building insulation systems - mankato concrete · building insulation systems . ... insulated...

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B y C o m p o s i t e T e c h n o l o g i e s C o r p o r a t i o n

BUILDING INSULATION SYSTEMS

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B U I L D I N G I N S U L AT I O N S Y S T E M


T H E S Y S T E M

Composite Technologies Corporation (CTC) was founded in 1980 by Robert T. Long. His

innovative thinking and vision led to the development of the THERMOMASS® Building

Insulation System. At the heart of the THERMOMASS® system is a patented continuous fiber

composite connector, which is used to structurally tie two layers of concrete together through

predrilled, prefabricated, extruded Dow brand insulation products. The non-conductive,

chemically resistant, fiber composite connector allows the creation of an uninterrupted

envelope of insulation throughout the exterior walls of the building. This creates a

highly energy efficient building system that is virtually maintenance-free and has the

ability to not only resist mold, but stand up to fire, earthquakes, hurricanes and

tornadoes as well.

The continued development of this system represents a dramatic advancement in

building technology for many types of temperature and atmosphere controlled facilities

throughout the world and offers unsurpassed advantages over block/brick, steel and

insulated metal panel construction.

A H I S T O R Y O F S U C C E S S

For over 20 years, THERMOMASS® has been the industry leading system for concrete

sandwich wall construction. Extensive testing, research and development of innovative

technologies keeps CTC at the forefront. With a track record of over 100,000,000-sq. ft. of

sandwich walls in the US and around the world in use today, we have more experience than

all other building insulation systems combined.

The energy efficiency of the finished building combined with the ease and speed of

construction has made our building system the preference of industries ranging from

education and correctional facilities to freezers, coolers, distribution centers and retail

facilities. They keep returning to the THERMOMASS® Building Insulation System because it

provides them with unparalleled construction quality, aesthetic versatility and energy savings.

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The THERMOMASS® Building System is a technologically advanced system that delivers

exceptional construction with superior insulation effectiveness.

Connectors

Our family of continuous fiber composite connectors is made from a resilient composite

matrix and possesses incredible strength and durability. They are far superior to steel and or

plastic connectors in sandwich wall panels because they are non-corrosive, chemically

resistant and have low thermal conductivity with unsurpassed structural strength.

Insulation:

Dow brand insulation products are a "closed cell" structure, that means no gaps or voids

between cells. The rigid board construction resists all forms of water penetration including

water vapor transmission. The high thermal resistance and high compressive strength make

it a valuable component in the THERMOMASS® Building System.

Dow insulation used in the THERMOMASS® Building System:

Styrofoam® Brand Extruded Polystyrene

ISOCAST R Polyisocyanurate

PROPEL® Extruded Polypropylene

A F A M I L Y O F C O M P O N E N T S

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C O N N E C T O R S

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C O N S T R U C T I O N

Sandwich panels can be load bearing or non-load

bearing. Load-bearing panels eliminate the use of

perimeter structural steel frame and protection curbing.

Non-load bearing panels are used as cladding panels,

which are attached to a steel structure.

� Reduces HVAC System Construction Cost� Fewer Construction Trades� Fast-Track Construction = Quicker Turn-Key

D O W I N S U L A T I O N

A variety of options to choose from depending on

climate, location and building needs and requirements.

� High R-value for energy e�ciency� Tested in accordance with ASTM C578� Lowest water absorption possible, impedes mold� High compressive strengths

E N E R G Y E F F I C I E N C Y

� Consistent thermal control� Higher R-values due to "Mass E�ect"� Reduces HVAC loads� Eliminates moisture condensation and

frost build-up in freezers� Impedes mold growth� Interior space comfort - no cold spots� Reduces energy bills by as much as 50%� Continuous �ber composite connectors� Third Party Testing� Traceable Third Party Quality Control

Thermomass® FiberComposite Connectors

have the strength to carrythe long term loads of the

facia wythe with outthermal bridges.

Modular/PIP

Megablock™

Composite Panel

Non-Composite Panel

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F L E X I B I L I T Y

Tilt-up

Precast

Modular Precast

Poured in Place

SUPERIOR STRENGTHSandwich wall can be load

bearing or non-load bearing.

