Progressive Engineering Inc.

Transcription

1 Progressive Engineering Inc. INTEGRASPEC ICF BY PHIL-INSUL CORPORATION ICC-ES AC353 Fastener Strength Testing on IntegraSpec ICF Panels 8/20/2009 Revised on 9/3/2009 This test report contains nineteen (19) pages, including the cover sheet. Any additions to, alterations of, or unauthorized use of excerpts from this report are expressly forbidden (B) State Road 15 - Goshen, IN Phone: Fax:

2 1. TITLE ICC-ES AC353 Fastener Strength Testing on IntegraSpec ICF Panels 2. OBJECTIVE To determine the allowable withdrawal load strength and lateral load strength of a screw inserted into the flange of a plastic cross tie used in an insulated concrete form, in accordance with the standards found in Section 6 of this report. This test report pertains only to the specimens tested. It remains the sole responsibility of the manufacturer to provide a product consistent to that which was tested. 3. TESTED FOR IntegraSpec ICF by Phil-Insul Corporation 735 Arlington Park Place, Unit 11U Kingston, Ontario K7M 8M8 4. TESTING ORGANIZATION Progressive Engineering Inc State Road 15 Goshen, IN See IAS Evaluation Report TL-178 for ISO Accreditation 5. TESTING PERSONNEL Laboratory Manager Technician - Jason R. Holdeman - Jacob Bontrager 6. REFERENCE STANDARDS ASTM D Standard Test Methods for Mechanical Fasteners in Wood ICC-ES AC353 - Acceptance Criteria for Stay-In-Place, Foam Plastic Insulating Concrete Form (ICF) Systems for Solid Concrete Walls (Effective November 1, 2007). 1

3 7. TEST EQUIPMENT Tinius Olsen Compression and Tension test machine ( PEI No. 144). Calibrated Data Acquisition System ( PEI No. 643). Calibrated Load Cell ( PEI No. 418). Calibrated Linear Transducer ( PEI No. 732). Calibrated Linear Transducer ( PEI No. 648). 8. TEST SPECIMEN The ICF panels used for this test were sampled by PEI personnel at EFP Corp. in Elkhart, IN. The panels were manufactured in Decatur, GA by EFP Corp. on March 26, A. Insulated Concrete Form IntegraSpec Insulating Concrete Form Panels sized 48" x 12-1/4" x 2-1/2" with PIC Inserts, set 8" o.c. that comprised of; (1) a 1-5/8" wide nailing flange, with an average thickness of.109"; (2) a 1-1/8" deep centered web having 1-1/8" diameter holes set at 1.58" o.c. and an average measured thickness of.118"; (3) and a cross-tie capturing "C" channel,.072" thick by.156" deep by.562" wide, with a.125" wide slot cut along the entire length. The 12-3/8" long PIC inserts were embedded in EPS foam with the cross tie channel flush with the foam on the inner face and approximately.75" of EPS foam between the outer face of the form and the PIC nailing flange. See attached drawing and Appendix for details. B. Fasteners A #8 x 2-1/2" long Type "S" Fine Thread Drywall Screw with an average thread diameter of.165" and an average head diameter of.324". The average measurements were based on ten (10) random fasteners. 2

4 9. TEST SET-UP A. Withdrawal Load Strength The test specimen was positioned in a Tinius Olsen test machine such that the ICF panel was parallel the rigid fixed crosshead. The specimen was positioned in a manner representative of end use configuration, with the nailing flange set inline with a loading fixture connected to the upper platen. A fastener was inserted into the nailing flange approximately perpendicular to the ICF panel face, as near as possible to the center web connections to the top flange. A screw gun was used to insert the fastener approximately 2.25" into the panel. A test fixture was slid under the head of the screw and then connected to the loading fixture. B. Lateral Load Strength The test specimen was positioned in a Tinius Olsen test machine such that the ICF panels were perpendicular to the rigid fixed crosshead. The specimen was restrained in a manner representative of end use configuration, with a nailing flange set inline with a load cell and loading fixture connected to the upper platen. A plywood (4 ply) prism 2" wide by 12" long by 1/2" thick* was set over the nailing flange. The prism overlapped the ICF test specimen a minimum of 4". The test fastener was then inserted at the center of the width of the prism 2" from the end and thru a predrilled hole approximately 90% of the root diameter of the screw, as near as possible to the center web connections to the top flange. The prism was oriented to permit the insertion of the test fastener perpendicular to the ICF face. The screw was inserted with a screw driver until it was flush with the pre-countersunk hole in the prism and tight to the ICF. A prebored hole in the free end of the prism was bolted to the loading fixture. A board was fastened near the bottom of the ICF to nailing flanges on either side of the testing location. One end of a linear transducer was pinned to the board and the other end was pinned to the prism to measure the fastener slip. *Per David Pereg of ICC-ES the thickness is to be representative of the end-use substrate. 3

