Product Installation Manual

Transcription

1 Product Installation Manual Rev

2 Fox Blocks Product Installation Manual Fox Blocks reserves the right to make improvements and changes to the information in this and any other published materials. The current version of Fox Blocks Product Installation Manual and technical materials are available on the Fox Blocks website or by calling Fox Blocks at Fox Blocks has no control over conditions of application, installation, accessory materials or systems, and workmanship during the construction of Fox Blocks walls. Fox Blocks assumes no responsibility expressed or implied, except as stated at the Fox Blocks website - Copywrite by Fox Blocks 2006 Chapters 4 and 6 of the International Residential Code 2006 reprinted with permission from the International Code Council. Panel Jack Installation Instructions reprinted with permission from Reechcraft, Inc V-Buck Installation Instructions reprinted with permission from Vinyl Technologies Inc Rev

3 Table of Contents 1.0 Introduction 1.1 General Description 1.2 Advantages of Fox Blocks Insulating Concrete Forms Strength of Forms Robust Corner Forms Reversible Interlock Web Design to Control Setting 2.0 Technical Information 2.1 Dimensions of Fox Blocks 2.2 Applicable Testing Standards 2.3 Structural Design of Fox Blocks Walls 2.4 Building Code Evaluation Reports 2.5 Fox Blocks Resin Materials and the Environmental Benefits 2.6 Fox Blocks Vapor Barrier and Air Barrier 2.7 Fox Blocks Industry Association Memberships 2.8 Fox Blocks Industry Affiliations 3.0 List of Compatible and Complimentary Products 4.0 Installation 4.1 Fox Blocks Installation Overview Planning the Build Footings or Slab-on-Grade Placing Forms Bracing and Alignment Window and Door Openings Placing Steel Reinforcement Utility Service Wall Penetrations Preparation for the Concrete Pour Concrete Placement Finishing Off the Wall Installation of Floor and Roof Connections Installation of Utilities Exterior and Interior Finishes. Dampproofing and Waterproofing 4.2 Planning the Build 4.3 Footings or Slab-on-Grade 4.4 Placing Forms 4.5 Bracing and Alignment 4.6 Window and Door Openings 4.7 Placing Steel Reinforcement Rev

4 4.8 Utility Service Wall Penetrations 4.9 Preparation for the Concrete Pour 4.10 Concrete Placement 4.11 Finishing off the Wall 4.12 Installation of Floor and Roof Connections 4.13 Installation of Utilities 4.14 Exterior and Interior Finishes 4.15 Dampproofing and Waterproofing Appendix A Typical Construction Details Appendix B Structural Design References Appendix C Compatible and Complimentary Accessory Products Appendix D Tables for Structural Requirements of Fox Blocks Brickledge (Corbel) for Applications Supporting Brick Veneer or Floors Appendix E Recommended List of Tools Appendix F Recommended Pre-pour Inspection Check List Appendix G Panel Jack by Reechcraft, Installation Instructions Appendix H V-Buck Installation Instructions Appendix I Appendix J Safety Guideline for Concrete Pumps and Trucks Typical Construction Framing Techniques Appendix K Construction Glossary Rev

5 Section 1 Introduction Rev

6 1.0 Introduction Welcome to Fox Blocks. You have made an excellent decision to use Fox Blocks Insulating Concrete Forms (ICF s) for your next project. Fox Blocks forms have been cleverly designed to be contractor friendly. The thick Expanded PolyStyrene (EPS) panels interlock tightly together and have internally reinforced corner forms and a reversible interlock that make building with Fox Blocks easy with less waste. Buildings constructed with Fox Blocks walls are generally energy efficient buildings, using less energy for space heating and space cooling than observed with buildings using other typical construction materials. Consistent with this, buildings built with Fox Blocks ICF forms will have lower operating costs than are typically observed with similar structures built with other typical construction materials. Fox Blocks are manufactured by Airlite Plastics Company in Omaha Nebraska, a business with over 50 years of combined experience with injection molding and shape molding of plastics. Airlite Plastics received the prestigious Edgerton Quality Award in 2003, which is a testament of their commitment to delivering quality product. Airlite Plastics has achieved the International Standard of Operation (ISO) 9001 certification, which is a quality program, associated with the injection molding operation. This Product Installation Manual will lead you through the steps needed to complete a successful build. Please review this manual in detail, as the construction sequence for Fox Blocks walls is a departure from construction with traditional building materials and systems. Figure 1 Shown here is a 6 Fox Blocks straight block Figure 2 A finished ICF home looks no different than a wood- frame home from the outside Rev

7 This Product Installation Manual has been prepared with the assumption that the installer is familiar with typical framing and has a basic knowledge of construction, and as such will provide product specific information to supplement that basic knowledge. Fox Blocks provides training, which installers may find beneficial to attend. Please contact Fox Blocks at or to ask for information on upcoming training sessions. The information contained in this Product Installation Manual is current as of the date it was published. There may have been subsequent updates, and as such all installers are advised to visit regularly to check for updates or obtain a current edition. Fox Blocks walls must be built in compliance with applicable codes and regulations. Installers are advised to check with the local authority having jurisdiction to confirm what the requirements are, then plan and construct the build to meet the requirements. Installers should consider this Product Installation Manual as a guide to be used in conjunction with their years of construction experience and advice from Fox Blocks personnel. If you have any questions, please do not hesitate to call us at General Description Fox Blocks are an Insulating Concrete Form (ICF) system to build walls. As this installation manual will show, ICF walls are stacked up on a footing or slab on grade, the specified rebar is placed in the cavity between the EPS panels, then concrete is poured into the cavity and consolidated. The resulting wall assembly has a reinforced concrete core, which serves as the structural component of the wall, the EPS which provides the insulation, and web flanges which serve as full length, continuous furring strips for the attachment of interior or exterior finishes. In traditional forms the webs would be known as ties. The building code requires that the EPS on the interior side of the wall be protected by a 15 minute thermal barrier, and ½ inch sheet rock is recognized as providing such a thermal barrier. Figure 3 A Fox Blocks wall assembly Rev

