face of the corners. Run the fiber tape around each corner return to the 2nd or 3rd plastic tie of the adjacent straight form. This method may not work so well if the forms have moisture or dew, dirt or any UV rBase Corner Bracing degradation. Otherwise this is a very beneficial method. 3. Use “scabs” of OSB or plywood fastened from the corner to the 2nd or 3rd plastic tie of the adjacent straight form.
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Intersecting “T” Walls
T-Form Reward’s product line includes an 11" T-form that provides a 6 inch (152 mm) concrete core for both the intersecting wall and the longitudinal wall. This form will make the construction of a T-wall more efficient by eliminating some cutting and bracing in comparison to manually constructing a T- wall with only straight forms.
The T-forms are shipped with both long and short sizes so that the forms will continue to be overlapped creating a running bond pattern. Also, the 11" T-form has additional plastic ties and EPS foam support at the back side of the wall intersection to reduce the bracing requirements.
When stacking forms, the T-form should be treated similarly to 90-degree corner forms. The corners and intersecting walls locations are defined by the plan design. The corners and T-forms should be placed at this location according to the plan. Then the forms are stacked to the middle between the corners and T-forms. Flip and alternate every other T-form course from long to short creating a running bond and eliminating a common seam at the T-intersection.
Place horizontal reinforcement with a 2'-6" (762 mm) bend on each end at each T-form course. These bars should alternate each direction in the longitudinal wall at every other course and have a proper lap splice with the horizontal rebar in the wall.
Concrete flowing around the corners of the intersecting wall will create great concrete pressures on the intersecting T-form and therefore the amount of bracing at this location must be taken into consideration.
When placing concrete at the T intersection, aim the concrete flow down the longitudinal wall letting the concrete flow itself into the intersecting wall. Have the concrete in the T-form wall build up slowly. Do not have the concrete flow from the intersecting T to the longitudinal wall.
When stacking a 90-degree corner for to the T-form, please refer to specific technical bulletin.
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Manually Constructing an iForm T-wall
An intersecting “T” wall can be constructed anywhere along the wall. The iForm installed to form the main wall is marked at the locations of each intersecting “T” wall location. The iForm panel of the main wall where the “T” intersects is cut vertically the thickness of concrete core of the “T” wall form and the foam is removed. It is possible that the main wall and the “T” wall may be different form sizes.
The “T” wall form is then butted up to the main wall where the cut was made. A solid monolithic concrete intersecting “T” wall is created.
Within each course of the main wall, center and place and tie wire a 3-foot long horizontal rebar to the iForm rebar chair. Tie wire this horizontal rebar dowel back to the plastic tie insert in the “T” wall. This will provide internal support to the wall intersection.
Horizontal rebar bent 90-degrees with 2' 6" (762 mm) returns on each end to be placed at every course, for horizontal rebar schedule. These bars should alternate each direction in the main wall at every other course and have a lap splice of 40 bar diameters with the horizontal rebar in the wall.
Concrete flowing around the corner will create great pressures on intersecting “T” walls and therefore, must be externally braced really well. Each side of the “T” wall should have a vertical brace or be glued to the main wall. The backside of the “T” on the main wall panel should be braced as well.
When placing concrete at the “T” intersection, aim the concrete flow down the main wall and into the “T” wall. Have the concrete in the “T” wall build up slowly. Do not have the concrete flow from the “T” wall and into the main wall.
End Walls
End walls or bulkhead walls are walls where the concrete will terminate at a dead end without a corner or a window or door buck. The end of the iForm needs to be blocked and braced with lumber.
Install an end buck using the same material that is used for the door and window bucks. A common practice is to construct a “U” shaped end buck the thickness of the form. Since concrete will be flowing to the end of this wall and will have to stop, the end wall must be braced well. Place kickers, placed at intervals one-third the height of the wall and stake them to the ground or floor.
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Gable End Walls
Reward recommends constructing the gable end walls with the iForm when the interior space is conditioned. A story pole is set-up at the desired height and a string line is placed at the desired angle or pitch of the roofline. As the forms are stacked, the iForm is cut at the desired slope by measuring and snapping a chalk line along the slope. After the forms are stacked and the slope line is marked, the forms are removed from the wall and each one is cut along the marked line. The cut forms are then re-stacked to form the wall. 1x4s are to be fastened along the slope on each side of the iForm. This will stiffen the form where the cuts are made and also provide a continuous attachment base to contain the concrete or for additional support.
Radius Walls
An iForm radius wall is easily accomplished by using either of the iForm straight forms. There are three main steps to constructing an iForm radius wall: • Cutting the required slots from iForm straight forms • Bowing the straight form and keeping it at the desired radius • Stacking the radius forms in the wall.
Cutting the iForm
On the inside EPS panel of the radius, a specific slot dimension must be cut out and removed from the form. As a guideline, follow the table below indicating the slot dimensions for certain radii. The slots may be removed either 6 or 12 inches (152 or 304 mm) on center depending upon the radius that is being built. The slots should be removed in the center between the ties.
On the inside EPS panel, one half of the slot dimension must also be cut off of each end of the iForm to provide a continuous symmetrical radius from end of form to end of form.
It is recommended to use a hot knife to cut the EPS slot. A hot knife wire attachment can be purchased or made to provide either a tongue and groove or V-notch cut for the slot. The wire attachment can also be adjusted to cut the required slot dimension. For efficiency, a wooden jig can be made if a large number of forms are needed to be cut.
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In addition to the slot that is created, a kerf or v-cut may be necessary for tight radii on the inside face of the outside EPS panel and opposite of the removed slot. This kerf or v-cut should only go ½" to 1 ½" (12.7 to 38 mm) through the 2 ½" (63.5 mm) thick EPS panel. It will provide material relief on the outside panel when the form is bowed to the radius and can be accomplished by using a handheld saw or hot knife.
If possible, cut the forms and bow them together inside a shop on a rainy day instead of doing it at the job site, to save time before they are needed.
Bowing and Holding the Radius
There are several methods that can be used to hold the form to its radius. One method would be to use compatible foam glue to glue the slots together. Run a bead of foam glue down each slotted area, bow the form together to the required radius, use ratchet tie down clamps attached to each end of the form to hold the radius in place as the glue dries. Wire, fiber tape or Masonite can be fastened to the outside EPS panel to hold the radius also.
For not so tight radii, one may be able to bow and stack the forms together with the interlocking teeth along while gluing the slots together.
Stacking the Radius Wall
If the radius is not too tight, a running bond may work as the forms are stacked in the wall. If the radius is too tight, the interlocking teeth may not fit together to stack a running bond. In this case use a stack bond method. Guide boards or track should be utilized on the first course of the radius wall to keep the radius together. After the radius wall is stacked, standard alignment and bracing is required for placing concrete into the radius walls. Maximum bracing spacing is 4'-6" (1.37 m).
Updated: April 2011 37 Release: K
The New Standard for Sustainability.
Updated: April 2011 38 Release: K
The New Standard for Sustainability.
Updated: April 2011 39 Release: K
The New Standard for Sustainability.
Horizontal and Vertical Transition of Form Sizes
A project may be designed and constructed using more than one form size. Different stories may utilize different form sizes. For example, basements many times are installed with a larger form size than the above grade walls. The vertical transition in form size is typically made at the floor level. Also the form size may change horizontally. For example, a basement may have backfill on three sides with a daylight walk-out back. A larger form size may be used for the backfill walls with a transition to a smaller form size on the walk-out side.
The vertical transition is made at the intermediate floor level. This hides the change of form sizes within the floor connection area. An example of this transition is shown in the detail drawings section of this manual. iForm is designed so that the outside face of the smaller form size can remain flush with the interlocking teeth and also rest on the inside face of the larger form size.
The floor system is installed on the larger form size so that the top elevation of the floor will be located at the top of the larger form size. Interlock one course of the smaller form size to the larger form. Concrete for the first pour is then placed so that the top of the pour is a few inches above the anchorage of the floor system.
The horizontal transition is recommended at the corners. The transition can be accomplished by fabricating two straight forms one of larger core size and smaller core size to the spacing below. The fabrication should allow the larger core size to run all the way to outside edge of corner. The smaller core size will start on the inside of corner and run the desired designed distance of wall thickness. Keep outside of the wall flush.
Four-Foot Foundation Walls
Preparation for Installation of iForm
Using chalk lines lay out the wall on the footing to the dimensions of the building. Use a metal track along the chalk line to align the forms. If the footing is not level, adjust the height of the first course when placing the forms in the metal track. The metal track is usually 2 ½" x 2 ½" (63.5 x 63.5 mm) 28-gauge galvanized metal bent to 90 degrees.
The metal track is shot down to the footing using ¾" to 1" (19 to 25.4 mm) long concrete pins with washer. A pin should be shot on each end and about 2 feet (609 mm) apart. Do not extend the track past any outside corners to avoid interference with bracing. The track does not need to be lapped together. Place the bundles of forms, bracing, rebar, equipment and materials in the interior of the wall perimeter.
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Installation of iForm
Place the forms by starting in a corner and working toward the middle of a wall. Working from corners to the middle, cut the last form to the proper dimension to complete the wall. For every wall, start in the corner and meet in the middle. Install the horizontal rebar in the first course.
For these short walls Reward recommends gluing each form together on each course horizontally as they are stacked. The glue is placed on both sides of the iForm. As the forms are stacked with glue on them be sure that they fit together tightly.
The second and third course is installed the same as the first course. Be sure any block outs, beam pockets or penetrations are installed as the wall is constructed. The forms are screwed to the metal tracking after the second course is installed. As it is fastened to the metal track a level is used to ensure the top of the second course is level. The Dur-O-Wal is placed inside the formwork of the third course.
Installation of Bracing
Each outside corner should have corner braces installed. The corner brace is made up of two 2"x6"s screwed together at a 90-degree angle. The corner brace should be the same height as the wall being constructed. Be sure the corner bracing is installed so that the wall is tight from corner to corner. Fasten kickers to both sides of the top of the corner brace at a 45- degree angle and fastened down to a solid block at the base of the wall.
