polywall icf - polyfoam australia

April 12 of 23

Proudly Australian Owned and Operated for over 25 years

Polywall® ICF

(Insulating Concrete Formwork)

A Guide to the Installation of Polywall®.

Energy efficient building design and

construction

Exciting opportunities limited only by

Imagination

April 12 of 23


TABLE OF CONTENTS

1.0 INTRODUCTION ................................................... 3 1.1 Engineering Specifications ..................................... 4 1.2 Relevant Australian Standards ................................. 6 2.0 COMPONENTS OF THE POLYWALL BUILDING SYSTEM....... 7 3.0 TOOLS, EQUIPMENT & CONSUMABLES ........................ 9 3.1 Tools................................................................ 9 3.2 Consumables for Project ...................................... 11 3.3 Quantity Survey ................................................ 12 4.0 INSTALLING THE POLYWALL SYSTEM ........................ 13 4.1 Setting Out the Site ........................................... 13 4.2 Assembling the Polywall ...................................... 14 4.3 Penetrations of Wall ........................................... 17 4.4 The Concrete Pour ............................................. 19 4.5 Placement of Services ......................................... 20 4.6 Finishing ......................................................... 20 4.7 Special Applications ........................................... 21 5.0 TRAINING ........................................................ 22 6.0 CONTACT INFORMATION ...................................... 23

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1.0 – INTRODUCTION ICF (Insulating Concrete Forms) systems provide a fast, strong, economical and environmentally-friendly method of building multi-level houses, retaining walls, fences, swimming pools, or any other structure that requires strong, reinforced concrete walls. An ICF structure consists of expanded polystyrene panels and reinforced concrete. POLYWALL® is erected onsite, and can be filled with concrete to a height of three metres in a single pour when used with the correct bracing and pouring techniques. The benefits of building with POLYWALL® are: - structural strength - high thermal efficiency - low sound transfer through walls - high fire resistance - quick to build - economical - environmentally-friendly POLYWALL® Insulated Concrete form work must only be assembled and installed by a suitably qualified building contractor who has been fully trained for this task. It is the builder’s responsibility that all installers are properly trained and are competent in these tasks. Serious safety hazards causing injury or death can result from incorrect assembly or installation of this building system. All relevant government, building regulations and codes etc. must be adhered to at all times during construction. This guide covers only typical examples and does not replace any engineering or safety requirements. Each building must be structurally designed by a suitability qualified engineer to comply with all relevant building standards.

April 12 of 23


1.1 Engineering Specifications

Thermal specifications

POLYWALL® forms a high energy efficient building system. The following data demonstrates why a POLYWALL® building will reduce heating and cooling costs significantly.

Item Construction

Resistance – R Value

Polywall

250

Polywall

270

Polywall

320 1 Outdoor air film 0.03 0.03 0.03

2 High density expanded polystyrene blocks - 60 mm 1.64 1.64 1.64

3 Concrete – aggregate 1 : 3.5 : 6 – K = 0.13 W/M/K 0.151 0.191 0.257

4 High density expanded polystyrene blocks - 60 mm 1.64 1.64 1.64

5 Drywall plaster board 10 mm 0.059 0.059 0.059

6 Air film 0.03 0.03 0.03

Total Resistance 3.55 3.59 3.65

Wall description ‘R’ Factor

M2 K/W

POLYWALL®

– 250 3.55

POLYWALL®

– 270 3.59

POLYWALL®

– 320 3.65

Brick veneer with 10mm plaster board and reflective film on outside

frame

0.489

Brick veneer as above plus R2 glass fibre blanket in the frame cavity 2.489

Solid brick with cavity and 25mm polyurethane foam in cavity 1.5

Pine weather board with 10 mm plaster board and reflective film 0.489

200mm concrete tilt up slab with hard plaster 0.359

Reference: The Australian Institute of Refrigeration, Air-Conditioning and Heating Inc Handbook

Notes: Full performance data available on application.

From the above table, POLYWALL® 250 has more than 3 times the heat efficiency of a brick veneer wall with reflective film and is still about 1 ½ times more efficient than with glass fibre batts included.