8 1.2 The Advantages of Fox Bocks ICF Forms The advantages of Fox Blocks ICFs are several. Fox Blocks provide a clever design that has the good features of the tried and true early brands of ICFs, and then has incorporated significant improvements, which enhance the ease of use to you, the installer. This combined with our direct shipment method of distribution will deliver what could be the best ICF on the market at very competitive prices. Significant features are: - Strength of forms: Webs engineered to provide superior strength, Foam panels 2 5/8 minimum thickness of EPS resulting in minimal deflection of EPS panels during concrete pouring. - Robust corner forms: Reinforced corner forms with significant areas provided for cladding exterior surface finishes, A hole in the 90-degree corner forms is designed for the insertion of a length of rebar or pipe to tie the corner together, The internal corner bracket (patent pending) connects the inside and outside EPS panels and thus improves both the strength of the corner form and safety during construction and placing of concrete in the Fox Blocks walls. - Reversible interlock: There is only one corner form as there is no need for left and right hand corner forms. This makes ordering and stocking easier and provides greater flexibility on the jobsite, Less job site waste as cut-offs can more readily be used elsewhere in the walls. - Continuous web design to control settling: The webs are engineered to rest one on top of the other (hard plastic to hard plastic) as the courses are placed one on top of the other. This makes achieving final elevations much easier than with other ICF systems, which do not have the webs in contact and where the forms compresses while the concrete is being placed. Figure 4 Fox Blocks corner block with ties embedded Rev

9 Section 2 Technical Information Rev

10 2.0 Technical Information The section provides the product specific technical information, which will assist in the design of walls with Fox Blocks ICF forms, the permitting of projects, and the construction of the Fox Blocks builds. 2.1 Dimensions of Fox Blocks w w w. F o x B l o c k s. c o m B l o c k T y p e S t r a i g h t W i d t h ( i n c h e s ) ( 6 " c o r e ) L e n g t h ( i n c h e s ) R e t u r n ( i n c h e s ) S u r f a c e A r e a ( s q u a r e f e e t ) C o n c r e t e V o l. ( c u b i c y a r d s ) 4 8 N A ( e x t. o r i n t. ) ( t o t a l ) 6 i n c h c o n c r e t e t h i c k n e s s 9 0 º C o r n e r 4 5 º A n g l e ( 6 " c o r e ) ( 6 " c o r e ) 3 2 ( e x t. ) ( i n t. ) 2 6 ( e x t. ) ( i n t. ) 2 4 ( e x t. ) ( i n t. ) 1 8 ( e x t. ) ( i n t. ) B r i c k L e d g e N A ( e x t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( e x t. c u r v e ) ( i n t. c u r v e ) T a p e r T o p N A ( e x t. o r i n t. ) T - B l o c k S h o r t L e g T - B l o c k L o n g L e g ( 6 " c o r e ) ( 6 " c o r e ) 44 ( e x t.) ( i n t.) ( i n t.) 44 ( e x t.) ( i n t.) ( i n t.) ( i n t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( t o t a l ) ( t o t a l ) ( t o t a l ) ( C o r b e l o n l y ) ( t o t a l ) ( L e d g e o n l y ) ( t o t a l ) ( t o t a l ) S t r a i g h t ( 8 " c o r e ) 4 8 N A ( e x t. o r i n t. ) ( t o t a l ) 8 i n c h c o n c r e t e t h i c k n e s s 9 0 º C o r n e r 4 5 º A n g l e ( 8 " c o r e ) ( 8 " c o r e ) 3 4 ( e x t. ) ( i n t. ) 2 8 ( e x t. ) ( i n t. ) 2 6 ( e x t. ) ( i n t. ) 2 0 ( e x t. ) ( i n t. ) B r i c k L e d g e N A ( e x t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( e x t. c u r v e ) ( i n t. c u r v e ) T a p e r T o p N A ( e x t. o r i n t. ) T - B l o c k S h o r t L e g T - B l o c k L o n g L e g ( 8 " c o r e ) ( 8 " c o r e ) 44 ( e x t.) ( i n t.) ( i n t.) 44 ( e x t.) ( i n t.) ( i n t.) ( i n t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( e x t. ) ( i n t. ) ( t o t a l ) ( t o t a l ) ( t o t a l ) ( C o r b e l o n l y ) ( t o t a l ) ( L e d g e o n l y ) ( t o t a l ) ( t o t a l ) Rev