Install vertical strong back braces fastened to the metal track and to the plastic ties spaced approximately 10 feet to 12 feet (3 to 3.6 m) apart. The vertical strong back braces are two 2 x 4’s fastened together at 90-dgrees. The vertical strong back needs to be 4 inches (101 mm) shorter than the height of the wall.
If there is an intersecting “T” wall, fasten a 24" (609 mm) wide sheet of 5/8" (15.9 mm) plywood or OSB to the metal track and plastic ties on the backside of the “T” wall. Fasten a vertical brace to the middle of the sheeting. The sheeting and vertical brace must be fastened to each course of forms and be the same height as the wall to allow room to attach whalers.
Install common splice bracing where the walls meet, somewhere in the middle of the wall. The common splice is a vertical joint all the way from bottom to top of the wall. Install the common splice bracing exactly the same way as the “T” wall bracing is described earlier. Place string lines along the top of the walls to assist in aligning the wall from corner to corner using screws fastened to the corner braces.
Install 2"x4" kickers with turnbuckles to the vertical strong backs. Attach the turnbuckle to the top of the vertical strong backs. Adjust the turnbuckle to have plenty of adjustment in both directions. Updated: April 2011 41 Release: K
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Install whalers centered between the corners and vertical braces using two 2"x4"s screwed together at a 90 degree angle. These whalers will be screwed horizontally to the top of the wall. Adjust the turnbuckles to align the walls before any concrete is placed in the walls.
Concrete Placement
Prepare the site for concrete placement by cleaning up all debris caused from the construction of the walls and making sure you have turnbuckles, stakes, screws, screw gun, and sledge hammer laid out for easy access if you need to add additional bracing to align the wall after placement of concrete.
Start the placement of concrete away from the corner. Never pump directly into a corner or into intersecting “T” walls. Place the concrete in two lifts or passes. If there are any areas that need attention where you are placing concrete, have the pump operator move down the wall or have him shut down the pump so the area that needs attention can be fixed. Add any additional turnbuckles to align the wall as needed. Use the string lines already installed to check the alignment of the walls and make any necessary adjustments to align the walls.
Control Joints
A control joint is considered on long wall runs. Temperature and shrinkage of the concrete will create cracks in the concrete wall. A vertical control joint is added in a wall at a specified location to reduce cracks due to temperature and shrinkage. It is an intentionally designed and constructed crack in the wall.
With ICF construction, control joints may be considered differently than a traditional cast-in place concrete wall or a CMU wall. First, with an ICF wall, the concrete is placed in an ideal situation for concrete curing. The moist curing environment will actually reduce the cracking due to temperature and shrinkage as the concrete wall is insulated on each side. Secondly, the ICF formwork remains in place. Cracks are not visible and therefore are not an aesthetic issue like an exposed traditional cast- in-place or CMU wall. All concrete will crack to a certain degree. The design and construction must control the cracking to eliminate structural issues. Lastly, proper structural design will place minimum and adequate reinforcement in the ICF concrete wall to control cracking both horizontally and vertically.
A control joint may not be considered unless the wall length is at least 100' (30.5 m), and ideally 150’ (45.7 m) in length. The structural engineer will determine the control joint location.
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Checklist Prior to Concrete Placement
1. Walls meet the design, drawings and layout 2. Walls are aligned and braced every 6 feet (1829 mm) and are level, plumb, square and straight 3. String line in place 4. Wall heights meet the plans 5. Window and door openings located and dimensioned correctly 6. Window and door bucks braced inside horizontally and vertically every 2 feet (609 mm) and square 7. Window and door bucks braced for plumb within the wall 8. Window and door buck anchors are in place 9. Intermediate floor connections are in place and supported 10. Sleeve penetrations for dryer vents, electrical and plumbing service in place 11. Penetrations for outside fixtures and outlets 12. Beam pockets located and marked 13. Beam pockets for porches located and marked 14. Brick ledge (if applicable) is reinforced and supported 15. Concrete ordered to meet recommended mix (slump, aggregate size, proper concrete compressive strength) 16. Ensure correct concrete volume is ordered. 17. Concrete pump (boom type preferred) reduced to 3" (76 mm) hose 18. Avoid placing concrete directly into the corners 19. Corners securely braced 20. Horizontal and vertical rebar is properly installed to meet the structural design 21. Special cut forms are properly reinforced and braced 22. Bulkheads and intersecting walls adequately braced 23. Ladders and scaffolding in place and adequate labor is available 24. Site is organized and clean 25. Site access 26. Interlock teeth protected if a second pour is necessary 27. Concrete vibrator is on site 28. Top course is secured to the next course 29. Concrete pump truck and ready mix trucks have easy access to the job site 30. If applicable get building inspector’s and engineer’s approval 31. Be sure there are no construction debris and/or tools and materials in the cavity of the forms.
This list is a guideline only for placing concrete. Reward Wall Systems assumes no control or responsibility over the installation of the formwork.
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Concrete Placement
Concrete Mix Design
It is important to use a proper concrete mix design when placing concrete in Reward iForms. A proper concrete mix will make for a successful pour, provide good concrete flow and provide the required strength to meet the design specifications. The following guidelines should be followed. These are only to be used as a guide, the mix design should be confirmed with the local building code and the designer. It is recommended to consult and develop a good relationship with the local ready mix supplier. This will help the ready mix supplier understand your needs and help you understand the materials and capabilities of the ready mix supplier. The concrete mix designs may vary as available materials can vary from region to region.
The mix design should include Type I Portland Cement and a minimum concrete compressive strength of 2,500 psi (17.5 MPa) at 28 days. A concrete compressive strength of 3,000 to 3,500 psi (20 to 25 MPa) is recommended as it will make a mix that is easier to pump. The recommended concrete slump and course aggregate sizes are shown in the table below.
9" iForm 11" iForm 13" iForm 15" & 17" iForm (228 mm) (379 mm) (330 mm) (381 & 432 mm) 6.5" - 7.0" 6.0" - 6.5" 5.5" - 6.0” 5.5” Concrete Slump (165 – 178 mm) (152 – 165 mm) (140 – 152 mm) (140 mm) Course 3/8” 3/8”-1/2” 1/2”-3/4” 3/4” Aggregate Size (9.5 mm) (9.5 – 12.7 mm) (12.7 – 19.0 mm) (19.0 mm)
A higher concrete slump and smaller aggregate size should be considered for the 9" and 11" iForm, and a lower concrete slump and larger aggregate size for the 13", 15" and 17" iForm. Additional admixtures such as fly ash, plasticizers and super plasticizers may be added to increase the workability and concrete flow. Materials can vary from region to region, and therefore, Reward recommends consulting with the local ready mix supplier to come up with the optimal concrete mix design.
When the concrete truck arrives, It is recommended to test the concrete slump to verify that it was the slump you ordered. Inform the ready mix supplier that you will be testing the slump of every truck that arrives at the jobsite. You have the right to refuse a concrete truck delivery if it did not meet your specifications.
Water should never exceed the amount of the mix design, if water is added at the jobsite, as it will reduce the strength of the concrete.
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Updated: April 2011 45 Release: K
The New Standard for Sustainability.
The concrete placed in the iForm is insulated. This is helpful in the curing of the concrete, in cold climates and hot climates. Concrete that cures slower will be stronger concrete than concrete that is exposed to the air right after the placement. During cold weather, the concrete dissipates heat as it cures. The insulation keeps the concrete from getting too cold and adversely affecting the concrete.
Chart of Hydration Rates
Concrete Pumps
Concrete can be placed into the Reward iForm using either a line pump or an overhead boom concrete pump truck. An overhead concrete boom pump truck is recommended because of its efficiency. The site conditions will play a part in determining the type of pump.
When using the overhead boom concrete pump truck, it is important to slow the velocity of the concrete by the reducing the diameter of the hose to 3" (76 mm) near the end of the line. (Reward recommends achieving this by using the Ruff-Neck hose reducer by Conforms). Due to safety concerns it is not recommended to have a metal attachment near the end of the hose.
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The concrete pump truck must be scheduled to arrive at the jobsite at least one-half hour prior to the first delivery of concrete to allow for set up time. The successive concrete truck deliveries should be set up to be released by a call to the ready mix supplier by you.
The material used in priming the concrete pump is not to be placed into the formwork. It should be placed on the ground and cleaned up later.
Concrete Placement Parameters
Generally use a slower rate of concrete placement in cold weather than in warmer weather. The rate of concrete placement is a function of the height of concrete placed per hour and not how many cubic yards of concrete per hour. The primary variables that affect concrete form pressure include the rate of placement, the concrete temperature, slump, and the vertical height of concrete before it begins to set up. When placing concrete, these variables need to be considered.
Placing the Concrete
Successful placement of concrete in the forms is dependent upon planning, layout, bracing and securing concrete placement and concrete mix procedures. It is a good idea to have extra workers on site during the placement of concrete. Workers are needed for placement, alignment, consolidation, placing embedments and for cleaning up.
Be sure the wall is aligned before placing concrete. Continue to check for alignment during and after the concrete pour. If another concrete pour is to occur at another time, the interlocking teeth on the iForm should be covered so that the next iForm course will interlock to the previous course. Strips of poly can be secured to the form with nails poked into the form or tape is another option.
It is important to study the layout of the building plan to determine how the concrete will flow and where the “outlet” for the concrete flow will be. This is accomplished by determining where the corners, windows, and doors are located. Outside corner braces should be used if a window, door or another corner is less than 12 feet (3.65 m) away from a particular corner. When windows, doors and corners are close to each other, they create greater concrete pressure on the corners. iForm is designed with plastic tie spacing of 6" (152.4 mm) on center. This gives the blocks the ability to hold more concrete pressure without deflections.