5 10. TEST PROCEDURE A. Withdrawal Load Strength The test fasteners were inserted no more than 1 hour prior to testing. The fastener was withdrawn by means of a tensile force applied at a uniform rate of 0.1 inches per minute (+/- 25%). The maximum value for each of the 10 samples tested was recorded to three significant digits. B. Lateral Load Strength The test fasteners were inserted no more than 1 hour prior to testing. The end of the prism provided freedom of alignment. A data acquisition system was used to record the load and deflection throughout the entire test. The fastener was loaded by means of a tensile force applied at a uniform rate of 0.1 inches per minute (+/- 25%). The maximum value for each of the 10 samples tested was recorded to three significant digits. 11. TEST RESULTS See attached data pages and charts for details. 12. CONCLUSION The allowable fastener loads for IntegraSpec's ICF panels, with the fastener set as near as possible to the nailing flange web, and as defined in Sections and of ICC-ES AC353 are as follows: A. Withdrawal Load Strength of 44.4 lbf B. Lateral Load Strength of 33 lbf which is based on the formula provided in AC353 Section

6 Progressive Engineering Inc. ASTM D Screw Withdrawal Test Date: 7/17/2009 Project No.: Client: IntegraSpec ICF by Phil-Insul Corp. Temp.: 72 Humidity: 46% R.H. Specimen: IntegraSpec ICF Load Rate:.1" per minute Test: Withdrawal Testing Ultimate Sample No. Load (lbf) Sample Sample Sample Sample Sample Sample Sample Sample Sample Sample Average 222 Failure: In all cases the screw pulled out of the flange with residual plastic remaining in the threads. 5

7 Progressive Engineering Inc. ASTM D Lateral Screw Resistance Test Date: 6/20/2009 Project No.: Client: IntegraSpec ICF by Phil-Insul Corp. Temp.: 69 F Humidity: 54% R.H. Specimen: IntegraSpec ICF Load Rate:.1" per minute Test: Lateral Strength Testing Ultimate Proportional Load at Sample No. Load (lbf) Limit* (lbf) 1/8" Defl. (lbf) Sample Sample Sample Sample Sample Sample Sample Sample Sample Sample Average Coefficient of Variation (COV): 30.11% Allowable Load (lbf)**: 33 Failure: The failure mode was consistent with Mode III as defined in ANSI/AF&PA NDS-2005 for single shear, with the fastener pulling out of nailing flange. * - The Proportional Limit Load was derived using the initial straight-line portion of the load-deflection curve as shown on the attached charts. ** - The allowable load was derived using the following formula, provided in AC 353 Section COV F all = ( 2.24 ) F all = Allowable Load, pounds COV = s/f = Coefficient of variation in a test series s = Standard Deviation in a test series F = Average ultimate load in test series, pounds 6

8 Progressive Engineering Inc. IntegraSpec ICF ASTM D Lateral Screw Resistance ReTest Deflection (in) Sample 1 Sample 2 Sample 3 Sample 4 Sample 5 Load (lbf) 7

9 Progressive Engineering Inc. IntegraSpec ICF ASTM D Lateral Screw Resistance ReTest Deflection (in) Sample 6 Sample 7 Sample 8 Sample 9 Sample 10 Load (lbf) 8

10 MIDDLE SECTION TOP AND OR BOTTOM VIEW SIDE VIEW FRONT VIEW 9

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13 Progressive Engineering Inc. Typical Fastener Insertion Typical Fastener Insertion Fastener Withdrawal Setup Fastener Withdrawal Setup Fastener Withdrawal Setup Fastener Withdrawal at load 12

14 Progressive Engineering Inc. Lateral Load Strength Test Setup Lateral Load Strength Test Setup Tested fastening strip is unsupported Lateral Load Strength at load Fastener Location on Fastening Strip Fastener Location on Fastening Strip 13

15 APPENDIX IntegraSpec ICF by Phil-Insul Corporation (B) A1

16 Insulating Concrete Forms (ICF) Building System IntegraSpec The User Friendly ICF By Phil-Insul Corp. Award Winning ICF A2

17 Award Winning ICF History... IntegraSpec was created with the input of structural engineers, computer assisted design and more than 75 years of field experience in the residential/commercial concrete forms and general construction industry. IntegraSpec insulating concrete form (ICF)/building system was developed to address and eliminate the problems that most ICF systems encounter: blowouts, form unit flotation/lift, bulging, wall compression and wavy walls. IntegraSpec was also designed to dramatically reduce waste, set up/bracing, labor costs and shipping costs. Design Features... The IntegraSpec system consists of stay-in-place expanded polystyrene concrete form panels which are shipped to site flat in easy to handle bundles, installed in courses and spaced with various sized patented interlocking spacers. The patented form units are bidirectional, allowing the panels to be laid no matter which way they are placed, reducing waste and installation time. The spacers are available in 4, 5, 6, 8, 10 and 12 which can be combined for increased concrete core thicknesses. Any wall thickness can be achieved by simply changing the spacers. Spacers are designed for fast snapin-place rebar for a choice of steel sizes and spacing and are easily cut to quickly form openings and provide specific heights. Most importantly, spacers provide mechanical interlock to eliminate form lift. After rapid wall set up and easy alignment, concrete is poured, resulting in a solid monolithic concrete wall structure, ready for exterior/interior finishes. Panel interior is dovetailed for proper concrete placement and bonding with flush inserts to easily slide in the spacer. Inserts are molded inside the panels every 8 on center and provide 1 5 / 8 furring/studs, reinforcement against form unit bulging and the connection for spacers. When forming a wall, the channels fit into the next to eliminate form compression. Eliminates woodbucks. Exclusive IntegraBucks provide a fastening strip at the face of any opening. Simply slide the piece into the dovetails grooves inside any two IntegraSpec panels to form windows, doors or any opening with IntegraHeaders (not shown). Panel exterior has visible 1 cut lines with logo to clearly indicate furring/studs and deep grooves for placement of steel channels to meet commercial fire codes. IntegraSpec 5 Steps in one application: 1) Diverse structural integrity 2) Super insulation 3) 1 5 / 8 furring strips/studs 4) Vapor barrier 5) Air barrier ONE STEP ONE CONTRACTOR/CREW LESS TIME PIC Phil-Insul Corporation A3