11 2.2 Applicable Testing Standards Fox Blocks ICFs comply with the requirements of the International Residential Code (IRC) and as such comply with the following standards: ASTM E84/UL 723 ASTM C578 The flame spread and smoke developed rating are determined in accordance with ASTM E84 / UL 723. The flame spread rating is less than 25 and smoke developed rating is less than 450. Testing at Underwriters Laboratories (UL) has confirmed the Flame Spread Rating of Fox Blocks at 10# and the Smoke Developed Rating of 300#. The Expanded Polystyrene (EPS) is tested in accordance with ASTM C578, and testing confirms it meets the requirements of Type II as defined by the standard. 2.3 Structural Design of Fox Blocks Walls Fox Blocks ICF walls must be constructed to comply with building code requirements. Figure 6 Fox Blocks walls are to be constructed with the concrete and steel reinforcement meeting with code requirements taken from the ICF flat wall prescriptive requirements of the applicable building code or as specified by the architect or engineer who designed the structure. Figure 7 ICF Design Table from IRC (Coming soon) More explicitly, the International Residential Code (IRC) has prescriptive design requirements and it is recommended these be used, provided the building falls within the applicability limits as stated in code Section 4 Foundations and Section R611 Insulating Concrete Form Wall Construction, Sub-Section R611.2 Applicability Limits. Rev

12 The code states that in the event of a structure not meeting the requirements of the Applicability Limits, the structure, is to be designed in accordance with ACI 318 by a design professional, such as an architect or engineer, licensed as required by the authority having jurisdiction. ACI 318 is the design standard for reinforced concrete published by the American Concrete Institute (ACI). ACI 318 is the recognized design standard for reinforced concrete in both the International Residential Code (IRC) and the International Building Code (IBC) as well as the Uniform Building Code (UBC), the BOCA National Building Code and the SBCCI Standard Building Code. For structural design requirements with respect to the placement of reinforcing steel in the Fox Blocks Brickledge (Corbel) Forms, Fox Blocks has developed Fox Blocks structural engineering design tables to be used with the Fox Blocks proprietary steel reinforcing placement in the brickledge forms. This can be found in Appendix D. There are other IRC documents providing prescriptive structural design requirements for ICF construction, which may serve as useful references, and these are listed in Appendix B. 2.4 Building Code Evaluation Reports Fox Blocks has submitted an application to the International Code Council Evaluation Service (ICC-ES) for an Evaluation Report. When the Evaluation Report is released Fox Block will post it on our website on the Technical Page. Please check our website regularly so that you have it shortly after it is complete and issued by ICC-ES. Following that, Fox Blocks will be making submissions to other jurisdictions for approvals, and as they are obtained the Fox Blocks website will be updated. 2.5 Fox Blocks Resin Materials and the Environmental Benefits The benefits of Expanded Polystyrene (EPS) foam thermal insulation products is its lightweight, energy efficiency and cost effectiveness. EPS resin is an excellent material for ICF construction for these and the following reasons: - Polystyrene is a lightweight cellular material composed of hydrogen and carbon atoms. There are two common types of Polystyrene foam, extruded polystyrene (popularly known by its Dow trademark Styrofoam and expanded polystyrene (EPS). - Both expanded and extruded polystyrene are used extensively as thermal insulation in industrial, commercial, and residential construction. Rev

13 - EPS is manufactured from expandable polystyrene beads containing a blowing agent and flame retardant additive. Steam heat expands the blowing agent to produce moisture-resistant multi-cellular particles or pre-expanded beads, which increase in size up to 40 times their volume during the process. - Following an intermediate period during which the beads lose their moisture, the blowing agent condenses out and air diffuses into the cellular structure. After the air has stabilized, the pre-expanded beads are thermally steam fused into blocks (which are then cured), or injected into molds to produce molded EPS. - EPS insulation can be molded in a range of densities to meet specific application requirements. Thanks to its closed cell, unique air-filled cellular structure, its resiliency and light weight, and its ease of convertibility from raw material to finished product, EPS works well under all kinds of applications. - EPS foam does not, and never has contained Chlorofluorocarbons (CFC s) or not fully Halogenated Chlorofluorocarbons (HCFC s). Following is an excerpt from the BASF Styropor technical bulletin #16 (original source: Carlos J. Hilado - Flammability Handbook for Plastics ). It compares the flash and self ignition temperatures of several materials that may be found in the home. Flash Ignition Temperature Self Ignition Temperature Material C F C F Paper Pine Cotton Wool N/A N/A Polyvinyl Chloride (PVC) Polyethylene Polystyrene Polystyrene Expanded The Flash Ignition Temperature is the temperature at which a material will give off a vapor to form a mixture with air which is ignitable by an external source. The self ignition temperature is the temperature of a material when smoking or flaming will begin spontaneously without a flame source. Rev