Start the concrete placement by going a maximum of 4-foot (1.22 m) lifts around the perimeter of the building and placing concrete below every window opening. Place the concrete using a constant steady flow. Try to keep the concrete flowing in front of you at a 45º angle inside the forms. For typical wall heights, the concrete is placed in two to three lifts around the perimeter of the wall. Each lift should be properly consolidated using one of the methods outlined later in this section to prevent voids and honeycombing. It is advisable to direct the concrete flow on top of an inner plastic tie to break the fall coming out of a boom pump on the first lift.
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The concrete must be placed so that it “pyramids” up in the corner and flows down from there. To achieve the pyramid of concrete in the corner, hold the hose steady to one side of the corner about two or three plastic ties away. When the concrete accumulates sufficiently in that side of the corner, move the hose two or three ties away from the corner on the other side and repeat the process. Never direct the hose straight into the corner.
A good corner pouring technique is to move the hose back and forth through the corner approximately 2 to 4 feet (609 mm to 1219 mm) on either side of it making sure to always direct the flow of concrete away from the corner and into the straight walls on either side.
The wall must be checked for alignment during each lift while the concrete is placed. The wall should also be checked and adjusted as necessary when the concrete placement is complete and before the concrete mixture sets up and final alignment of the wall adjusted before the concrete has set up, and by the last person on the scaffolding.
If the wall is to continue upward, the joint should be left rough to allow better concrete bond, and the vertical rebar must extend 40 times the bar diameter past the first pour. Another method would be to place a vertical dowel into the concrete before it sets up during the first pour. The vertical dowel must extend 40 times the bar diameter past the first pour. If the wall does not continue upward, the top of the concrete must be smoothed and leveled to accommodate anchors and top plates.
Do not place concrete when bad weather is expected, during bad weather or near the end of the day. Be sure to cover the top of the forms if snow is expected. When the wall reaches the final set, remove laitance material using a water hose, pressure washer, chipping or bush hammer before subsequent concrete placement.
Placement of concrete in cold weather must follow ACI 306. Cover the top of the forms in cold weather to keep the wall insulated.
Always wear protective clothing and eyewear when mixing and placing concrete. Concrete is a caustic material and can burn exposed skin.
Plumbness Tolerance for Cast in Place Concrete
When constructing the cast-in-place concrete ICF wall, the wall must be built within certain tolerances. These tolerances may be found in the construction documents, code, or relevant standard. The following ACI references are for information and may be used as a guide for maintaining a plumb wall.
ACI 318 – Building Code Requirements for Structural Concrete
Does not address other than saying walls to be true, square and plumb.
ACI 347 – Guide to Formwork for Concrete 7.4 Permanent forms – nothing 3.3 Tolerances – References ACI 117 Updated: April 2011 48 Release: K
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ACI 117 – Specifications for Tolerances for Concrete Construction and Materials
4.1.1 Deviation from plumb – for heights less than or equal to 83’-4” (25.4 m) the lesser of 0.3% (0.003) times the height above the top of foundation or +/- 1” (25.4 mm).
This is a reference standard only and not part of the building code and therefore not mandatory unless it is referenced in the construction documents.
The engineer-architect may accept the element if it meets one of the following criteria: a. Exceeding the tolerances does not affect the structural integrity, legal boundaries, or architectural requirements b. The element or total assembly can be modified to meet all structural and architectural requirements
Within reason, rasping of the ICF EPS foam may be used to meet architectural and aesthetic issues.
Cold Weather Concreting See technical bulletins for more in depth information on Cold Weather Concreting
If certain precautions are taken when building with insulating concrete forms (ICFs), concrete can be placed properly throughout the winter months even in cold climates. ACI 306 is the standard used for placing concrete in cold weather. ACI 306 defines cold weather as a period when for more than 3 successive days the mean daily temperature drops below 40º Fahrenheit (F) or 4.4º Celcius (C). Normal concreting can resume once the ambient temperature is above 50º F (10º C) for more than half a day. Fresh concrete that begins to freeze can reduce the strength gain and its durability.
The concrete mixture and its temperature must be adapted to the construction procedure during cold weather. This means making preparations to protect the concrete’s temperature from the cold air. The insulating concrete forms, reinforcing steel and concrete embedments must be clear of snow and ice when the concrete is placed.
Concrete strength gain is a function of the temperature at which it cures. Typical concrete compressive strengths are based upon the concrete curing at an ideal temperature of 72º F (22.2º C) the entire 28 days. Temperatures higher than 72º F (22.2º C) will shorten the curing time and temperatures lower than 72º F (22.2º C) will increase the curing time. Concrete gains very little strength at low temperatures. The concrete must be protected against freezing effects until the degree of saturation of the concrete has been sufficiently reduced by the process of hydration. This time corresponds to the time that it takes the concrete to attain a compressive strength of 500 psi (3.75 MPa). During normal temperatures, this time is usually within the first 24 hours of concrete placement. Significant strength loss of up to 50% can occur if concrete is frozen shortly after placement or before it reaches strength of 500 psi (3.75 MPa).
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Heat of Hydration Concrete generates heat as it hydrates through a chemical reaction of the cement reacting to the water. The heat generated is affected by the dimensions or mass of the concrete, the air temperature, the initial concrete temperature, the water-cement ratio, the cement composition, the amount of cement and admixtures. The heat of hydration sometimes generates enough heat to provide adequate curing in cold weather.
Concrete Mixture Concrete mixtures may be adjusted in cold weather to accelerate the curing time by using one or a combination of 1) Type III Portland cement – high-early strength cement; 2) additional Portland cement of 100 to 200 pounds per cubic yard (59.3 to 118.7 kg/m3); 3) chemical accelerators such as a maximum of 2% by weight of calcium chloride and 4) air-entrained concrete to help the concrete absorb stresses due to ice formation.
Temperature of Concrete The recommended temperature of the concrete as mixed and as placed should be not less than what is shown in the table below. Mixing concrete to temperatures higher than 70º F (22.2º C) can have adverse effects of shrinkage and cracking.
Tips for Strong Concrete • Keep forms covered before concrete placement if any precipitation is expected. This will prevent snow and ice from forming inside the cavity of the ICFs. • Cover the top course after concrete placement in order to contain the heat produced and to insulate the top of the concrete wall. Rigid or batt insulation blankets of R-10 or greater work well for both covering the forms before concrete placement and for insulating the top of the wall after concrete placement. • Work closely with a local ready mix supplier to determine concrete mix requirements for the specific project and climate. • Do not rush a concrete pour late in the day or if bad weather is approaching. This can lead to problems.
Concrete Consolidation
A good flowable concrete mix is the first step towards ensuring a well consolidated solid concrete wall. Additionally, to prevent voids and honeycombing and ensure that solid contact is made with the reinforcement bars, it is very important to consolidate the concrete as it is being placed in every lift. While ICF professionals often employ various methods to accomplish this, Reward Wall Systems recommends using the internal vibration method.
Internal vibration can be used with a light-duty pencil vibrator. The wand should not be greater than 1” (25.4 mm) in diameter. When vibrating the wall internally always keep the vibrator moving fast in and slow out. Do not leave it in one spot very long. This is the best method but appropriate caution should be used to avoid deflections or blowouts in the wall.
Internal vibration has proven to be performed effectively with the Reward product without creating bulging or blowouts within the wall. The Reward iForm has plastic tie inserts spaced 6 inches (152.4 mm) on center that support the foam panels every 48 square inches (0.03 m2). This provides a strong form for placing concrete and internally vibrating the wall.
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Fixing Blowouts
A "blowout" is the term used to describe the rare instance when a section of the form fails during placement of concrete and allows a small amount of concrete to flow out of the form. If proper bracing, installation, concrete mix and concrete placement methods are followed, blowouts will rarely occur. If a blowout does occur it will only affect a small portion of the wall. The best solution is to be prepared and not overreact. If a blowout does occur use the following procedures to repair it:
• Keep the concrete pump hose moving past the blowout area • Scrape away the excess concrete into a wheelbarrow • Place the broken EPS foam back into place • Apply a temporary plywood patch fastened to the nearest plastic ties • Remove the temporary patch after the concrete sets up
Backfill
Backfilling the soil against the excavated basement wall should not take place unless the following conditions are met:
• The concrete has achieved sufficient strength • The top of the basement wall is supported or is sufficiently braced
The top of the wall can be supported by having the properly designed structural floor system (joist and deck) in place, or by adequately bracing with temporary supports that remain in place until the floor deck is installed.
The floor to wall connection must be designed properly to transfer the lateral loads into the floor shear diaphragm. These issues become extremely important when a wood or metal frame, modular, or manufactured home is placed on top of a Reward basement wall.
Typical concrete construction should set for seven days before backfilling, to allow the concrete to reach sufficient strength.
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Checklist After Concrete Placement
1. Be sure walls are straight, plumb, level and square 2. Concrete consolidation 3. Anchor bolts, embedments, beam pockets are installed 4. Concrete is insulated in cold weather 5. Spilled concrete is cleaned up 6. Site is cleaned up
Intermediate Floors
Wood Frame Floors
Several installation methods and different types of floor systems can accommodate intermediate floor decking. The following procedures will focus on wood frame floor decking. There are several typical iForm floor construction details in the detail section of the manual.
There are basically four installation methods to accommodate a wood frame floor deck—ledger board or rim joist, Simpson Strong-Tie ledger connector system, embedded ICF joist hanger, or the Reward ledge form.
Ledger Board
The installation of a ledger board allows the builder to use standard joist hangers such as those used in traditional wood framing. It also allows the framers to correctly lay out the floor joists as required without further involvement by the Reward installer. The ledger board is anchor bolted to the Reward concrete wall. See the engineering section for the Reward Ledger Board Connection Table.
