ARCHITECTURAL SPECIFICATIONS MANUFACTURER: InterBlock LLC PO Box 1123, Sheboygan, WI 53082 Phone Number 920-207-7234 SECTION 03100 STAY-IN-PLACE INSULATED CONCRETE FORMING SYSTEM PART 1 GENERAL 1.01 Summary A. InterBlock refers to one component of an entire wall construction system. B. Supply and installation of InterBlock Insulating Concrete Forms (ICF s) for stay in place structural cast in place concrete walls. These may include basement and above grade walls in load bearing and non-load bearing walls for both exterior and interior, and in both commercial and residential applications. C. Includes the installation of steel reinforcing, placement of concrete, ledgers, anchors and or bearing plates for attaching to the wall system. D. Install any required openings for other work associated with InterBlock ICF walls E. Adequate bracing and scaffolding to be provided by installer that meets and complies with all applicable codes. 1.02 Scope of Work A. Furnish all materials, tools, equipment and labor for the installation of InterBlock ICF s B. Furnish all labor to install the steel reinforcing bars, build and place window and door openings, install all through wall penetrations, sleeves and rim joist brackets, install all bracing and scaffolding to shore walls and openings for concrete pour, placement of concrete within the InterBlock forms, and set all bearing plates anchor bolts or plate anchors 1.03 SECTION INCLUDES A. InterBlock insulated wall forms for concrete. B. Reinforcing. C. Concrete. InterBlock LLC 1
1.04 RELATED SECTIONS A. Section 03200: Concrete Reinforcement. B. Section 03250: Concrete Accessories. C. Section 03300: Cast-In Place Concrete. D. Section 03370: Concrete Curing. E. Section 06050: Fasteners and Adhesives. F. Section 06100: Rough Carpentry. G. Section 07100: Waterproofing. H. Section 07200: Insulation. I. Section 07240: EIFS. J. Section 07480: Exterior Wall Assemblies. 1.05 REFERENCES A. ASTM C-236 - Steady State Thermal Transmission by means of a "Hot Box." B. ASTM E-84 - Flame Spread and Smoke Developed. C. ASTM C-203 - Flexure Strength. D. ASTM C-273 - Sheer Strength. E. ASTM D-1621 - Compressive Strength. F. ASTM C-303 - Density. G. ASTM C-272 - Water Absorption. H. ASTM E-96 - Water Vapor Permeability. I. ASTM E-336 - Measurement of Airborne sound insulation in buildings. 1.06 SYSTEM DESCRIPTION A. FORMS InterBlock Insulated Concrete Forms are manufactured from expanded polystyrene (EPS) as a fully molded and solid piece. The forms are built in two cell sizes. The 6 inch cell, which is the most common size, is 9-5/8"W x 48"L x 12"H, with five vertical cells. The 8 inch cell is 12 W x 48 L x 12 H, with four vertical cells. The InterBlock form comes in four basic shapes. -Standard Form -Corner Form -Closed End Form -Pilaster Form InterBlock LLC 2
Each form is reversible, with no defined left, right, top or bottom, and will interlock regardless of direction. The interlocking tabs ensure that the vertical cells will align whether running in a straight line or at 90 angles. Each InterBlock form has lines between cells to indicate cutting locations. B. REINFORCEMENT Refer to local building codes and use the information in the Reinforcing Tables for the proper amount and placement of reinforcing rods. Placement of reinforcement should be reviewed by an engineer who is familiar with the project. Rebar must be placed within ACI tolerances. Rebar should be placed using InterBlock Rebar Chairs and/or No-Tie Rebar Chairs. These rebar chairs are designed to eliminate tying, ensuring better placement of the steel and giving maximum structural integrity to the InterBlock wall. C. CONCRETE All applications require a minimum 3,000 psi mix concrete. Concrete should be poured at a 5" to 6" slump, with a maximum aggregate size of 3/4"; pea gravel is ideal. Placement of the concrete is most easily accomplished using a pump truck equipped with a double elbow. However, it can also be placed by conveyer, bucket, concrete pump or chute. 1.07 Quality Assurance A. Submit shop drawings and product data under provisions of Section [01300.] [01340.] B. Submit most recent version of manufactures text titled Construction Guidelines, which contains specific installation instructions and other important information needed for construction. C. Contractor is responsible to comply with all applicable governing codes and regulations. D. All materials that are to be in contact with the InterBlock ICF s must be compatible with the expanded polystyrene used in their production. E. Pre-Installation Meetings: Prior to any work performed all contractors involved with the installation of InterBlock, placing of the rebar and/or steel, the concrete, electrical and/or mechanical equipment are to meet and discuss all aspects of the installation and scope of work to be performed. InterBlock LLC 3
1.08 Submittals A. Product data: Provide data on form materials and installation requirements and procedures. B. Drawings & Calculations: Submit project drawings, details of construction, structural calculations as required by the local building department, indicate pertinent dimensions, materials and arrangement. 1.09 DELIVERY, STORAGE, AND HANDLING InterBlock is manufactured out of 100% modified expanded polystyrene (EPS). EPS has good resistance to acids, bases, salts and alcohol-based products, and poor resistance to fuel oils, solvents, ketones, esters and oil based chemicals. Where insects are a problem, protect InterBlock with HDPE film. A. Deliver to job site in original manufactures wrapping clearly marked to identify contents. B. When stored outdoors for extended periods protect product from direct sunlight. C. Handle and Store product in a location to prevent damage and soiling. 1.10 Project Conditions and Scheduling A. During installation bracing and shoring are to be in place to protect walls from wind and weather conditions B. Coordinate all material deliveries to meet construction schedules. Note all contractors that require penetrations, attachment points or who need to attach items to the InterBlock Walls will need to be coordinated with before the placement of concrete. C. Follow manufacturer s requirements to protect concrete after placement during periods when the weather is below minimums specified by the building cods. This will ensure proper curing of the concrete. InterBlock LLC 4