14 Q A Q A Q Does Expanded Polystyrene (EPS) present a serious fire hazard? It is true that expanded polystyrene will burn if exposed to a large enough heat source. There are many materials in the home that will ignite at lower temperatures than expanded polystyrene, as shown in the previous table. Also, to reduce the hazard of accidental ignition, all expanded polystyrene insulation board produced in Canada for construction use, has flame retardant additives incorporated during manufacturing. What about the effects of flame retardant additives? The addition of such chemicals helps to prevent ignition of the material from small fire sources, such as a lighted match or a burning cigarette - a very valuable safety factor in handling and insulation. Is it true that burning Polystyrene releases toxic gases? A All organic materials, including plastics, wood and paper products, wool and cotton, give off a variety of toxic products of combustion, including carbon monoxide. This is generally the most dangerous gas in a fire situation. Burning of the above organic materials can also contribute to oxygen deficiency. Knowledge of the chemical com position and structure of organic materials provides a basis for understanding the formation of smoke and toxic gases from the combustion of these materials. Most combustible materials contain the element carbon, and therefore oxidize in fires to produce carbon dioxide (CO2). When oxidation is not complete, CO, a toxic gas is produced. About 0.3% or 3,000 parts per million (PPM) of CO is lethal to man in 30 minutes. Polystyrene heated to 300 C will give off only 10 parts per million of carbon monoxide (CO); at 400 C, only 50 PPM; at 500 C, only 500 PPM and at 600 C, it will give off 1,000 parts per million of carbon monoxide gas. To put the above in perspective, a National Research Council report, relating to a flammability test on polystyrene, indicated that the maximum index obtained from the combustion of polystyrene was of the same order as that of wood. 2.6 Vapor Barrier and Air Barrier Vapor barrier is defined as the element of the building that is installed to control the diffusion of water vapor through the building envelope. (Commentary on Part 5 of the 1990 NBC). When the Fox Blocks Insulating Concrete Form Wall System is used to separate heated space from unheated space, there is no requirement for the EPS thermal insulation to be protected by a vapor barrier when it is in continuous contact with the concrete. Rev

15 The EPS foam that Fox Blocks are manufactured from is Type II, with a wator vapor permeance of 3.50 perms in (200ng/Pa s m²). Condensation occurs when warm, moist air comes in contact with a surface which is at a lower temperature than its dew point. (Dew point is the temperature at which water will condense from the air, based on the air temperature and relative humidity). By design, the interior surface of a Fox Blocks wall is relatively close to the ambient temperature of a room. This is due to the insulation value. Windows on the other hand, have a considerably lower insulation value, and therefore have an interior surface temperature closer to that of the outside air. Condensation will therefore occur on the window surface. By design, walls constructed with Fox Blocks have a 6 (153.6mm) or 8 (200mm) monolithic concrete core. This solid mass of concrete WILL NOT allow the infiltration or exfiltration of air through the wall. Thus, the concrete acts as an air barrier, as required by most building codes. Air Permeability Material cfm/ft² l/s m² 3/8 (mm) plywood /2 (10mm) Gypsum Board High Density Bead Board ASTM proposed air barrier standard Tyvek Typar Low Density Bead Board (Type 1) In addition, Fox Blocks unique design creates a zero air cavity between the cured concrete within the ICF block and the EPS foam. At every 8 on-center tie spacing there is an internal recess space that lines up with the block above or below. When the concrete is placed, the space is filled and when the concrete is curing, it holds the EPS form firmly against the concrete and eliminates any air gaps with the ICF form. 2.7 Fox Blocks Industry Association Memberships Fox Blocks Insulating Concrete Form System, or its employees as applicable, are members of the following industry associations: Insulating Concrete Form Association American Concrete Institute (ACI) Rev

16 Construction Specifications Institute (CSI) Metro Omaha Builders Association (MOBA) National Association of Home Builders (NAHB) United States Green Building Council (USGBC) Aggregates & Ready Mix Association of Minnesota (ARMAM) International Code Council (ICC) Nebraska Concrete & Aggregates Association (NCAA) Iowa Ready Mixed Concrete Association (IRMCA) Nebraska State Home Builders Association (NSHBA) Fox Blocks is pleased to contribute to the growth of the insulating concrete form industry through participating in the activities of these industry associations. 2.8 Fox Blocks Industry Affiliations Fox Blocks Insulating Concrete Form Wall Systems takes part in the following industry affiliations: Energy Star (applied for June, 2006) Recycling of Expanded Polystyrene (EPS) Resin and Polypropylene (PP) Injection Molding Resin Rev

17 Section 3 List of Compatible and Complimentary Products Rev

18 3.0 List of Compatible and Complementary Products The following is a list of complementary products, which you, the contractors, may wish to use on your projects. Contact information is provided in Appendix C: Footings Form-A-Drain Window and Door Bucks V-Buck Window and Door Flashings Tyvek Bituthene Mastic Bracing/Alignment/Scaffolding Panel Jack Plumwall Brace E-Z Accessories ICF Tools and Accessories Simpson Strong-Tie Ledger Connection System Multi Purpose Anchor/Joist Hanger System Wind-lock Parging Foundation Insulation Coating DuRock B-2000 Dampproofing Delta MS Clear Platon Perm-a-Barrier Waterproofing Bituthene 3000 Bakor, Blue Skin Polyguard 650 Waterproofing Membrane AC Hydroseal 3000 Waterproofing and Termite Control Polyguard XTM and XTP Membrane Rev

19 Exterior Surface Finish Systems TAFS Finestone Acrocrete Acrylic Based Finishes Senergy Sonowall Hard Coat Stucco Permacrete Steel Framing, Floors and Roofs Dietrich Metal Framing Composite Steel & Concrete Floors Hambro Concrete Floor Comflor Floor System Rev