• Establish the top and bottom elevation of the ledger board using a chalk line • Cut out the EPS foam section at every anchor bolt location. The holes should be a minimum of 4 ¾" (120.6 mm) wide and 1" (25.4 mm) below the top and 1" (25.4 mm) above the bottom of the ledger board. Taper the cut at 45-degree to allow concrete to flow into this cut out area. This is the area where the anchor bolts will penetrate the ledger board to later become encapsulated in the concrete. • Be sure to insert a vapor barrier between the concrete and the ledger board (felt) when using non-pressure-treated lumber. This can be 15 lb roofing paper, a peel and stick waterproofing membrane or poly sheet. • Temporarily screw the ledger board to the furring strips embedded in the form Updated: April 2011 52 Release: K
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• Vertically support the bottom of the ledger board • Lay out and install the J-shaped anchor bolts as required on the ledger board. Adjust the anchor bolt to proper depth by having a nut on the back face of the ledger board and another nut with a wide flat washer on the front face of the ledger board. • For single bolts, stagger the anchor bolts up and down to avoid splitting the board • Follow the edge distance and clear spacing requirements for the anchor bolts • As an option, small pieces of plywood or OSB can be temporarily fastened to the iForm with the anchor bolt centered in the small piece of lumber to position the anchor bolts during the concrete placement. After the concrete hardens, the small piece of lumber is removed and the ledger board is fastened to the embedded anchor bolts. This option may be necessary when the bracing and alignment system would interfere with the ledger board.
When top chord bearing trusses are utilized for the floor support, a double ledger board can be anchor bolted to the iForm wall. This provides a 3-inch (76.2 mm) bearing surface for the top chord bearing trusses.
Steel Angle Iron Ledger
A steel angle iron ledger can also be anchored to the iForm wall. This application may be used when the floor spans or weight of the floor exceeds the capacity of a wood ledger. It also eliminates the need for joist hangers as the floor system will bear right on the steel angle.
The steel angle is installed similarly to the steps followed above for a wood ledger. The option of using plywood or OSB or anchor tunnels to position the anchor bolts during concrete placement is recommended.
Anchor Tunnels
Another method on installing a ledger board or rim joist is by the installation of anchor tunnels. There are two advantages to this method: the Reward installer needs only to install the anchor tunnels and anchor bolts, not the ledger board, and the concrete never comes in contact with a wood ledger.
Installation of Anchor Tunnels: • Snap a chalk line marking the center of where the bolts will be located. When the design calls for a single anchor bolt, stagger anchor bolts to avoid splitting the ledger board. • Cut holes using a 6-inch (152.4 mm) hole saw on the end of a drill. When cutting through plastic furring strips, reverse the drill to avoid binding. • Install the anchor tunnels into the pre-drilled holes. Place anchor bolts into the anchor tunnel. • Place the concrete. • The ledger board can then be installed at a later time.
Simpson Strong-Tie ICF Ledger Connector Simpson’s ledger connector system is easy, quick and versatile to use. The perforations in the embedded leg of the ICFVL* permit the concrete to flow around it, anchoring the ICFVL securely within the block. The exposed flange provides a structural surface for mounting either a wood or steel ledger. See the load table found in the engineering section. The ICFVL-W is designed for a Updated: April 2011 53 Release: K
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1½" (38.1 mm) thick ledger board and the ICFVL-CW is designed for a 1 ¾" (44.4 mm) thick engineered ledger. Installation of ICFVL • Snap a line for the top and bottom of the ledger and mark off the required on-center spacing • For wood ledgers equal to or smaller than 10 ½" (266.7 mm) the ICFVL is installed on the top chalk line. For wood ledgers greater than 10 ½" (266.7 mm) the ICFVL is installed on the bottom of the chalk line. For steel ledgers the ICFVL is installed centered on the ledger. • Cut vertical kerfs at the marked location on the ICF • Insert an ICFVL bracket through each cut. To secure the ICFVL prior to placing concrete, glue the exposed flange to the iForm or fasten it to a furring strip. • Place the concrete Attachment of Wood Ledger, ICFVL-W or ICFVL-CW • Slip the ICFVL-W or ICFVL-CW underneath the wood ledger • Attach the 6 screws provided by Simpson Strong-Tie partially into the ledger, starting at the bottom of the ICFVL-W or ICFVL-CW • Position the ICFVL-W or ICFVL-CW with the ledger up against the ICFVL and drive the screws through the wood and the ICFVL Attachment of Steel Ledger • Position the steel ledger up against the ICFVL and drive the required number of screws through the steel ledger into the ICFVL • All screws shall be located at least ½" (12.7 mm) from the edge of the ICFVL • Space screws evenly
*Simpson Strong Tie does not recommend using the ICFVL for exterior applications such as decks.
Embedded Joist Hangers
The embedded joist hangers are designed specifically for the ICF systems. This method requires the Reward installer to lay out the floor joists. An Embedded Joist Hanger Load Table can be found in the engineering section. • Establish the bearing height of the embedded joist hanger using a chalk line • Fasten a temporary horizontal 2x mounting board to the plastic ties at this elevation • Create an imprint of the hanger in the EPS foam at the joist hanger locations • Using a keyhole saw carefully cut slots out of the foam where the joist hangers will be located • Insert the joist hanger into the newly created slots in the foam • Screw the bottom of the joist hanger to the temporary 2x mounting board • Insert the manufacturer’s required reinforcement into the joist hanger • During concrete placement be sure the concrete is placed completely around the joist hanger and reinforcement
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Ledge Form Reward xLerator® The iForm ledge form can be turned in toward the interior U.S. Patent Number 7437858 of the building and utilized to bear wood framed floors. When reinforced with the Reward xLerator®, this will provide a 4 ½" (114.3 mm) wide ledge for floor bearing up to a service load of 1,700 plf in the U.S., or 1,100 plf (16.7 KN/M) in Canada. A 2x sill plate and sill seal is anchored to the top of the ledge form. Either a standard wood joist floor or a top or bottom chord load bearing truss floor can then be fastened to this ledge. The underside of the ledge form should be braced vertically during concrete placement to avoid tilting the wall.
13" Taper Top to 9" iForm Transition
The 13" iForm taper top transitioning to the 9" iForm can be utilized as a bearing ledge for wood frame floors. This will not work for the 11" taper top as there is not adequate bearing.
The 13" taper top is installed as the top course of the lower wall. The 9" iForm will stack on top of the 13" taper top form. The 9" iForm will require support on both sides. Foam adhesive, 1"x4" wood and rebar can be used to support the form. The taper top must be reinforced with the xLerator.
Run a temporary wood band on exterior face between the 13" and 9" Since the 13" taper top is a terminating form, place and screed concrete on the top of 13" taper top.
A 2x sill plate and sill seal is anchored to the top of the 13" Taper Top. Either a standard wood joist floor or a top or bottom chord load bearing truss floor can then be fastened to this ledge.
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Sill Plate for Wood Frame Walls Above Reward iForm Foundation
When the iForm is only utilized for the foundation walls such as basement, crawl space, and frost walls, a sill plate is anchored to the top of the iForm foundation. These applications may include typical wood frame, modular home, manufactured home or log home construction above grade.
Reward recommends using the Reward taper top form on the top course of the foundation for these applications. The taper top should be reinforced with the xLerator®. When using the taper top for the top course, one can get the framed walls installed to the outside and bear on the concrete foundation.
A 2x sill plate and sill seal is anchored to the top of the taper top form. The 2x sill plate can be installed flush to the outside of the wall or held back to the thickness of the exterior sheathing of framed wall.
It is very important to brace the top of the wall against sway as many of the wall designs assume this support at the top of the wall. The floor-to-wall connection is critical in providing a structurally sound attachment. In order to provide this sound connection, the size and spacing of the anchor bolts and the fastening of the wood frame floor to the sill plate must be adequate.
Concrete Floors
Commercial and larger projects that require longer floor spans, fire rated and noncombustible floors or stronger and thinner floors can be constructed with one of the concrete floor options discussed below. Each of the options has its own advantages.
Precast Hollow Core Concrete Floor
Precast hollow core planks are manufactured at a factory and delivered to the job site. Overhead cranes are used to lift the planks into position. The planks are usually 3 or 4 feet (914 - 1219 mm) wide with grooves on the sides. After the planks are craned into place side by side, the grooves are grouted together and a concrete topping is placed over the entire top of the hollow core floor.
The hollow core floor is connected to the concrete wall by 90-degree bent rebar placed between the planks in the grouted groove area. The vertical rebar or vertical rebar dowels must extend past the first and second concrete pour a minimum of 40 bar diameters. The minimum bearing area, concrete wall and rebar connection must be designed by an engineer of record.
It is very important to pre-plan by figuring out the elevation of the floor with respect to the hollow core depth and the iForm height to optimize the construction efficiency and minimize form support. The iForm is usually stacked so that the top of the plank elevation will be at the top of an iForm course. This will minimize form support on the exterior of the wall.
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The planks can be installed to either bear directly on the wall or to bear on the Ledge Form. The Ledge Form reinforced with the xLerator has a uniform bearing capacity of 1,700 plf in the U.S., or 1,100 plf (16.7 KN/M) in Canada. The planks cannot be placed on the Reward wall until the concrete in the iForm has reached adequate strength.
An Optional Method of Constructing Precast Planks with the ICF walls
Using standard 2-foot (609.6 mm) long light gauge steel studs provides a method of reducing or perhaps eliminating the external bracing of the wall at the elevations of precast hollow core plank floor systems while providing a means to avoid bulging of the forms.
The light gauge steel studs can be inserted 12 inches (304.8 mm) into the wet concrete of the first pour. The studs are placed so that the flat side of them are on the interior core, along the inside face of the foam and as tight to the plastic ties as possible. The studs should be spaced anywhere from 1’ to 2’ (304.8 to 609.6 mm) on center along the wall at the elevations of the precast floor planks. The spacing is determined by whether or not a rim band is placed along the outside of the wall or not. Two 3" (76.2 mm) long screws are placed through the plastic ties at an angle and into the studs.
