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Build Icf Brazil

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seminar presentation for UKTI Brazil mission October 2009

seminar presentation for UKTI Brazil mission October 2009

Published in: Technology
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  • 1. 08/10/09 Presentation title INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 2.
    • ICF consultancy
    • ICF product design & manufacturing
    • ICF industry training & Continued Professional Development (CPD)
    • ICF project management
    • ICF site management
    • ICF waste management
    What we do 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 3.
    • Sustainable Construction & ICF – Principles of Energy Efficiency, Water & Waste
    • EPS Material & ICF Production
    • EPS / ICF Assessments & Certifications
    • ICF History
    • ICF Design
    • ICF Engineering
    • Some Benefits of ICF Systems - Operational & HRM Considerations
    • Sustainable ICF Solutions
    • Strategic Opportunities & Conclusions
    Presentation Outline 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 4. Sustainable Construction We rely on Principles of Energy Efficiency 08/10/09 wood construction ICF construction http://www.cs-construction.com/icf-construction.htm INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 5. Sustainable Construction: Water reduction & reuse
    • Manufacturing
      • Waste water used in process of expansion – reducing h2o need
      • Energy requirements are low, as steam is captured in expansion process, condensed and recycled
    • Constructing
      • The specific ICF design can reduce concrete volume & thus water needs
      • Admixes in concrete can reduce water need – ICF cures all concrete in a stable environment
      • Cleaner sites – less water required post concrete pour
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 6. Sustainable Construction: Green Concrete 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 7. 08/10/09 Sustainable Construction: Site Waste Management INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 8. EPS Material & ICF Production 5 manufacturing stages 

1) Pre-expansion 
Polystyrene granules are expanded by free exposure to steam to form larger beads, each consisting of a series of non-interconnecting cells. 

2) Conditioning 
After expansion, the beads still contain small quantities of both condensed steam and pentane gas. As they cool, air gradually diffuses into the pores, replacing, in part, the other components. 

3) Moulding 
The beads are moulded to form boards, blocks or customised products. The mould serves to shape and retain the pre-foam, and steam is again used to promote expansion. During moulding, the steam causes fusion of each bead to its neighbours, thus forming a homogeneous product. 

 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 9. EPS Material & ICF Production 
 4) Shaping 
Following a short cooling period, the moulded block is removed from the machine, and after further conditioning, may be cut or shaped as required using hot wire elements or other appropriate techniques. 