20 Section 4 Installation Rev

21 4.0 Installation Plan the job from the start for an efficient and profitable build! 4.1 Fox Blocks Installation Overview a) Planning the Build Have the materials and tools at the site. Have adequate bracing to do the project. Plan good access for the concrete pump and ready-mix trucks. See Appendix I for Safety Guidelines associated with concrete placement using pump and ready-mix trucks. Check and align the walls prior to placing the concrete. Align the walls again just after the pour. Figure A A well organized Fox Blocks Jobsite b) Footings or Slab on Grade Footings must be constructed to comply with building code requirements. As a better building practice, Fox Blocks recommends the placement of horizontal rebar in the footing, vertical dowels and a keyway between the footing and Fox Blocks wall. Footing forms are typically wood or steel, however, prefabricated PVC forming systems are an acceptable alternate. Place and pour the footings level to + or ¼ inch. This is a much tighter tolerance than frequently used for typical residential construction, but it will save time and money when the Fox Blocks walls are being stacked. Figure B Early stages of a Fox Blocks job showing the forms on a footing Rev

22 c) Placing Forms When the first course of forms are placed the contractor has a choice of cutting off the protruding portion of the interlock, on the bottom of the Fox Blocks forms, and then placing the forms flat on the footing, or placing the Fox Blocks forms on the footing and applying adhesive foam in the gaps to seal the bottom of the form to the footing, so the wet concrete cannot leak out. Accurate placement of the first course is most important. This can be easily achieved by one of four methods. Method #1 - mark out the location of the interior surface of the wall with a string-line on the footing and then using a small amount of adhesive foam on the bottom of the Fox Blocks set them in position. Method #2 - use a 2 x4 as a cleat fastened to the top of the footing, marking the location of the interior surface of the forms and then place the first and second courses of Fox Blocks forms snug against the 2 x4. Method #3 - mark where the exterior surface of the forms will be placed, use a 2 x4 as a cleat fastened to the top of the footing, then place the first and second courses of Fox Blocks forms snug against the 2 x4. Next, prepare to pour the interior basement floor to secure the forms. Method #4 - for use by experienced ICF installers, is wet-setting the first course of Fox Blocks forms immediately after the footing is poured, leveled and marked, by pressing the forms in the wet concrete. Fox Blocks have furring (fastening) strips on the ends of the webs (ties), which are positioned 8 on-center down the length of the forms. The furring strips run the full height of the forms and when the furring strips are stacked one over the other, a continuous furring strip is created on both sides of Fox Blocks walls. Each form is marked with Fox Blocks directly over the fastening strips. Therefore to achieve continuous furring strips up both sides of a Fox Blocks wall, simply stack the forms so the Fox Blocks markings line up vertically. The forms are to be stacked in a running bond manner so that the interlock connects the forms together. This is easily achieved because the corner forms have a short leg and a long leg which provides this offset as the orientation of the corner forms alternates in each course, by flipping them over. The reversibility of the Fox Blocks forms reduces job site material waste. When forms must be cut to make the wall the correct length, these short forms should be used in the middle of the wall. Cut on the lines marked on the forms because if this is done, the interlock will work as designed and the cutoffs can be easily used elsewhere on the job. The corner forms are designed with a vertical hole in the outside corner panel to receive a length of rebar or pipe. Inserting a bar or pipe through all the courses in a story will provide the corner with additional alignment support, and strengthen the corner during the concrete pour. d) Bracing and Alignment After the third course of Fox Blocks has been installed, the bracing and alignment system should be installed as per Reechcraft's instructions for use. See Appendix G. Rev

23 At the corners it is important to position the upright-brace (strongback support) closest to the corners, in both walls leading to the corners, so that the upright-braces bridge over the running bond connection between the corner forms and the straight forms. This reinforces the connection of the corner forms to the walls and assists keeping the corners plumb. Figure C drawing or photo showing upright at corner bridging over running bond connection between the corner forms and the straight forms. (coming soon) Some contractors may find it beneficial to install additional bracing on the outside of the corners depending on the rate of placing the concrete. The walls should be aligned, plumbed, prior to the pour and then again after the pour to ensure a straight, plumb and level job. Follow all OSHA Safety & Health Guidelines associated with the installation of Fox Blocks Insulating Concrete Form Wall Systems. e) Window and Door Openings It is strongly recommended that bucks be built ahead of time, be on site, and ready for placement as the Fox Blocks walls are being constructed. Bucks can be either the plastic variety as is sold by V-Buck or fabricated out of wood with 2 x 12 s or with plywood and 2 x4 s running the length of the buck along each side. The installed bucks should have internal bracing to support the jams and top to keep them plumb and level. The bottom sill member of the buck should be removable for placement of concrete. All window and door openings should be poured first. Figure D Photo of Fox Blocks wall with properly installed and braced window buck. (coming soon) The bucks must be constructed to provide the necessary Rough Stud Opening dimensions as required by the specifications of the window or door manufacturer. f) Placing Steel Reinforcement The rebar must comply with building code requirements, or engineering specifications. If required, the owner is responsible for providing site specific structural engineering. The horizontal reinforcement must be installed as specified, as each course of Fox Blocks is placed on the wall. At corners the rebar must be continuous around the corner for a minimum of 24 inches. This will require the use of pre-bent corner bars or the ability to bend the rebar on site. Rev