The next course of formwork then is interlocked to the lower course. Here again, two screws are fastened through the plastic ties and into the studs. The studs will remain permanently in the concrete wall.
No more than one iForm course of concrete should be placed past this location before proceeding any higher.
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Composite Concrete Floor
Composite concrete floors consist of a steel corrugated deck pan and concrete. The corrugated steel pan has deformations that bond together with the concrete to provide a very strong and thin floor system. The steel pan deck acts as both the formwork for placing the concrete and the reinforcement for the concrete floor.
As with the precast hollow core plank system, the composite concrete floor should be designed and installed so that the top elevation of the floor will be at the same elevation as the top of an iForm course. The floor cannot be placed on the Reward wall until the concrete in the iForm has reached adequate strength.
Steel Truss Metal Deck Concrete Floor
The steel truss metal deck concrete floor system consists of steel trusses or open web steel joists, light gauge metal deck and a concrete floor, such as eco span. A proprietary system called Hambro is similar except without the light gauge metal deck. In place of the metal deck, temporary plywood forms are installed and removed after the concrete is placed and has cured sufficiently.
The steel truss bears on a bearing plate anchored to the concrete wall after the concrete has sufficient strength. The trusses are placed at approximately 4 foot (1.2 m) centers. Next, the light gauge metal deck is installed over the trusses. Finally a concrete floor is placed on top of the deck.
As with the precast hollow core plank system, this composite concrete floor system should be designed and installed so that the top elevation of the floor will be at the same elevation as the top of an iForm course. The floor cannot be placed on the Reward wall until the concrete in the iForm has reached adequate strength.
Refer to the engineer of record of floor system manufacturer to determine adequate bearing for the trusses and floor design and connection to the wall.
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Post Tension Slabs
The Reward iForm insulating concrete form can be used as in-fill walls between post tension slab concrete floor slabs. This application is typical of mid-rise or high-rise construction. The iForm is installed after a couple of stories of floor levels are in place. The iForm is structurally connected to the bottom floor slab. The forms are stacked between the two post tension slabs. The top of the wall is left unattached to the upper floor slab so that it is not load bearing. The wall is designed to cantilever from floor to floor. Concrete is placed inside of the forms through port holes cut into the post tension slabs.
Roof Connections
Top Sill Plate
The most common method of connecting a roof to the Reward wall is by anchor bolting a top wood sill plate to the wall with sill seal under the plate.
The sill plate can be installed so that either the bottom of the plate is bearing on top of the wall or the plate is recessed into the iForm so that the top of the plate is flush with the top of the iForm. The recessed method may provide better energy efficiency. In either case, most installers prefer to cut the interlocking teeth off the top course to provide a smooth surface to trowel the wall level. The anchor bolt size and spacing is to be determined by local building code and/or the engineer of record.
Simpson Strong-Tie has many different anchor and strap connectors that can be utilized for increased hold-down support such as hurricane straps. These are usually embedded into the concrete wall.
Direct Bearing
Wood or steel trusses may be designed and installed so that they bear directly on top of the concrete wall. The bottom chord of the roof trusses are to be connected to the top of the wall with concrete roof truss connectors. Simpson Strong-Tie is a major supplier of these connectors. Follow the recommendation of the manufacturer of the connectors.
Wood trusses should not be in direct contact with the concrete. Choose a connector that has a moisture barrier pad for the truss to bear on such as the Simpson Strong-Tie META with TSS connector.
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Parapet
Many commercial applications are designed with parapets to conceal mechanical systems mounted on top of the roof.
These are designed and installed similar to the direct bearing connection. The difference is that there will be an additional length of wall extending past the roof line. This will require an additional concrete pour after the trusses are set in place. The top of the parapet wall must have a concrete cap installed using good detailing methods.
Any material or product that is applied in contact with the expanded polystyrene (EPS) foam plastic material of the iForm must be compatible. Petroleum, solvent, ketones, and esters based products are not compatible and will deteriorate the foam.
Electrical and Plumbing
Electrical
Electrical wiring and electrical boxes can be placed in the Reward iForm wall by cutting chases into the EPS foam using a router or hot knife. The placement must be in accordance with local codes and regulations. The iForm has consistent 2 ½" (63.5 mm) thick EPS foam on each side of the wall. Horizontal chases can be made between successive courses of iForm to avoid interference of the plastic tie where there is a ¾" (19 mm) clearance. Make the chases narrow so that the wiring and boxes fit snug into the foam cut out. The chase should be cut at least 1 ½" (38.1 mm) deep into the foam. A protective shield can be placed where the electrical wire crosses behind a plastic tie. The electrical wire can be spot glued in place with compatible foam or adhesive.
The electrical boxes can be either glued in place with compatible foam or adhesive or anchored to the concrete using concrete fasteners. Electrical boxes with tabs for mounting to the face of a stud can be used and secured to the plastic tie. Fasten utility boxes directly to the concrete wall using concrete fasteners or anchors.
Plan ahead for future indoor and outdoor outlets and fixtures. Whenever and wherever possible, run the horizontal chases between two courses of forms to avoid cutting through the plastic ties.
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Plumbing
Plumbing lines and pipes can be installed in similar fashion to electrical wiring by cutting chases into the EPS foam using a router or hot knife. All plumbing must be installed in accordance with the local code and regulations.
When the pipes are too large (greater than 2 ½" or 63.5 mm diameter) to be accommodated in the EPS foam, the pipe may be framed in using standard construction methods, or it may be installed in an interior framed wall whenever possible. It is not recommended to place plumbing lines in the concrete cross section of the wall as this weakens the structural integrity of the wall. In cases where plumbing lines must be run in the concrete wall, a structural engineer must create a design to compensate for the weakness created by placing the line in the concrete.
Whenever and wherever possible, run the horizontal chases between two courses of forms where there is a ¾" (19 mm) clearance, to avoid cutting through the plastic ties.
Wall Penetrations
Utility access ports and sizes must be planned and positioned into the Reward wall prior to placement of concrete. These ports will allow access between the outside and inside of the solid reinforced concrete wall to accommodate incoming dryer vents, electrical, gas, sprinkler, telephone or water lines or pipes.
An access port is accomplished by permanently installing a PVC or steel sleeve into the wall large enough to carry the required utility. An imprint of the sleeve is made on the wall and the EPS foam is removed using a long blade keyhole saw. When the sleeve is inserted into the opening, it should be positioned slightly higher on the inside face of the wall. It is very important to remember to seal and caulk around all access ports to avoid the intrusion of water.
Interior and Exterior Finishes
Interior Finishes
The Reward walls must be finished with an approved fifteen-minute thermal barrier on the interior face of all walls in habitable spaces. A ½” (12.7 mm) thick regular gypsum wallboard meets the criteria. This includes unfinished basement walls and garage walls.
All interior finishes can be applied directly to the Reward wall. Common interior finish material such as drywall or gypsum wallboard can be fastened to the wall using coarse thread drywall screws and compatible EPS adhesives. Other types of interior finishes may be installed, but they must meet the
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fifteen-minute thermal barrier criteria tested to ASTM E119 (CAN ULC S101) over EPS foam in habitable spaces.
The Reward iForm includes vertical plastic furring strips located 6" (152.4 mm) on center. These furring strips are 1¼" (31.8 mm) wide and take the place of the wood or metal studs. The fastening strips are clearly marked by two parallel lines of raised EPS beads on the surface of the EPS foam panels.
Reward recommends that permeable paint and plaster interior finishes is specified. Vinyl wall coverings on the interior face of the Reward wall are not recommended. It is very important that the wall is able to breath.
Corner Attachment
The first plastic tie or furring strip nearest to the corner in the iForm is centered and located at the following dimensions:
Dimensions for Corner Attachment
9" iForm 11" iForm 13" iForm 15" iForm 17" iForm
(228 mm) (279 mm) (330 mm) (381 mm) (432 mm) Standard 90 1 ¼" 1 ¼" N/A N/A N/A Inside Return (31.8 mm) (31.8 mm) Standard 90 10" 16" N/A N/A N/A Outside Return (254 mm) (406.4 mm) Extended 90 1 ¼" 1 ¼" 1 ¼" 1 ¼" N/A Inside Return (31.8 mm) (31.8 mm) (31.8 mm) (31.8 mm) Extended 90 10" 12" 14" N/A 18" Outside Return (254 mm) (304.8 mm) (355.6 mm) 45 Inside 2 ½" 2 ½" 2 ½" N/A N/A Return (63.5 mm) (63.5 mm) (63.5 mm) 45 Outside 7" 7" 7" N/A N/A Return (177.8 mm) (177.8 mm) (177.8 mm)
The 45-degree corner forms have a plastic tie or furring strip right at the apex of the corner as well.
The 11", 13" and 17" iForm has a double-bridging H- Bracket molded into the 90-degree corner forms. This corner bracket provides a 1 ¼" (31.8 mm) wide continuous fastening strip right in the apex of the corner. There is another 1 ¼" (31.8 mm) wide continuous furring strip that is centered 6 inches (154.2 mm) from the corner’s apex. Additionally there is a 1 ¼" (31.8 mm) wide fastening strip running perpendicular to these two vertical strips. This horizontal strip will be staggered vertically and located approximately every 6 to 8 inches
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(154.2 to 203.2 mm). All of the fastening strips are recessed ½" (12.7 mm) beneath the face of the EPS foam face. Therefore the 11" iForm will have continuous vertical fastening located 1 inch, 6 inches and 12 inches (25.4, 154.2 and 304.8 mm) from the corner, the 13" iForm will have a fastening strip located 1 inch, 6 inches and 14 inches (25.4, 154.2 and 355.6 mm) from the corner and the 17 iForm will have a fastening strip located 1 inch, 6 inches, and 18 inches (25.4, 154.2 and 457.2 mm) from the corner.
The 9" and 15" 90-degree corner iForm has a corner tie that is not continuous vertically. The corner tie is located 5 ½" and 10 ½" (139.7 and 266.7 mm) from the top and/or bottom of each form. It depends which side the form is stacked. The corner tie extends 6 inches (152.4 mm) around each outside return and is 2 inches (50.8 mm) wide.
