The Insulating Concrete Forms Magazine

June/July 2006

Becoming an ICF Distributor

ICF Builder Competition

Castle in Connecticut

Window Details

The Insulating Concrete Forms Magazine

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Wall Finishes that Work

� ICF BUILDER

Inside This IssueFeatures11 Second Annual ICF Builder Awards

This popular “project of the year” competition is back again.

12 Project Profile: Castle in Connecticut Stone veneers, inside and out, turn this home into a showpiece.

16 Wall Finishes for Commercial ConstructionThis versatile, inexpensive finish is perfect for commercial ICF work.

20 How To: Window and Door DetailsWindow detailing tips that work for challenging architectural styles.

24 Becoming an ICF DistributorLeading manufacturers discuss what it takes to be successful.

Departments6 As I See It: Beauty Makes the Difference

7 ICF News Roundup

28 New Products

30 Green Building: Selecting Energy-Efficient Windows

32 Design Perspectives: Make Good Elevations Even Better

33 Coming Up

On the Cover: This museum and IMAX theater near Salt Lake City, UT, demonstrates the wide range of finishes that can be applied to ICFs. This issue’s special section on wall finishes begins on p. 12.Photo by Alan Murray

12

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11 PublisherSummit Publishing, LLC

Advertising ManagerCraig Shorts

Editorial DirectorClark Ricks

Art DirectorJason Robinson

ContributorsJim Eggert

Paul ForesmanJody GarrettPhil Loscoe

Alan MurrayKent Stumpe

Summit Publishing884 East 700 North

Mapleton, UT, 84664toll free: 877-229-9174

editorial: ext. 2sales: ext. 1

subscriptions: ext. 3fax: 801-494-3232www.icfmag.com

ICF Builder magazine is the sole property of Summit Publishing, LLC. Publishing schedule is bi-monthly: February, April, June, August, October, and December.Copyright © 2006 by Summit Publishing. All rights reserved. Printed in the USA. ICF Builder is a trademark of Summit Publishing.For subscription service or change of address, write to: ICF Builder Magazine, 884 East 700 North, Mapleton, UT, 84664. Please include your address label from a recent issue.Mail any correspondence about the magazine to: ICF Builder Magazine, 884 East 700 North, Mapleton, UT, 84664. Send story ideas and unsolicited manuscripts to the above address for consideration. Include a self-addressed, stamped envelope if you wish to have the materials returned.

� ICF BUILDER

Simply put, ICFs are one of the best building materials available. They’re durable, energy efficient, easy-to-use, and environmentally friendly. They do cost slightly more than stick frame construction, though, so ICF structures have to be marketed slightly differently.

Several months ago at the World of Concrete, I met an ICF contractor from Oregon who faced a daunting challenge. He was trying to get his construction business off the ground, but he just couldn’t trim his costs enough to offer ICF homes at the same price his competitors were selling wood-framed houses.

The solution, I told him, lay in helping potential customers see the value of ICFs. He was, in essence, trying to sell a Cadillac at Volkswagen prices, an effort that is doomed to failure, regardless of the industry. He needed to change his business model to attract customers

who understand quality, and are willing to pay a little more for it.

That’s where exterior finishes come in.

Real estate agents will tell you that “street appeal” is a major factor in how well a home sells. A quality home demands a quality exterior finish. It’s a lure that gets buyers out of the car and into the structure, where the benefits of ICFs

practically sell themselves. In this issue, we take a look at finishing options for commercial structures, a custom home with an unusual finish, and how to properly detail troublesome windows and doors.

Hopefully, this issue will help you increase the “wow factor” on your next job.

As I See It… by Clark Ricks

Beauty Makes the Difference

Real estate agents will tell you that “street appeal” is a major factor in how well a home sells. A quality home demands a quality exterior finish.

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Green Building Gaining in PopularityA new study by the National Association of Home Builders

indicates the green home building movement is “barreling into the mainstream.” Green Building refers to environmentally sensitive construction techniques and products that reduce energy and water consumption and improve residential comfort and safety.

“It’s a whole paradigm shifting thing that we are seeing with the general public,” says Fort Worth builder Don Ferrier of Ferrier Custom Homes. He claims that green building inquiries are coming in at 10 times the rate that they did even three years ago.

“It’s the huge wave of building that’s coming,” he says. “I don’t think there’s anything more satisfying than helping people achieve their dreams of building a home and to do it so it’s green, efficient, healthy and durable. It’s a great investment,” he said.

The NAHB study reports that there was a 20% increase last year in contractors who are focusing their attention on green building issues, and that this is expected to increase by another 30% in 2006.

“Green home building is at a tipping point among the builder population,” said Harvey Bernstein, vice president of Industry Analytics and Alliances for McGraw-Hill Construction. “Within 10 years, everybody’s going to be building green,” he says.

A final version of the report should be available within a few months, Bernstein said.

New ICF Brand hits the MarketAfter a decade

of manufacturing ICF blocks for others, Airlite Plastics has created their own brand of ICF. The Omaha, Neb.-based company is marketing the product under the name Fox Blocks.

The new ICF is reversible, pre-assembled, and will be marketed factory-direct to the installer, allowing contractors to purchase a high-quality, construction friendly block at a price lower than the competitors.