24 Lap splicing, both contact and non-contact, in compliance with the IRC is permitted. The vertical reinforcement is placed (nested down through the horizontal rebar) after the Fox Blocks are stacked to the full height of the wall. Figure E Photo of Fox Blocks wall with both horizontal and vertical rebar in place (coming soon) The reinforcing steel must be placed in accordance with the structural requirements of the build code or as specified by the engineer of record. The reinforcing steel can be tied together using black annealed wire, plastic zip ties, or plastic Kodi-Klips. g) Utility Service Wall Penetrations Utility services such as electrical service, cable, water, and dryer vent can be accommodated by inserting a pipe through the wall, or use a 4 diameter tube through the wall. Remember it is much easier to do this before the concrete is poured than to cut through the concrete later. h) Preparation for the Concrete Pour It is strongly recommended that a pre-pour inspection be completed. The pre-pour inspection should include checking for: - Properly stacked forms with no gaps at the bottom ends of the blocks or between courses, - Any holes or gaps in the wall should be filled with foam, but please note that a badly stacked wall cannot be easily patched with foam. The complete engagement of the interlock between forms is necessary for the Fox Blocks forms to have adequate strength to support the concrete, - Tie the top course of Fox Blocks forms to the course below it with wire ties or plastic zip ties. As well, tie the forms end-to-end around the top course. In this way every form in the top course is secured to the adjacent forms it is in contact with, - Check forms which have been cut to ensure they have adequate support, - Check the site for cleanliness, as this is a great time to clean up the site and get it organized, Rev

25 - Have several blow-out kits on site. A blow-out kit consists of a piece of lumber ( 1 x4 or strip of plywood or OSB) a screw gun and screws. Finally, plumb the wall just prior to placement of concrete, and then tilt the wall towards the bracing units slightly (¼ inch at the top of the wall) as it is easier to push a wall into plumb than to pull it. It is recommended that the concrete design mix for Fox Blocks walls typically has a design strength of 3000 psi, slump of 5 to 6 inches and use 3/8 inch pea gravel for the large aggregate. i) Concrete Placement It is recommended that the forms under the windows be filled with concrete first, with the placement down through the bottom of the buck. Then, go to the top of the wall and start placing the concrete down into the forms. The placement rate should be 3 to 4 feet per hour per lift. j) Finishing Off the Wall Before placing the concrete, cut off the protruding portions of the exposed interlock. When the concrete is placed to the top of the wall the concrete must be troweled flat and level in preparation for the top plate. The use of a construction lazer level may assist with this task. Then, place the anchor bolts in the concrete as per code or engineers specifications. In high wind areas, hurricane tie down straps are to be installed as per code and/or the specifications of the manufacturer. k) Installation of Floor and Roof Connections Floor systems to be placed on the top of the Fox Blocks wall are built as typical floor platforms are built, as per code requirements. Floor systems to be connected to the side of the Fox Blocks wall are installed using a rim joist and floor hangers for the floor joists. The rim joist is connected to the wall using 1 of 2 methods: i) removing foam and casting bosses of concrete out to the outer face of the EPS panel and inserting anchor bolts to connect the rim joist to the wall, as shown in Figure U, or ii) using the proprietary system sold by Simpson Strong Tie. There are four further alternatives: a) use the Fox Blocks Taper Top Form, placed on the wall so the ledge faces inward and then set the floor joists on the ledge, Rev

26 b) use the Fox Blocks Brickledge (Corbel) Form, placed on the wall so the ledge faces inward and then set the floor joists on the ledge. For the requirements for the rebar in the form to support the floor loads, please see Appendix D, c) attach the floor joists to the Fox Blocks walls using the proprietary system sold by ICF Connect Ltd., d) use the Dietrich Metal Framing system, floor, roof and interior wall systems. Connection details are available from Dietrich. For further information on the systems provided by Simpson Strong Tie, ICF Connect Ltd, and Dietrich Industries, please see Appendix C. Roof trusses are attached to the top plate, as would be typically done in framed construction. In high wind areas the code may require the installation of hurricane tie down straps to further secure the roof. l) Installation of Utilities Electrical wire can easily be installed by cutting a groove in the EPS panel and then placing the wire in the groove. Cutting the groove can be done with a hot knife, a router, or an electric chain saw. Electrical boxes can be installed by removing the EPS and placing the box in the cavity. The box can then be fastened to the furring strip, or fastened through the back of the box to the concrete wall, if required by code. Similarly, plumbing, heating, refrigeration and air conditioning can be installed in conjunction with the Fox Blocks walls per building code requirements. Testing standards for mechanical utility equipment must meet American Society of Heating, Refrigeration, and Air Conditioning Engineers (ASHRAE) standards. m) Exterior and Interior Finishes Interior: The interior of ICF walls must be finished with a thermal barrier. The most convenient material to do this is ½ inch sheet rock, as it is recognized as providing the 15 minute thermal barrier required by code. The sheet rock must be mechanically fastened, and so should be screwed to the furring strips. Adhesives can be used in conjunction with mechanical fasteners. Exterior: Exterior finishes can be attached to the continuous full height furring strips in the EPS blocks in a similar fashion as would be typically done with frame walls. Attachment can be made at the corners to the special fastening strips embedded in the foam in the corner forms. Rev