Also available from Reward is a 1" (25.4 mm) square plastic corner dowel that can be placed in the square cavity in the outside corner of the 90-degree corners. This will provide a continuous plastic furring strip directly in the outside corners. It can also be used to strengthen the outside corners.
If additional corner attachment is required, light gauge metal strapping can be fastened around the corners or between plastic ties to bridge any gaps. The light gauge metal should be fastened with a minimum of two fasteners to the plastic ties on each side of the gap.
Attics and Crawl Space
The interior face of attics that are not habitable and where there is no entry for service of utilities typically does not require a 15-minute thermal barrier. Local building code requirements must be followed.
The interior face of the iForm in crawl spaces applications may be exposed without a covering if all of the following conditions are met.
• Entry to the crawl space is limited to service of utilities. Heat producing appliances are not permitted. • There are no interconnected basement areas. • Air in the crawl space is not circulated to other parts of the building. • Ventilation of the crawl space is provided in accordance with the applicable building code.
Baseboards
There are three methods of attaching the baseboard to the Reward iForm wall. The method used is determined by the contractor, designer, and owner of the building based upon the specific project and the type of baseboard. The thickness and depth of the baseboard should be considered when choosing the proper baseboard attachment method.
Method 1
This method is accomplished with the use of a pneumatic nailing gun after the drywall is installed. Using standard finishing nail brads, shoot the nail directly into the baseboard, through the drywall and into the Reward plastic furring strip or stud. The plastic stud can be found by 1) marking the floor before the drywall is installed, 2) following the drywall nailing pattern or 3) by using a magnetic Updated: April 2011 63 Release: K
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stud finder to find the location of the nails behind the drywall. It is best to shoot the nail in at an angle toward the top and bottom side of the baseboard. Alternate the angles of the nails along the length of the baseboard.
For additional connection strength, use compatible construction adhesive. Run a bead of construction adhesive along the backside of the baseboard prior to nailing it to the wall. Do not use adhesive exclusively.
If one does not desire to use finishing nails, finishing screws may be used in the same fashion. The length of the fasteners must be long enough to go through the thickness of the baseboard, the thickness of the drywall, the thickness of the EPS foam in front of the plastic stud and a minimum of ½” (12.7 mm) beyond the plastic stud. It is not necessary to butt two baseboards over the plastic ties. Reward walls have a solid continuous foam and concrete substrate behind the drywall. Be sure that the baseboard is tight against the wall when fastening the board to the wall.
Method 2
This method involves fastening an OSB or plywood backing strip along the base of the wall. The thickness of the wood backing strip must be the same thickness as the drywall thickness to be used. The wood backing strip is installed prior to the drywall. The height of the backing strip should be a ½” (12.7 mm) lower than the baseboard material. The drywall is then butted up to the top of the wood backing material.
The wood backing is screwed directly to the plastic studs using course threaded number 8 or 10 drywall screws. If desired, a compatible construction adhesive may be used on the back of the wood backing material to provide additional strength.
After the backing strip is in place and the drywall is hung, the baseboard can then be fastened to the wood backing strip using a pneumatic nail gun with finish nails.
It is recommended to use course thread drywall screws for fastening the wood backing to the Reward wall. The screws are fastened to the plastic studs molded into the forms. Fine thread screws do not have as much pullout strength as the course thread screws. When screwing into the plastic stud, bring it to “snug tight” and stop, to prevent stripping out the plastic stud. It is recommended to use cordless drills instead of electric drills. Keep the cordless drill at its lowest power setting. Please follow the local building code jurisdiction regarding the fastener schedule.
Some contractors may decide to use a combination of screws and adhesive when installing the baseboards. This method is acceptable as long as they are sure that they are compatible and approved for use on EPS foam materials. Petroleum or solvent-based products will deteriorate the foam.
Curtain Rods and Towel Racks
A product called the Grappler can be used for items that are not excessively heavy, but require extra strength for attachment such as curtain rods and towel racks.
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A Grappler plate is a 4"x 8" (101.6 x 203.2 mm) mesh metal plate designed specifically for the ICF industry. Install the Grappler by pushing it into the foam wall before the drywall is hung. Once the Grappler is sandwiched between the drywall and the foam, it becomes a locking washer with increased holding power. Screws or finishing nails pilot a hole into the Grappler and securely hold heavy items.
Cabinets
There is one main method with some slight variations of hanging cabinets to the Reward ICF walls. The method used is determined by the contractor, designer, and owner of the building based upon the specific project and the type of cabinet. Always consider the length, type, size, weight of the cabinets, and weight of the contents during the planning phase. The recommended method entails fastening a plywood backing to the Reward ICF wall. The plywood backing is fastened to the concrete with concrete anchors prior to the drywall installation. The cabinet area is laid out by marking on the ICF wall. The plywood is installed ½" to 1" (12.7 to 25.4 mm) short of the perimeter of the cabinet area so that the drywall will inset behind the cabinet. The thickness of the plywood must be the same thickness of the drywall. Do not use OSB.
Instead of fastening the plywood backer directly on top of the ICF wall surface, an optional method would be to remove the EPS foam to the thickness of the plywood so that it is flush with the EPS surface. Use ½" (12.7 mm) plywood fastened to the concrete with concrete anchors. With this method the drywall can be installed behind the cabinets.
Once the area where the plywood is going to be fastened is laid out, the next step is to fasten it to the wall. This can be accomplished using any combination of compatible construction adhesive, course threaded drywall screws and concrete fasteners (tapcons). The combination chosen should include a minimum number of concrete fasteners.
The cabinet is then fastened directly to the plywood backing.
An alternative method is to fasten a 2x material horizontally or vertically to the concrete wall using concrete fasteners (tapcons) after removing the EPS foam so that the 2x material is flush with the EPS surface.
When installing lighter and smaller cabinets to iForm, one may consider fastening them directly to the plastic stud and concrete. Use a course threaded screw every 6 inches (152.4 mm) on center, both on the top and on the bottom of the cabinet, in addition to a minimum number of concrete fasteners.
Reward recommends using course thread drywall screws for fastening the wood backing to the Reward wall. The screws are fastened to the plastic studs molded into the forms. Fine thread screws do not have as much pullout strength as the course thread screws. Turn the screw into the plastic stud to snug tight and stop to prevent stripping out the plastic stud. Use a cordless drill instead of an electric drill and keep it at its lowest power setting. Follow the local building code jurisdiction regarding the fastener schedule.
Some contractors may decide to use a combination of screws and adhesive when installing the cabinets. This method is acceptable as long as they are sure that they are compatible and approved for use on EPS foam materials. Petroleum or solvent-based products will deteriorate the foam.
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Heavy Wall Loads
The plastic ties embedded in the Reward form that act as the "stud" or furring strip can support most items that will be fastened to the Reward wall. For hanging other heavier objects, such as cabinets and large pictures, use supplemental bracing or concrete fasteners. There are a number of methods to accomplish this.
A lumber 2x stud can be fastened or anchored to the concrete wall by creating a channel in the EPS foam before or after placing the concrete. The heavy item can then be fastened to the 2x stud. For some heavy items, a concrete fastener can be used without the lumber stud.
A second option is to use a Grappler plate. Install the Grappler by pushing it into the foam wall before the drywall is hung. Once the Grappler is sandwiched between the drywall and the foam, it becomes a locking washer with increased holding power. Screws or finishing nails pilot a hole into the Grappler and securely hold heavy items.
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Exterior Finishes
Standard exterior finishes such as various types of sidings, acrylic and natural stucco, brick or masonry veneer and cultured stone can be applied to the Reward wall. This section addresses the application of these exterior finishes relative to the specifics of the iForm. In addition to these guidelines, the exterior finish manufacturer procedures must be followed.
Aluminum, Steel and Vinyl Horizontal Siding
To fasten vinyl siding to iForm, use course thread #10 pan head screws or course thread #8 or #10 screws with a flat washer large enough to cover the vinyl siding slot. The fasteners should have a sharp point and be corrosion resistant. See the corner attachment section for fastening the corner trim. Fasten to the door and window buck around openings.
Vertical Siding iForm has plastic furring strips located vertically every 6 inches on center. If a siding panel or strip is not conducive to these dimensions, a ½" or ¾" (12.7 or 19 mm) strip of furring wood can be fastened horizontally to the plastic ties.
Wood Siding
Traditional lap or panel or sheet wood siding should be fastened using #6 or #8 course thread, trim head, corrosion-resistant screws. See corner attachment section for fastening the corner trim.
Fiber Cement Board Siding
Fiber cement board siding is fastened directly to the iForm using ITW Buildex Backer-On or Rock- On screws. These screws are available at the main construction supply stores. They have a ribbed head and serrated threads that work real well in getting the head flush with the siding. See the corner attachment section for fastening the corner trim.
Textured Acrylic Finish Stucco Systems (TAFS)
Textured acrylic finish stucco systems (TAFS) can be applied directly to the Reward iForm. The density of the EPS is 1.5 pcf (24.0 kg/m3) and the plastic ties are recessed ½" (12.7 mm) beneath the EPS surface. It is not necessary to install additional sheets of EPS. When using TAFS products a fiberglass mesh is required. This mesh is embedded into the base coat of the TAFS product. There are different grades of mesh for higher impact application areas of buildings. Any UV degradation of the EPS must be rasped clean before applying the TAFS. Follow the detail recommendations of the manufacturer.
Review and follow the TAFS supplier’s specifications. Many of the leading TAFS suppliers have a tolerance of 1/16” (1.6 mm) gap or void tolerance for the EPS substrate. Gaps or voids in the EPS less than ¼” (6.4 mm) can be filled using spray foam. Gaps larger than ¼” (6.4 mm) are typically filled using slivers of EPS.
The TAFS suppliers also recommend that the wall be flat and smooth in any direction.