18 According to Mr. Michel Philippe, President, Phil-Insul Corp. Insulated concrete has always had the potential to decrease construction costs and time, provide outstanding energy performance, indoor air quality, superior sound, fire resistance and lessen the overall operating/maintenance costs. IntegraSpec is your best choice of insulated concrete form (ICF) to deliver these benefits. IntegraSpec quality and performance gives builders the edge in delivering a higher end finished product while increasing profits. Many awards have been won recognizing the contribution IntegraSpec has made to the building industry and more specifically to the Insulated Concrete Form (ICF) industry Awards... Residential (light) ICF BUILDER Best Heavy Commercial ICF Project Award and Best Overall ICF Project 2005 Received for the overall design complexity of Conservatory Pond Retirement Home, inlcuding a combination of 6 and 8 IntegraSpec ICF walls, IntegraSpec exclusive buck and header system, concrete hollow core floors, stucco/masonry finish and the unique IntegraSpec Exposed Concrete Face (ECF) for the elevator shafts. Residential (large) Conservatory Pond Retirement Home Commercial Project: McGahuey Residence Location: Mount Ayr, Iowa Features: 6 IntegraSpec garage 8 IntegraSpec foundation 8 IntegraSpec above grade 3,950 ft 2 country home was built with very little waste. Owners wanted an energy efficient home that could stand up to tornados and the test of time. Obvious choice ICF - R. McGahuey IntegraSpec quality and performance means: Design 8 unique panels secured with variable size spacers allow the user to build a super insulated wall with any concrete thickness. Each panel is completely reversible requiring less effort on site, less waste and offering flexibility to any design. Project: Dothan Residence Location: Alabama Features: Concrete Pour IntegraSpec is compatible with most ICF alignment and scaffolding systems. Bracing is not required for walls up to 4 feet. Form flotation, compression and blowouts are eliminated by the patented interlocking system. 12 IntegraSpec foundation, 16 high 6 IntegraSpec above grade walls 19 IntegraSpec colonnade walls 20,000 ft 2 residence built with the design flexibility that only IntegraSpec ICF could offer. The independent panel design assembled faster and with less waste on site than other systems. IntegraSpec made it look easy - Wingham A4 After Pour Professional, straight, true walls. Form unit bulging eliminated by the patented panel design. Fully insulated wall structure is ready for any exterior or interior finish. Project: Grande Caribbean Condominium Location: Orange Beach, Alabama Features: 6 IntegraSpec walls, parapet balcony supports, columns and underground garage 160,000 ft 2 condominium with 101 units. 100% pre-sold due to ICF advantages. Withstood forces of Hurricane Ivan in 2004 with minimal damage to the roof only. Versitility & Strength - D. Lindsey Finished Building A stronger, more durable, better insulated, quicker to build and less costly building to construct than alternative construction methods can provide. PIC Phil-Insul Corporation

19 General specifications Approvals Patents - ICC # ESR US Patent No. 5,428,933 - Standard and Uniform Building Codes (USA) - Canadian Patent No. CA CCMC #12938-R, Minister s Ruling (ON) National Building Code Canada/CMHC Wall design principle - monolithic structural concrete wall Exterior surface area/std. form unit ft 2, 0.38 m 2 Concrete volume required/std. form unit Imperial Metric 4 Cavity yd m 3 5 Cavity yd m 3 6 Cavity yd m 3 8 Cavity yd m 3 10 Cavity yd m 3 12 Cavity yd m 3 Material - HIPS+ type II flame retardant EPS Thermal resistance - R-22+ per ASHRAE Fundamentals (1997) Sound resistance - Minimum STC(Sound Transmission Class) =50+ Fire resistance - flash 705 F (374 C) - self 842 F (450 C) - per DIN fire channel profile 8 o.c. Pour height - up to 10 ft, 3.1 m continuous pour Typical Views End Views Standard Unit 90 Corner Unit Various Web Sizes Different Concrete Thickness Brick Ledge Panel 90 Commercial Corner Unit 45 Corner Unit Typical End View IntegraSpec Insulating Concrete Form (ICF) Building System Head Office: tel (800) Website: PIC-US11 A5 DISTRIBUTED BY: ISO 9002