27 In the case of brick veneer, a ledge is cast with the special Fox Blocks Brickledge Form and then the bricks are layed up on the ledge. Brick ties are installed with fasteners to the furring strips. EIFS lamina can be installed directly to the EPS foam. The EPS surface must be prepared in accordance with the EIFS manufacturers specifications. This is a barrier system and to perform satisfactorily, the detailing around windows and doors is important. Dampproofing and Waterproofing: The exterior of below grade walls must have a dampproofing or waterproofing material applied and free draining backfill or other drainage material be provided to allow water to move to the foundation drain and be drained away from the foundation. 4.2 Planning Plan the job from the start for a fast profitable build. A well-planned job will work much more smoothly and save you, the contractor, from experiencing unnecessary additional costs. Information needed before the start of construction to plan the build: - building plans, - rebar specifications for the walls, the lintels and around openings, - specification for the concrete, - rough stud opening measurement requirements for the window and door openings, - anchor bolt specifications and on-center spacing (in hurricane prone areas, high wind areas, and regions having a high seismic design category, there may be additional requirements to connect the floors and roofs to the walls). The key planning steps are: - plan for job safety, - complete an accurate takeoff and order sufficient Fox Blocks, - draw a wall cross-section elevation view in advance and determine where the coursing will be, the window openings, lintels and the top of the wall. This exercise will assist in planning the build, - pour footings level + or 1/4 inch, - plan to have the necessary tools at the site, see Appendix E, - plan to have adequate crew, - designate a space on site for the storage of the Fox Blocks forms. Frequently it is near the center of the build where access will be easy during the construction of the walls, - mark out the wall on the footing or slab and then mark where doors, windows, utility services and the dryer vent will go. This will enable you to easily visualize the layout and identify potential difficulties, and then you can plan in advance how you will deal with these items, - schedule the pour so you have adequate time to inspect the Fox Blocks walls with the forms empty and confirm they are ready and all the bracing and support is in place for the concrete, Rev

28 - prior to the pour, walk through the site and complete a checklist to confirm the walls are ready for the concrete. See the checklist in Appendix F, - order the concrete pump to come ½ hour before the concrete so it has adequate time to set up, - request the concrete pumper bring a double 90 degree or a reducer to 4 and short length of 4 flexible hose, to be added on the end of the pipe to slow the velocity of the concrete during placement, - plan to have a vibrator on site, confirm power source and have adequate extension cords, - ensure there is adequate access for the concrete pump truck, ready mix trucks and make sure there is a location for the ready-mix trucks and the concrete pump truck to clean out, - remember to check the alignment of the wall immediately after the pour is complete, - do not backfill against the ICF foundation walls until the floor system has been installed, or adequate lateral support has been provided. The temporary bracing systems designed to brace and align the walls are not designed to provide adequate lateral support to resist the forces imposed by the backfilled soil. 4.3 Footings or Slab on Grade Footings can be trench footings, formed footings, grade beams supported on piles or slabs on grade. All of these are viable footing systems provided they have been properly designed and engineered as required by local soil conditions and building department requirements. If site specific structural engineering is required it is the responsibility of the owner. Footings must be constructed to comply with building code requirements. As a better building practice, Fox Blocks recommends the placement of horizontal rebar in the footing, vertical dowels and a keyway between the footing and Fox Blocks walls. See Appendix A for typical construction footing and foundation details. Pour and level footings to + or ¼ inch. This is a much tighter tolerance than used for typical residential construction but it will save time and money when the Fox Blocks walls are being stacked. If the footings are not level, the bottom of the forms may have to be cut (scribed) to sit properly on the concrete, or shimmed, or have foam placed in the gaps, or a combination of these techniques. When the wall is 2 or 3 courses high, check and confirm that the build is going well and that there are not any irregularities in these lower courses, which are causing problems. If there are problems, address these irregularities as noted above. It is important to note that the bottom 2 courses should be level and properly supported by the footing or slab as this makes it much easier for the rest of the build to go smoothly and quickly. Time taken to have the bottom 2 courses installed properly is time well spent to achieve a successful build. Rev

29 4.4 Placing Forms Prior to starting the build there are several techniques which can be used to make the job easier: - Mark out the wall on the footing or slab and then mark in where doors and windows will go. This enables you to easily visualize the layout and identify potential problems, and then you can plan in advance how you will deal with these items, - Mark out with a chalk line the location of the interior of the wall to guide placement of the first course of forms. Then using adhesive foam, place a small amount of foam on the bottom of the forms and set them in place, - An alternative is to place a 2 x4 as a cleat on the top of the footing and fasten it to the footing, marking the location of the interior edge of the wall and then set the first course of forms in place, making sure the forms are snug against the 2 x4, - A second alternative, mark where the exterior surface of the form will be placed, use a 2 x4 as a cleat fastened to the top of the footing with a double-headed nail of mechanical anchor, then place the first and second courses of Fox Blocks forms snug against the 2 x4 cleat. Next, prepare to pour the interior basement floor to secure the ICF forms. - A third alternative, for use by experienced ICF installers, is wet-setting the first course of Fox Blocks forms immediately after the footing is poured, leveled and marked, by pressing the forms into the concrete. This method of placement of the first course of forms must be approved and compliant with local building code requirements. When the first course of forms are placed, the contractor has a choice of cutting off the protruding portion of the interlock on the bottom of the Fox Blocks forms, and then placing the forms flat on the footing to an interior or exterior chalk line marking, or placing the Fox Blocks forms on the footing and applying adhesive foam in the gaps to seal the bottom of the form to the footing, so the wet concrete cannot leak out. The forms are to be set in place using a running bond. This enables the interlock to tie the wall together. The running bond is achieved with the corner forms as each corner form has a short leg and a long leg, and by reversing the corner forms in each course as the wall is stacked the running bond is created. Fox Blocks have a furring (fastening) strips on the ends of the webs (ties), which are positioned 8 on-center down the length of the forms. The furring strips run the full height of the forms and when the furring strips are stacked one over the other a continuous furring strip is created on both sides of Fox Blocks walls. Each form is marked with Fox Blocks directly over the fastening strips. Therefore, to achieve continuous furring strips up both sides of a Fox Blocks wall, simply stack the forms so the Fox Blocks markings line up vertically. When forms must be cut to make the wall the correct length, these shorter forms should be placed in the middle region of the wall about midway between the corners. Remember to cut along the lines marked on the forms because if this is done, the interlock will work and the cutoffs can be easily used elsewhere on the job. Rev