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Traditional Portland Cement Stucco
When using a traditional cementitious stucco system, a wire lath mesh is required. Traditional stucco is much heavier and thicker than the TAFS stucco. The wire lath mesh is fastened to the Reward plastic ties using corrosion resistant screws with a wide head or a washer. The installer must follow the application procedures and details provided by the stucco manufacturer.
Consult the local designer and building code for the fastener schedule.
The EPS foam has a very low modulus of elasticity. There is essentially no bond of the stucco to the EPS or if there is, it does not matter because of the low modulus. Therefore, the stucco will expand and contract on its own and must follow these widely known plaster and stucco specs to control cracking.
Use control or expansion joints. A control joint is a ‘V’ joint and an expansion joint is a ¾” (19 mm) joint all the way thru the substrate material. Use these joints every 144 square feet (13.4 m2) for panels at no greater than a height or width ration of 2 ½ to 1. Do this at windows and corners or stress points and at dissimilar substrate interfaces.
Masonry Veneer (Brick and Stone)
Brick or masonry veneers are secured to the Reward wall with standard brick ties or by installing Reward’s tieKey® anchor. Standard brick ties are fastened with coarse thread screws to the Reward furring strips or inserted into the hollow form prior to placing the concrete and embedded into the mortar joint of the masonry. The brick ties hold the veneer against the wall. A brick ledge is installed to support the weight of the brick or masonry veneer. Several different methods can be used to construct a brick ledge on the Reward wall. A 1" (25.4 mm) air gap behind the masonry face with proper flashing and weep holes is required. tieKey® Anchor Installation
Brick anchor spacing should be a minimum 16 inches (406.4 mm) on center vertically and 24 inches (609.6 mm) on center horizontally to meet the building code requirements and to work well with the iForm design. This meets the building code requirements for both spacing and wall area.
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The brick anchor should be placed at mid-height of each iForm course. The mid-height of the iForm is identified with a small, raised, EPS horizontal bead line. Center one of the brick anchors on this line next to a plastic tie insert that is marked with two raised EPS vertical lines. This positions the anchor between the two plastic tie insert tie rods that connect each panel of foam. This will allow for good concrete flow.
Wall and brick mortar joint layout must be coordinated between the locations of the brick and mortar joints and the positions of the brick anchor relative the iForm design.
The 2-inch (50.8 mm) slot in the brick anchor allows for adjustable flexibility and movement of the brick wire tie so that the mortar joints line up with the brick anchor.
Using a keyhole saw, make a 2 ½” (63.5 mm) long vertical cut centered on the mid-height line and along one of the raised EPS lines identifying a vertical tie insert.
Insert the pointed end of the brick anchor through the cut line until the 90-degree bent tab is flush with the face of the iForm. The brick anchor must be inserted so that the bent tab is aligned over the vertical tie. The bent tab is 1 ¼” (31.8 mm) wide, the same width as the plastic tie and the double vertical EPS lines identifying the location of the plastic tie. Fasten the brick anchor to the plastic tie insert by screwing one or two corrosion resistant course thread sharp point 1 ¼” to 1 ½” (31.8 to 38.1 mm) long screws through the screw holes on the bent tab and into the plastic tie insert. This is to temporarily hold the brick anchor in place during placement of concrete.
The mason contractor now has anchors cast-in-place to connect tie wires to the 2” (50.8 mm) slot in the anchor. The brick anchor is designed for either W1.7 (9 gauge) or W2.8 (3/16” or 4.8 mm) tie wires.
Seismic applications require a continuous horizontal rod imbedded in the mortar joint and anchored to the wall. For these seismic applications, we recommend one of the following options. 1. Dur-O-Wal 1-800-323-0090 a. DA 700QT Lite Duty Seismic Triangular Tie
2. Hohmann & Barnard 1-800-645-0616 a. Byna-Lok b. Byna-Tie with Seismiclip
3. Wire Bond 1-800-849-6722 a. 1100 Triangular Tie with Wire Bond Clip
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Cultured Stone
Installing cultured stone is a cross between masonry veneer and traditional stucco. A wire lath is mechanically fastened to the iForm using course thread corrosion resistant screws with a washer. A scratch coat and base coat of mortar is applied to the iForm and metal lath and the cultured stone is mortared directly to the wall.
Air and Vapor Retarder
The Reward iForm wall assembly is a solid monolithic cast-in-place concrete wall with 2 ½ inches (63.5 mm) of closed cell EPS on the interior and exterior faces. There is no wall cavity.
This assembly does not require an air barrier. The solid monolithic concrete 4", 6", 8", 10" or 12" (102, 152, 203, 254, or 305 mm) wall acts as the air barrier as required by the building codes and does not allow air infiltration. For more information, refer to the Reward research report on air barriers.
The assembly does not require a vapor retarder. A combination of the low permeance of less than 3.0 perms per inch for the 2½" (63.5 mm) of Type II EPS foam panels on each side of the concrete core and the concrete core prevents condensation and moisture penetration. The Reward iForm assembly has a 0.70 perm, which is less than 1.0 perm that would require a vapor retarder. For more information, refer to the Reward research reports on vapor barriers and condensation.
Exterior Transition Area
The EPS foam must be covered by an approved exterior finish. Below grade basement walls must have a waterproofing membrane attached to the exterior wall face. Above grade walls must have siding, brick veneer, stucco, EIFS or some other type of exterior finish.
An area that is sometimes overlooked is the transition area between a Reward ICF basement wall and the above-ground wall, whether wood frame or ICF. This is the transition area where the basement wall extends above grade for a distance before the sill plate transition to the wood frame structure or where the exterior finish of an above grade Reward wall terminates.
The basement walls require a waterproofing membrane below grade. The EPS foam on the ICF wall above grade must also be covered for protection. Usually the Reward wall or wood frame wall is covered with some type of siding finish that terminates a few inches above grade or near the sill plate. Some methods of covering the EPS foam include a peel and stick product called Protecto Wrap, a waterproof type stucco or EIFS or traditional parging method. The siding or exterior finish should overlap the material covering the foam above grade and that material should overlap the waterproofing material below grade. Overlapping the materials provides for good drainage. The materials should never terminate or butt up to each other.
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Waterproofing
It is critical that waterproofing be addressed for below grade Reward wall installations to ensure that the basement and crawl space areas are dry. It is essential not to cut corners in this area. The EPS on both sides of the wall and the concrete will not prevent water from leaking into the basement. In order to ensure a dry basement, install a drainage system around the outside (and sometimes inside) perimeter of the footing, place aggregate above and below the drainage system, backfill with free draining material, slope the grade away from the building, install gutters and downspouts and use and install a compatible waterproofing sealant system.
The most important part in waterproofing is choosing the right waterproofing sealant system and installing it properly. Always verify that the system you choose is compatible with the EPS foam. Do not use a petroleum based product or one that contains solvents, ketones and esters. This applies to primers as well. These types of products are not compatible with the EPS and will deteriorate the foam.
There are generally three types of waterproofing sealants available from several different manufacturers:
• Air gap or drainage membrane systems • Contact membrane systems (primer is recommended) • Brush, roll or spray-on coatings
No matter which product you choose, be sure to follow the manufacturer's instructions.
Reward recommends the air gap or contact membrane waterproofing type systems. Reward does not recommend any brush on, trowel on roll on or spray on type waterproofing systems.
The air gap membranes work the best because they not only provide a waterproofing membrane but they also allow ground water to self drain to the footing drain. It is also mechanically fastened to the wall. This eliminates issues with hot and cold temperatures and also avoids any adhesion issue.
In heavy soils, we recommend a drainage mat to go over the air gap waterproofing membrane. In very heavy termite infested areas, Reward would recommend the Polyguard 650 XT termite protection and waterproofing membrane. The ultimate waterproofing system consists of the air gap system covered with a drainage plane or a contact membrane in addition to an air gap system.
Reward Wall Systems has prepared a partial list of waterproofing sealant systems that have worked well on Reward projects. These can be found in the product compatibility section. Membrane systems that offer drainage and backfill protection work the best.
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The following are basic reminders for installing waterproofing systems:
• Extend the waterproofing sealant down the wall, over the top of the footing and down the side of the footing a few inches • On brick ledge applications, extend the waterproofing sealant up and over the brick ledge and up the wall a few inches • Always remember to seal the top of the waterproofing sealant and to install membrane type systems with the proper overlap • Use care when backfilling against the wall so that the backfill material will not damage or puncture the waterproofing system • Prior to backfilling be sure that the walls are braced well or that the structural floor diaphragm system is in place • Do not drive equipment parallel to the wall when backfilling • Always use basic construction flashing and sealing techniques around openings and penetrations
HVAC and Indoor Air Quality
The following characteristics of the energy efficient buildings constructed with Reward walls must be taken into consideration when specifying the size and type of both the heating and air conditioning equipment. It will be necessary for the heating and air conditioning equipment supplier to be familiar with these characteristics in order to select the proper equipment for the new building.
First, the R-value of the Reward walls (the method of stating the insulating properties of the form) will be necessary information for the heating contractor. The actual R-value is 22, but due to the low air infiltration and thermal mass effects, it performs much better than that. A Reward building typically has an effective R-value of 32 or greater.
Second, modern construction practices recognize the necessity of limiting air infiltration through leaks, which along with good insulation, is the primary factor in determining the energy efficiency of the building. Reward walls develop an extremely tight building envelope. The air infiltration factor varies from project to project, but can be as low as 0.04 to 0.20 air changes per hour. A blower door test will provide exact air infiltration values for each building.
In addition to the superior insulating properties of the EPS foam and the reduced air infiltration, the thermal mass of the wall must also be taken into consideration when selecting heating and air conditioning units. The thermal mass is dependent upon the local climate. Geographical regions where there is a greater change in temperature within a 24-hour time period benefit the most.
An air conditioner sized too large for the building will not provide a comfortable environment because it will cycle too frequently to remove the humidity from the building. It also adds unnecessary energy costs.