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L O W M A I N T E N A N C E

■ Withstands forklift and truck damage

■ Resists insects and vermin

■ Easily cleaned

■ Maximum Security Advantage

I N V E S T M E N T V A L U E

■ Longer building life

■ Lowers building maintenance costs

■ Fire and theft resistance lowers insurance costs

■ Continued ROI and energy cost savings

throughout the life of the building

■ Healthy Building – Impedes mold growth

A E S T H E T I C V A R I E T Y

The THERMOMASS® building system offers finishes ranging from natural

concrete, paint, sandblasting, exposed aggregate, as well as cast in brick

veneer, rustications and reveals. Our building system has been used in scores

of buildings that have received numerous design awards.

Drawings are sent directly from CAD to CNC to assure

there are no breaches in the insulation envelope by

providing a precision fit and taking the guesswork out of

foam and connector placement. This process dramatically

reduces the cost of installation.

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T E C H N I C A L D E S I G N A S S I S T A N C E

■ Determination of system compatibility with your project

■ Recommendation of design modifications to assure the integrity of the project

■ CAD generated panel layouts that simplify and speed up the construction process

■ CAD generated panel and joint design and construction details

DETAILS ON CDComplete architectural

details are available on CD in AutoCAD format.

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C O N S T R U C T I O N A S S I S T A N C E

■ Pre-Construction meetings

■ On site installation training and assistance

■ Ongoing project consultation

With our State-of-the-art analysis application suite, we can produce studies and testing

on the transfer of moisture, heat migration and humidity levels on panel wall systems. By

using these software applications, we can accurately predict reactions to weather from both

external and internal climate conditions. Our analysis application suite includes:

■ Isothermal analysis

■ Mass Performance analysis

■ Energy Efficiency and Cost Reduction analysis

■ Construction Cost Estimates and Building Life Cycle Payback analysis

■ Dewpoint analysis, Moisture and WUFI

■ Thermographic analysis

■ Finite Element analysis

A N A L Y S I S S O F T W A R E A P P L I C A T I O N T O O L S

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The THERMOMASS® System has undergone, and continues to undergo extensive third

party testing. Connectors have been tested for tensile strength, compression strength,

shear strength, fatigue and cyclic loads, low temperature stress, fire resistance and

flexure.

■ Our family of connectors has been tested to have pullout capacities in concrete

exceeding 5,000 lbs.

■ Our family of connectors possess shear capacities as great as 2500 lbs each.

■ The tensile strength of the composite materials used in our family of connectors is

up to 145,000 psi.

The connectors have been tested by a leading United States fire testing agency where

a panel constructed with THERMOMASS® fiber composite connectors was subjected to

1093˚ C (2000 ˚F) for 4 hours with no degradation. The temperature of the surface of the

wall opposite the fire rose only 20.8 ˚C (37.6 ˚F) during the testing period. The standard

for passing this test was 121 ˚C (250 ˚F).

The THERMOMASS® System has proven itself in the laboratory and in the field.

Institutions have verified the outstanding structural capabilities and energy efficiency of

the THERMOMASS® Building Insulation System:

Southwest Research Institute

TESTS:■ Tension and Shear ■ Fire ■ Pullout ■ Pullout Tests at Elevated Temperature

Iowa State University

TESTS:■ Effect of Elevated Temperature ■ Pullout Strength■ 100 Year Aging Alkali Resistance ■ Shear Capacity■ Compression Capacity■ Full Scale Panel■ Low Temperature Fatigue Behavior■ Connector Orientation■ Mechanical Properties

United States Department of Energy

TESTS:■ Steady State / Dynamic Studies

Architectural Testing, Inc.

TESTS:■ Full Scale Composite Panel – Pre-

stressed and Post Tension

Underwriters Laboratories, Inc.

TESTS:■ Fire

Construction Technologies Lab

TESTS:■ Sandwich Panel Flexural ■ Connector Fatigue

University of Kaiserslautern, Germany

TESTS:■ Panel Shear■ Pullout and Shear Capacity■ Tension, Shear and Combined

Tension/Shear■ Long-Term Shear/Creep■ Cyclic Tension■ 100 Year Aging Alkali Resistance■ Cyclic Shear

"We are committed to the total success of each project we encounter."