30 Figure F A Fox Blocks 90 corner block has a long leg and a short leg Figure G Show photo with running bond stack (coming soon) The corner forms have additional plastic reinforcement embedded in the foam. This reinforcement provides both added strength to the forms and additional furring opportunity for attachment of cladding and exterior finishes at the corner. See Section 4.14 for more details. For additional strength, a hole is located near the tip of the corner forms, and once the corner forms are stacked, a length of rebar or plastic pipe can be pushed into this hole through the several courses which make up the story, thus tying the whole corner together. Figure H A Fox Blocks corner form with PVC pipe When installing the Fox Blocks Brickledge Forms, the corners must be mitered and glued together to create corner forms. Once the mitered Brickledge Corner Forms are in place, they should be reinforced with the addition of supplementary strips of 1 x4 s and tape around the outside of the corner to hold the form in place. Rev

31 T-Block Wall Connections: Fox Blocks have developed T-Block Corner Forms. The use of these forms significantly reduces the labor traditional required to splice typical ICF forms into this common style of wall interface. When T-Block Wall Forms are used, they should be alternated as one has a short leg and one has a long leg. In this manner the running bond pattern can be easily maintained in both walls. If the walls are to be built higher with Fox Blocks, the tops of the forms in the walls should be protected from being filled with concrete. This is accomplished by covering the interlock with 3 self-adhered tape that can easily be removed later. The tape can be clear pressure sensitive packaging tape, duct tape, or masking tape. Figure I A Fox Block T-block has a long leg, a short leg, and an offset T-wall which will create the running bond pattern. 4.5 Bracing and Alignment Figure J Reechcraft s Panel Jack bracing installed on a Fox Block wall After the third course has been placed, the bracing and alignment system should be installed as per Reechcraft's instructions for use. Please see Appendix G. Conventional 2 x4 bracing and alignment can be used, however, construction time is increased and is less effective in aligning the Fox Blocks wall before and after placing the concrete. At the corners, it is important to position the upright-brace (strongback support) closest to the corners, in both walls leading to the corners, so that the upright-braces bridge over the running bond connection between the corner forms and the straight forms. This reinforces the connection of the corner forms to the walls and assists keeping the corners plumb. Rev

32 Figure K Drawing or photo showing upright at corner bridging over running bond connection between the corner forms and the straight forms (coming soon) The walls should be aligned, plumbed, prior to the pour and then slightly tilted towards the bracing (1/4 inch at the top of the wall) as it is easier to push the wall into plumb after it has been filled with concrete than to pull it. Fox Blocks walls should be plumbed again immediately after the pour has been completed to ensure a straight, plumb and level job. Follow all OSHA Safety & Health Guidelines associated with the installation of Fox Blocks Insulating Concrete Form Wall Systems. 4.6 Window and Door Openings It is recommended that bucks be built ahead of time and be on site and ready for placement in the walls at the appropriate time in the construction of the Fox Blocks walls. Bucks can be either the plastic variety as is sold by V-buck or fabricated out of treated wood with 2 x 12 s or with plywood having 2 x4 s running the length of the buck along each side. For installation instructions for V-buck please see Appendix H. Figure L A V-buck installed in an ICF wall Rev

33 When building wood bucks, it is recommended that the bottom of the buck be constructed with 2 x4 s so that a space is left between the 2 x4 s. Concrete can then be placed into the forms below the buck through this space. Also, when constructing wood bucks remember that untreated wood cannot be placed directly in contact with the concrete, and therefore the bucks must be constructed with pressure treated lumber or a moisture barrier must be installed between the concrete and the wood. Wood bucks can be anchored to the concrete wall with anchor bolts or by driving long nails through the buck material into the space to be filled with concrete. When using pressure treated lumber ensure the anchor bolts or nails are compatible with the pressure treated lumber. The bottom sill member of the buck should be removable for access to the cavity below the window of door. This cavity is filled with concrete prior to pouring the ICF walls. Once this area is filled, the bottom sill member is installed and the remaining wall is ready to pour. All areas under window and door bucks are filled with concrete and vibrated. Figure M Detail of a wood buck made with 2 x12 s in Fox Blocks wall. (show 1 x4 around edges securing the buck in place in wall) (coming soon) Figure N Detail of a wood buck made with 2 x4 s and strips of plywood. (show 1 x4 around edges securing the buck in place in wall) (coming soon) Figure O Image of wood buck being installed. (coming soon) Rev