It is important to make certain that the HVAC supplier calculates the energy load on the building using an actual R-value of 22 and takes into consideration the low air infiltration rate and thermal mass of the wall assembly. The long recognized “rule-of-thumb” method of sizing heating and air conditioning equipment does not apply to a building built with Reward walls.
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The Portland Cement Association (PCA) has a software program available for sizing HVAC systems for residential concrete construction. It is titled HVAC Sizing Software for Concrete Homes and the PCA publication number is CD044.01. It can be purchased by contacting the PCA publication department at 847-966-6200.
A properly sized HVAC system can be reduced by 30% to 50% compared to a system prescribed for a similar building constructed with other building materials. To maximize the energy efficiency and comfort of the structure, high-quality, energy efficient windows and doors are recommended. The ceiling should be insulated with cellulose to an R-38 to achieve the greatest energy efficiency and comfort, and if applicable, can lighting should be sealed and insulated.
The wall assembly consists of EPS on the exterior and interior face with solid reinforced concrete in between. The EPS and concrete is virtually mold and mildew resistant. EPS has a permeable rating that acts similar to a vapor barrier.
The dew point temperature within the wall will never occur and therefore is impossible to calculate. In order for a dew point temperature to occur, both air and a large enough temperature differential must be present. With the EPS on both sides insulating the concrete wall and the large amount of thermal mass, the design of the wall is such that it is essentially airtight and the temperature of the concrete wall is consistent.
Concrete and lumber will always have a certain amount of moisture in the material. Once the concrete is placed into the stay-in-place insulating concrete forms, the majority of the water and slurry seeps out of the forms through the joints. The rest of the moisture self drains and evaporates. After 4 to 6 weeks the concrete will be essentially dry.
Because of the tight exterior building envelope it is very important to control the indoor air humidity. Reward recommends that the relative humidity be kept at below 50%. Mold and mildew and other indoor air pollutants such as dust mites will not survive with relative humidity less than 50%. Air from the outside, people and pets, cooking, bathing and mechanical systems produce moisture inside a building once it is occupied. It is especially important to remove this moisture from a building having exterior walls that create a tight building envelope such as Reward walls.
Reward also recommends an efficient heat recovery ventilation system (air-to-air heat exchanger).
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Termite Protection
Reward buildings must be protected against termite infestation in accordance with local construction standards and building codes. When materials susceptible to termite attack, such as wood, are placed on or above ICF construction, the ICF foundation walls in areas subject to termite infestation must be protected by approved chemical soil treatment, physical barriers (i.e., termite shields), or any combination of these methods in accordance with the local building code and acceptable practices.
Termites need wood (cellulose) and moisture to survive. Expanded Polystyrene (EPS) provides termites with no nutrition, but can provide access to the wood structural elements. Recently, some building codes have prohibited rigid foam plastics (EPS) for near- or below-grade use in very heavy termite infestation areas. (See map below.) Local building code requirements, a local pest control company, and the ICF builder should be consulted regarding this concern to determine if additional protection is necessary. A brief list of some possible termite control measures follow.
• Polyguard 650 XTM and XTP waterproofing and termite protection membrane is approved by SBCCI PST & ES (#2136). • Rely on soil treatment as a primary defense against termites. Periodic re-treatment and inspection should be carried out by the homeowner or termite treatment company. • Install termite shields. • Provide a 3- to 6-inch (76.2 to 152.4 mm) high inspection clearance above finish grade around the perimeter of the structure where the foam has been removed to allow visual detection of termites. • Be sure all tree stumps, wood debris and construction debris is removed before backfilling and landscaping the project • Install a proper foundation drainage system and slope grade away from building to remove water • Use pressure treated lumber or vinyl buck systems • Construct all interior framing walls, floors and roof with light gauge steel members
In areas where hazard of termite damage is very heavy, foam plastic insulation is permitted below grade on foundation walls in accordance with one of the following conditions: 1. When an approved method of protecting the foam plastic and structure from subterranean termite damage is provided (i.e. Polyguard 650 XTM and XTP). 2. The structural members of the walls, floors, ceilings and roofs are entirely of noncombustible materials or pressure preservative-treated wood. 3. On the interior side of basement walls.
In jurisdictions that have adopted the Standard Building Code© International One and Two Family Dwelling Code, and the International Residential Code™, where foam plastic insulation is used with wood construction in areas of very heavy termite infestation, the foam plastic must be installed in accordance with Sections 1916.7.5 and 2603.3 of the Standard Building Code©, Section 323.4 of the International One and Two Family Dwelling Code and Section R324.4 of the International Residential Code™. Areas of very heavy termite infestation must be determined in accordance with Figure 2304.1.4 SBC, Figure 301.2 (6) /1&2 FDC and Figure R301.2(6) IRC.
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Termite Infestation Probability Map
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Reward Ledge Form and xLerator® and tieKey® Anchor
The Reward ledge form can be used to support brick or stone exterior finishes or to support floor systems on the interior of the building. The ledge form is available in the 11" and 13" iForm sizes, and both sizes feature a 4 ½" (114.3 mm) ledge containing eight concrete corbels. See the typical application details in the library of iForm details.
The volume of concrete for the corbels is 0.03 cubic yards (.02 m3) for both the 11” and 13” ledge form corbels. This does not include the volume of concrete in the wall.
Brick and Stone Exterior Finishes
The ledge form easily supports the gravity loads of exterior brick or stone veneer. In the U.S., the ledge form (reinforced with the Reward xLerator), can support a 40-foot height of standard 3 ½", 40 psf brick or a 20-foot height of 80 psf stone. For Canada, refer to the engineering table for the ledge form reinforced with the xLerator. It is designed for the brick or stone to bear on the ledge. The veneer must be designed to be held to the wall by brick ties to resist lateral loads according to the local building code. The brick ties are typically mechanically fastened to the iForm plastic tie or use of the tieKey anchor and integrated with the mortar joint. See the Engineered Ledge Form Load Table in the engineering section.
® tieKey Anchor Patent Pending
A cast-in-place adjustable tie brick anchor embedded into the ICF concrete wall.
The ICF brick anchor is a two-part system –the ICF brick anchor and the unit wire tie. The brick anchor is installed as the ICF wall is constructed. The tie wire is installed as the brick faced wall is constructed.
This adjustable tie can accommodate construction tolerances and allow for larger differential movement.
The anchor is designed with a large opening that is cast into the concrete wall. This large opening allows concrete to flow easily and embeds the anchor into the concrete wall.
The brick anchor is corrosion resistant. It is available and made from stainless steel or hot dipped galvanized steel.
The ledge form does not need to be braced but should be supported directly beneath it so that the wet weight of the concrete does not tilt the wall inward.
Typically, an air/water gap should be specified by the designer between the face of the wall and the back face of the veneer. Proper flashing and weep holes must be provided at the top of the ledge to provide adequate drainage.
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Floor Systems
The ledge form is also commonly used for supporting floor systems on the interior of a building. A wood joist or truss floor system can be fastened to a 2 x 4 sill plate that is anchor bolted to the ledge form. In another application, a pre-cast hollow core floor can be designed to bear on the ledge and integrated to the wall. The design of the floor/wall connection must be according to local building code requirements. Refer to the Engineered Ledge Form Load Table in the engineering section.
Transitions of different form sizes can be accommodated in various ways according to details in the Reward manual. Similarly, corners are installed according to the detail found in the manual by mitering the ledge form. When mitering the ledge forms at corners, the installer must ensure that maximum concrete volume possible is placed in the corner. This is accomplished by cutting EPS foam from the inside cavity. The mitered corner must be supported on the outside adequately prior to concrete placement.
The ledge form does not need to be braced but should be supported directly beneath it so that the wet weight of the concrete does not tilt the wall inward.
xLerator® Ledge form reinforcement is made easy with the Reward xLerator rapid reinforcement system. The patented xLerator is designed to meet ACI 318 (CAN CSA A23.3) requirements and reduce labor significantly. The same one- piece xLerator is used to reinforce the ledge form for the support of masonry veneer as well as floor loads. It is available for both the 11" and 13" ledge forms.
Place the xLerator into the foam slot of the ledge form with the 90-degree bend side resting on the plastic ties in the wall cavity. Center the xLerator in each of the corbels. The adjacent xLerators merely need to be butted up to each other—no tying or lapping is required. Refer to the Reward xLerator® application details and the load tables found in the U.S. Patent Number 7437858 engineering section.
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Taper Top
The purpose of the taper top is to allow for more concrete structural bearing on certain applications. The taper top is utilized for the top course of a particular story. Some of the applications where the taper top should be utilized include: 1. Any wood framed structure constructed on top or above a Reward basement or crawl space. This includes modular homes, manufactured homes and log homes. 2. Roof trusses bearing on the top of the above grade Reward wall. 3. A 13" Reward basement to a 9" above grade Reward wall with the taper top and a wood frame floor bearing on the tapered area. 4. A wood framed structure constructed on top of a Reward basement or crawl space with masonry veneer bearing on the tapered area. 5. A demising wall with a floor bearing on each side of the wall.
The taper top should be reinforced with the taper top xLerator. To simplify matters, always reinforce the taper top with the xLerator.
The xLerator for the taper top is necessary for certain applications
1. The xLerator is not necessary in the taper top when the structural element (most commonly the wood frame floor system) extends across the top of the concrete wall, such as described in applications #1, #2 above. For those applications use the taper top without any taper top reinforcement. Obviously, the wall still needs proper horizontal and vertical wall reinforcement. 2. The xLerator is required in the taper top for applications, such as described in #3 and #4 above.
The taper top form will hold more concrete than the standard straight form. The 11” taper top will hold 0.1210 cubic yards (0.0925 m3) and the 13” taper top will hold 0.1539 cubic yards (0.1218 m3) of concrete.
All iForm products are covered by U.S. Patent # 6,820,384
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