Part 2 - Products 2.01 - MANUFACTURER A. InterBlock LLC, PO Box 1123, Sheboygan, WI 53082 1-920-207-7234 2.02 MATERIALS A. InterBlock is manufactured using 100% Modified Expanded Polystyrene from one of the following manufacturers: NOVA Chemicals, BASF, or, Huntsman Chemical. All of the raw materials used shall meet or exceed the following guidelines: Property Test Result Maximum Thickness 3.6 Density Minimum 1.8 pcf Color White Maximum Recommended use Temperature 165 degrees F R-value ASTM C-236 20-38 Flame Spread ASTM E-84 <25 Smoke Developed ASTM E-84 <450 Tensile Strength MIL-P-19644 50 psi minimum Water Absorption % by Volume ASTM C-272 <2% Water Vapor Permeability (Perm-In) ASTM E-96 2.0 5.0 Sound ASTM E-336 52 STC B. For a complete list of accepted compatible materials refer to the manufacturer's Construction Guidelines. Any material may be used with InterBlock upon obtaining notice of compatibility from the Manufacturer. 2.03 SOURCE QUALITY CONTROL A. Test InterBlock at the time of manufacture in accordance with ETL Laboratories "Report and Procedural Guide for complying with ETL classification in-plant labeling, and follow-up requirements for leave-in-place formwork for concrete" Report No. 513149. ETL Laboratories, Inc., Industrial Park, Cortland, New York 13045 InterBlock LLC 5
2.04 Accessories and Auxiliary Materials A. Bracing, Wall Alignment, and Scaffolding: Must meet all local building codes. B. Window and Door Bucks: May be treated wood, V-Buck, or other approved material specified by architect. C. Bearing plates and Rim Joist Brackets or Anchors: Must meet engineer s specifications. D. Anchor Bolts and/or Plate Anchors: must have 5 inches of concrete penetration or meet engineer s specifications. E. Sleeves and Penetrations: Sized to meet design specifications. F. Water Proofing Materials for Below Grade applications: As per design specifications. G. Exterior Finishes: As per design specifications. H. Interior Finish: Must meet 15-minute thermal barrier requirements. PART 3 EXECUTION 3.01 Examination A. Site Conditions Verified: Verify all building lines and building dimensions. Verify footings and/or slabs level within 1/8 inch. Verify elevation of site before proceeding with formwork. B. Verify all materials, tools, equipment and forms are available for installation. C. Verify the proper size and placement of steel vertical dowels as specified by the plans or design. 3.02 Surface Preparation A. All footings and/or slabs must be clean in areas where forms are to be installed. B. If vertical dowels are not present they must be installed according to engineers designs and/or manufactures recommendations. InterBlock LLC 6
3.03 Installation of Formwork A. Install InterBlock ICF s according to Manufacture s recommendations*. All aspects of formwork must conform to these requirements with regards to the following: 1. Erection of shoring and bracing to meet design requirements in accordance with ACI 301. All shoring must stabilize formwork for all types of construction loads place on the walls. All bracing and shoring must hold formwork plumb and straight 2. Placement of InterBlock forms at corners alternating corner directions at each row and aligning all furring strips to facilitate wall-covering attachments. 3. Install all reinforcement as per engineer s specifications 4. Verify all window and door openings are placed in correct locations and braced properly. 5. Install reinforcing as per engineers shop drawings over openings to provide for lintels within the walls. 6. Final pre-pour checklist per manufacture s recommendations and job specific specifications. Check with other trades to insure placement and necessity of all accessories, penetrations, openings, sleeves, bolts, anchors, and other items. 7. Placement of concrete with specified design mix. Concrete placed according to manufacturer s recommendations. 8. All anchors, rim joist brackets, top plate anchors and/or straps and penetrations installed per design or manufacture s recommendations. 9. All walls rechecked and adjusted for straight and plumb right after concrete is placed. 10. Brush and clean forms, bucks, and sweep floors before leaving job site after pour. *Please refer to the manufacturer's Construction Guidelines for all installation procedures. For additional or added installation information the manufacturer can be contacted directly for consultation as to the uses of its products. InterBlock LLC 7
3.04 Field Quality Control A. Inspect erected formwork, shoring and bracing to ensure that work is in accordance with design and that elements are secure. B. Ensure that all formwork is level, plumb, square and straight and that all dimensions are correct as per plans or drawings. 3.05 Cleaning A. Clean forms as installation proceeds, to remove foreign matter within forms. B. Clean formed cavities of debris prior to placing concrete. C. Flush with water or use compressed air to remove remaining foreign matter. D. During cold weather, remove ice and snow from within forms. Do not use de-icing salts. Do not use water to clean out forms unless formwork and concrete construction proceed within heated enclosure. Use compressed air or other means to remove foreign matter. E. All formwork should be free and clear of concrete overspills. All bucks and openings should be clean and bracing removed after concrete cures as per engineer s specifications. All floors should be scrapped and cleaned of concrete spills. F. Clean up and dispose of all debris on the job site related to the installation of InterBlock. InterBlock LLC 8