Acoustic specifications

Please refer to our technical department for further details

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Combustibility As with all other organic materials, EPS (expanded polystyrene) insulation products must be considered combustible and to constitute a fire hazard if improperly used or installed. POLYWALL® products should not be exposed to open flames or other ignition sources. The material contains a flame retardant additive to inhibit accidental ignition from small fire sources. The table below shows test results for EPS and other common building materials, it provides a good guide as to how these products compare. Comparative testing of some materials to AS 1530, Part 3 – Early Fire Hazard Tests. A lower number indicates better Early Fire Hazard properties.

Material Ignitability

Index (0-20)

Spread of Flame

Index (0-10)

Heat Evolved

Index (0-10)

Smoke Developed

Index (0-10)

POLYWALL® EPS 12 0 3 5

Australian Softboard 16 9 7 3

Oregan 13 6 5 3

Bluegum 11 0 3 2

Note. Source EBS Notes on the Science of Building. NSB66

Other references: “Comparative Toxicity of Thermal Decomposition Products”, H Hofinmann & H Oettel. “Toxicity Considerations of Combustible Products from Cellular Plastics” P.R. Nicholl & K.G. Martin

April 12 of 23


1.2 Relevant Australia Standards

Applicable Standards AS3600 Concrete Structure AS/NZS/ISO 9000 Quality Control Standards AS 3700 Masonry Structures AS4055 Wind loading for Housing

Concrete Specifications Concrete is generally specified in accordance with the provisions of Australian Standards AS 1379 Specification and supply of concrete and AS 3600 Concrete structures. The following Standards are also referred to by this guide: AS 1012 Methods of testing concrete AS 2758.1 Aggregate and rock for engineering purposes Part 1 Concrete aggregate. AS 3582.1 Supplementary cementations materials for use with Portland cement Part 1 Fly ash. AS 3582.2 Supplementary cementations materials for use with Portland cement Part 2 Slag – ground granulated iron blast furnace. AS 3582.3 Supplementary cementations materials for use with Portland cement Part 3 Amorphous silica. AS 3972 Portland and blended cements. Reference: http://www.concrete.net.au

Parameter Unit Concrete identification

Basic parameters

Strength grade designation – 25 MPa minimum

The slump at the point of acceptance mm 120

The maximum nominal size of aggregate mm 7 mm

The intended method of placement – pump

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2.0 COMPONENTS OF THE POLYWALL® BUILDING SYSTEM

POLYWALL® - Code 201

The POLYWALL® Flat Panel has been designed with tongue and groove edges, to allow quick, strong installation. The T-Slots in the top and bottom, in conjunction with the Connecting Bridges, provide a quick and easy process to assemble the bricks into position.

• Size 1200 x 300 x 60

• Supplied at – 60 (30 pairs) per pallet

POLYWALL® Corner - Code 203

Forms a square corner with left and right inner and outer blocks available, to create an overlap on each course of panels.

Size 250mm

Cavity 120

Build Size 240

• Supplied on pallets at 16 sets per pallet

• Supplied at - 8 pairs of left and right hand inner and outer per pallet

Size 250

Starter Bridge

The Starter/Finishing Bridge provides an excellent start and finish to the Polywall. This provides a strong, stable base to begin building, and keeps the base of the panels together when the concrete is poured. This bridge also finishes off the wall with a flat edge. The initial row can be bench assembled for speed.

Code 202 205 208

Size 250mm 270mm 320mm

Cavity 125 150 200

Build Size 245 270 320

Size 270

Size 320

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Size 250

Connecting Bridge

The POLYWALL® Connecting Bridge is a bridge made from 100% recycled polypropylene and ties the Polywall® panels together while the concrete is poured. The design of the bridge forms a solid surface which can be screwed into.

Code 204 206 207

Size 250 270 320

Cavity 125 150 200

Build Size 245 270 320

Size 270

Size 320

Starting Steel Channel – Code 209

This channel fixes the first row of blocks firmly and accurately in place. Providing stability to the wall during pouring.

• Size – Width 61 mm x 4.2 metres long.

• Suitable for all walls.

polywall icf - polyfoam australia

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