T E S T I N G

I N D E P E N D E N T T E S T I N G


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Korte Recreation Center

Tilt-up Construction is an economically efficient way of casting wall panels with the

THERMOMASS® System. Panels are produced on-site by using the building floor slab as the

primary casting surface. This eliminates the cost of transporting panels to the site plus it uses

local materials and labor.

First the exterior layer of concrete is poured and leveled. Then the pre-fabricated, pre-drilled

insulation sheets are arranged on top of the unhardened concrete according to the individual

panel drawings. The patented THERMOMASS® connectors are inserted through the pre-

drilled holes. After placing lifting devices, bracing inserts and required reinforcement, the

structural wythe is poured.

Once cured, these panels are lifted into place to form the building envelope. The high

strength of the THERMOMASS® connectors hold the sandwiched layers of concrete and

insulation secure during the entire process.

Tilt-up construction is used for all types of buildings including:■ Warehouse and Distribution Facilities■ Office Complexes / Shopping Centers■ Manufacturing Buildings■ Schools / Churches■ Correctional Facilities■ Freezers / Coolers


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M O D U L A R P R E C A S T C O N S T R U C T I O N

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■ Correctional Facilities■ Motels■ Schools■ Apartments

George R. Vierno Center on Rikers Island

Modular Precast Construction allows the opportunity to construct an entire facility,

room by room, in a quality controlled environment. There are never any weather-

related delays or problems. Individual sections can then be transported and erected

on-site.

Modular Precast Construction provides a continuous, fireproof enclosure that is free

of construction joints and is extremely secure. Composite Technologies Corporation

is the only producer of a vertical pour system featuring fiber composite connectors

for insulated modules.

A reinforcing skeleton for the modular unit is assembled and lowered into the mold

by a roof crane. Insulation with THERMOMASS® fiber composite connectors is

placed in the mold. After the walls have been cast the roof of the module is poured.

Finished modular units are then shipped to the construction site and assembled into

the final structure.

Modular Precast Construction is used in many types of buildings including:


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Vista Grande Community Church

The THERMOMASS® Poured-in-place technology (PIP) produces highly energy efficient,

load-bearing, insulated concrete walls. The patented fiber composite connectors and Dow

insulation eliminate thermal bridges that are often found in other poured-in-place methods.

The THERMOMASS® System allows for rapid construction and can use any forming system,

with or without liners. The state-of-the-art technology reduces on-site construction time and

the monolithic pour gives one step finished wall construction.

The THERMOMASS® Building System is prepared by inserting the patented fiber composite

connectors into pre-installed snap locks in the insulation. After the forms are set, concrete

is poured on both sides of the insulation, which results in a finished interior and exterior

concrete wall.

PIP construction with the THERMOMASS® system offers fire resistance, low maintenance

costs and protection against above and below grade pest infestation.

PIP construction can be used with virtually any type of building.


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Precast concrete sandwich wall panels are produced in a quality controlled factory

environment. Panels are produced using all the benefits of the THERMOMASS®

System and can be stacked and stored to await shipping to the construction

locations. This provides a controlled timely delivery system to the construction site

for easy assembly. Panels are available in a variety of designs including prestressed,

hollow core, double-tee, inverted waffle and architectural precast.

Precast panels are used in all types of buildings. The creative use and design of

panels make this an excellent choice for just about any shape and type of

construction. Precast panels with the THERMOMASS® system were used to construct

the Chicago Bulls Training Facility in Illinois and the Seattle Times Newspaper

complex in Washington state to name a few.

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Federal Bureau of Prisons Metro Center, Miami Florida

Photo courtesy of W

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Alvarez &

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TOLL FREE: 1.800.232.1748 LOCAL: 515.433.6075 FAX: 515.433.6088 www.thermomass.com

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Chicago Bulls Coors Dole

Anheuser Busch Mercedes / Benz Lowe’s

Miller Brewing Nordstrom Pepsi

Cook County Hospital Indiana Packers Cintas

US Postal Service Rikers Island Home Depot

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