5) Post-production processing 
The finished product can be laminated with foils, plastics, roofing felt, fibreboard or other facings such as roof or wall cladding material. 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 10. EPS Material Properties – EU standards EPS TYPE   EN 13163 [unit] EPS 60 EPS 100 EPS 150 EPS 200 EPS 250 Thermal conductivity EN 12667 'Lambda' 38 36 35 34 34 EN 12939 mW/mºK38 Compressive stress 10% EN 826 CS(10)kPa 60 100 150 200 250 Bending strength EN 12089 BSkPa 100 150 200 250 350 Dimensional stability EN 1603 DS(N)% 0,5% 0,5% 0,5% 0,5% 0,5% Approximate Density  kg/m³ 15 20 25 30 35 08/10/09 www.eumeps.org INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 11. EPS/ ICF Assessments & Certifications Products: ETAG, CE, BBA, BRE, IPT, ABNT, INMETRO Processes: Carbon Foot-printing (CF), Life Cycle Assessment (LCA), Environmental Impact Assessment (EIA), Site Waste Management Program (SWMP) Buildings: BREEAM, LEED AQUA 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 12. ICF Product Certification: ETAG , CE, BBA, BRE,IPT, ABNT, INMETRO 08/10/09 ETAG 009 Edition June 2002 GUIDELINE FOR EUROPEAN TECHNICAL APPROVAL OF NON LOAD-BEARING PERMANENT SHUTTERING KITS/SYSTEMS BASED ON HOLLOW BLOCKS OR PANELS OF INSULATING MATERIALS AND SOMETIMES CONCRETE www.eota.be INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 13. EPS for ICF Manufacturing: the standard for EU certification 08/10/09 www.eumeps.org/whiteb.htm INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 14. EPS/ICF Process Assessments: Carbon Footprint, LCA 08/10/09
    • An LCA of a building includes environmental impacts due to: 
    • Extraction - of materials and fuel used for energy
    • Manufacture - of building components
    • Transportation - of materials and components
    • Assembly - and construction
    • Operation - including energy consumption, maintenance, repair & renovations
    • Demolition - disposal, recycling & reuse of the building at the end
    • of its functional or useful life
    • A full set of impacts includes land use, resource use, climate change, health effects, acidification, and toxicity.
    INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 15. EPS/ICF Process Assessments: LCA model 08/10/09 www.cement.org/bookstore/profile.asp?itemid=SN3041 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 16. ICF Building Assessments: LEED , BREEAM , AQUA
    • Energy efficiency/CO 2
    • Water efficiency
    • Surface water management
    • Site waste management
    • Household waste management
    • Choice & use of materials
    • Lifetime homes (applies to Code Level 6 only)
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 17. ICF History 08/10/09
    • 1960’s - From EPS insulation component to a core building product – first patent applied
    • 1980 &90’s - Tested as a Permanent shuttering system – considering values for insulation, air, sound attenuation, water permeability, fire
    • 1990’s – development of branded ICF’s in North American & European markets
    • 1990’s –International green programmes (LEED, BRE, EOTA ) move ICF into mainstream construction
    • 2009 - 140 ( and growing) ICF designs sold world wide – third generation now considered a benchmark
    • 2009 – Increase of ancillary products/companies ( scaffolding, exterior finishes,etc…)
    INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 18. Insulated Concrete Form (ICF) Systems Design FOOTING DECK WALL ROOF 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 19. ICF Wall Systems
    • 9 wall elements - 1 product
    • Structural wall – reinforced concrete
    • Exterior insulation & fastening
    • Interior insulation & fastening
    • Air barrier
    • Sound barrier
    • Vapour barrier
    • Water barrier
    • Wind resistant
    • Fire resistant
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 20. ICF Design: Wall systems -1 Post & Beam 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 21. ICF Design: Wall systems - 2 Waffle/Grid 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 22. ICF Design: Wall systems - 3 Flat Panel 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 23. ICF Design: Wall Systems Tall Walls Commercial 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 24. ICF Engineering: Types of ICF Buildings
    • Residential & Multi-Residential
    • Industrial
    • Agricultural
    • Commercial & Institutional
    • Below Ground
    • Swimming Pools
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 25. 08/10/09 http://www.quadlock.com INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 26. 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 27. 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 28. 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 29. 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 30. Some Benefits of ICF Systems Operational & HRM considerations 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 31. Speed of build 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 32. Lightweight logistics 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 33. EPS & ICF Recycling – Energy & new products from waste 08/10/09 compacting densifying new product development INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 34. Supply chain benefits – site management issues logistics & EPS/ICF recycling are interlinked 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 35. On-site training - E learning - Professional Accreditation 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 36. Reduced labour - Easy project management 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 37. 08/10/09 Luxury residence UK BREEAM - Code for Sustainable Homes 5 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 38. Freedom of design - Built on site 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 39. Code for Sustainable Homes 6 – concept CREO House BRE UK 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities http://www.creoprokoncept.com/?page_id=295
    • High performance building fabric - ICF
    • Low impact heating technologies & mechanical ventilation
    • 131% reduction in carbon emissions compared to 2006 UK building standards
  • 40. Code for Sustainable Homes 6 – actual CREO House BRE UK 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities http://www.insite09.com/progress-blog.jsp Outline Energy Strategy Envelope Walls - U value 0.15 W/m 2 k Roof -U value 0.15 W/m 2 k Windows -U value 0.16 W/m 2 k Air-tightnesss – 2.5 m 3 /m 2 /hr 50 Pa Low Impact heating/cooling & Power ASHP- air source heat pump MVHR & hot water - mechanical ventilation heat recovery PV Panels - photovoltaic
  • 41. Large long straight walls 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 42. Easy engineering – Steel &/or fiber reinforcement 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 43. 08/10/09 Freedom in engineering – Easy onsite build INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 44. External finishes - Silicone render 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 45. External finishes - Stone face on garage 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 46. External finishes – Render, wood, aluminimum 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 47. External finishes - Aluminium 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 48. External finishes - Silicone render with EPS mouldings 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 49. External finishes - Silicone render 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 50. External finishes EPS external insulation refurbishment with silicone render system 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 51. Sustainable ICF Solutions
    • There is an opportunity across a range of industries in the supply chain
    • ICF solutions must embedded in supply chains –locally, regionally & nationally
    • As a MMC, ICF must include training as a strategic activity
    • There is no ONE ICF solution – partners must work together across international certifications and engage with local partners for best practice projects
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 52. Strategic Innovation
    • There is an opportunity to network strategically with PPPs, NGOs, Educational Institutions, diverse businesses, and certification bodies for national/regional/local solutions at the beginning of the ICF technology transfer
    • There is also continued improvement in the materials, product design and integration with other renewable products through knowledge partnerships
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 53. Strategic Innovation
    • There is an opportunity to place training at the heart of this modern methods of construction (MMC)
    • ICF success can be measured by key performance indicators across a range of construction professionals
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 54.
    • ICF products are sustainable, accredited, and offer superior built environment opportunities
    • ICF technologies enable economic
    • growth in other employment areas,
    • such as with supply chain partners
    Conclusions 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 55.
    • ICF training is important to establish at the outset – to enable professional ICF installers to support design professionals in delivery & manufacturers of ICF products
    • Brazil has an opportunity to take the best
    • of the ICF industry forward and continue to
    • improve ICF products & services
    • Brazilian ICF products & ancillary products can be exported back to countries already using ICF systems in mainstream construction worldwide
    Conclusions 08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 56.
    • Brazil demonstrates the 3
    • components for sustainable
    • construction
    • economic opportunity
    • environmental mandates
    • social/political structure
    • … we look forward to a long relationship with our partners here ….
    08/10/09 INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities
  • 57. Thank You 08/10/09 download this presentation at www.slideshare.net visit us at www.buildicf.co.uk & www.noncongroup.com INSULATED CONCRETE FORMS Innovative, Sustainable & Strategic Opportunities

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