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The build process starts with the ICF blocks,
which consist of two layers of insulating material, usually
expanded polystyrene (EPS) or extruded polystyrene (XPS)
separated by plastic webs. The plastic webs hold the panels
together, but they also make a place for laying reinforcing bar,
and are shaped to form a nailing/fastening surface just under
the surface of the foam. The blocks themselves are similar to
children's blocks, and are shaped to allow them to stack quickly
and easily. |
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The blocks are stacked as required to form
walls and openings. Special blocks allow the easy formation of
90-degree and 45-degree corners. The blocks can be trimmed to
any required length. |
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Heavy dimensional lumber is used to create
frames (or "bucks") for openings to accommodate doors, windows,
and so forth. These bucks provide a seal for the concrete, and
are left in place after the concrete is poured to provide the
rough opening into which the door or window is mounted. |
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As each course of ICF block is laid, steel
reinforcing bars are laid into the plastic web, taking advantage
of the positioning tabs provided. The rebar is overlapped and
tied together to provide strength and flexibility to the
structure, while the concrete that is added later provides
tremendous compressive strength - an ideal combination! |
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The wall structure and larger openings are
then braced to support them while the concrete is being poured. |
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Finally, the concrete itself is poured into
the forms, using a vibrator to ensure that the concrete fills
the forms completely, and that no air pockets ("voids") are
left. |
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For multi-storey structures, floor joists
are now laid in place, and work starts on the next storey. When
all storeys are completed, roof trusses are put in place in much
the same manner as normal construction, and doors and windows
are installed in the rough openings. The ICF walls are now ready
for waterproofing, if below-grade, or for application of siding
or other finish selected by the proud owner. |
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