Airlite Plastics will mold both the ties and the forms to guarantee quality and cost savings. Airlite already has a reputation as one of the largest and best ICF molders on the continent; last year, they manufactured 10 million sq. ft of insulating concrete forms. The company is ISO 9000 Certified and the recipient of the 2003 Edgerton Award for quality.

Currently, Fox Blocks are available in 6” and 8” core sizes, with straight, 45°, and 90° corners. Brickledge, T-blocks, and taper tops are also available.

For more information about Fox Blocks, visit www.foxblocks.com, or email Dave Jackson at Dave@FoxBlocks.com.

Lumber Prices Set to FallThe Bush administration announced last month that it had

reached a tentative settlement to a bitter three-decade-long battle with Canada over softwood lumber.

Neena Moorjani, a spokeswoman for U.S. Trade Representative Rob Portman, said that despite some reservations, American lumber producers have “indicated a willingness to accept it.”

Canadian media reports said the deal involved capping Canada’s share of the U.S. lumber market at 34 percent. According to the reports, the United States agreed to return 78 percent of the $4.3 billion in penalty tariffs that had been imposed on imports of softwood lumber from Canada.

According to the reports, Canada would impose an export tax starting when North American lumber prices fall below $360 per 1,000 board feet of softwood lumber. The levy could go as high as 15%. The agreement also requires all parties to drop trade litigation and puts a moratorium on future trade complaints.

A similar agreement was reached in 2003, but fell apart after some provinces balked.

Immigration Reform Will Affect ConstructionThe biggest issue in politics right now is immigration reform,

and the results of that debate could radically alter the construction industry.

“If immigration reform doesn’t include a guest worker program and a program to address illegal immigrant issues, the home building industry could be in danger of losing a significant portion of its labor force,” says Michael Strauss of the National Association of Home Builders.

The NAHB estimates 20% of construction workers nationwide are foreign-born workers, and undocumented immigrants constitute a sizable share of that.

“They are productive workers and they are needed in our industry,” Strauss said. “An efficient and effective guest worker program should be created in order to stop the incentive for illegal immigration into the U.S.

The NAHB supports a “guest worker” proposal that allows immigrants to work legally in the U.S. “Obviously, these workers should be required to pay all taxes and other fees; in short, they should be held to the same standards as U.S. workers” Stauss says.

New Brochure For Commercial ICFsThe National Ready Mixed Concrete Association has introduced

a new promotion brochure to promote commercial ICF construction. The four-page publication is designed to inform owners, lenders, engineers, specifiers and others about the many economic and “green” benefits of ICF technology.

Developed through the NRMCA-sponsored Concrete Collateral

June/July 2006 �

ICF News Roundup

� ICF BUILDER

Working Group, this attractive and informative brochure outlines

ICFs’ many advantages, with helpful illustrations and appealing photos of

complete projects. A PDF of the brochure can be previewed at this magazine’s

website, www.icfmag.com. To order copies of the brochure, go to www.nrmca.org.

Quad-Lock Honors Distributors Quad-Lock Building Systems Ltd. presented awards to their most

successful dealers at the recent Team Quad-Lock Dealer Conference. Peter Townend, Quad-Lock, UK was presented the award for

International Sales. Townend oversees sales of Quad-Lock throughout the United Kingdom and Ireland.

Kevin Spaulding of Miles Supply in Barre, Vermont was presented the award for Eastern North American sales, and Don Tietz of Boise Cascade, Spokane was presented the award for the Western North American sales.

Mike and Robin Hanes of Northern Shores Enterprises in Caro, Michigan were presented the award for the Central North American sales. The Hanes’ have been very successful in positioning themselves as our premier dealer in this area.

Real and Lyne Gagne were honored as the best dealer in the Rocky Mountains/Prairie region. In addition to the regional award, Real and

Lyne were also named the top Quad-Lock dealer worldwide. “All of our dealers have made a major commitment to Quad-Lock

ICF” remarked Rhyno Stinchfield, Director of North American Sales for Quad-Lock Building Systems Ltd., “we are of course, particularly proud of these companies who help us to maintain our dominant position within the marketplace.”

For more information on Quad-Lock and its products visit www.quadlock.com, or call 1-888-711-5625. For more information on becoming a Quad-Lock dealer, see the story on page 12 of this issue.

Fossilcrete Purchased by ShastaFossilcrete, the leader in vertical concrete stamping, has been

purchased by Shasta Industries, an Arizona-based swimming pool design, manufacturing and construction firm.

Andy Blake, manufacturing operations officer for Shasta Industries, will oversee the new business segment. Business operations and some manufacturing will move to Phoenix, Ariz., with secondary manufacturing and all new product development remaining in Oklahoma City.

Stanton Pace, Fossilcrete’s former owner, will become director of new

product development and continue to provide technical assistance. Fossilcrete won the prestigious “Expert’s Choice Most Innovative Products Award” at the 2006 World of Concrete Show in Las Vegas, and is gaining popularity as an exterior finish for ICFs.

“Fossilcrete is an excellent product for ICFs,” says Blake, “and we will continue to serve that market. In fact, one of the reasons Shasta purchased the company is to expand the market and visibility of the finish both nationwide and eventually internationally.”

With the purchase of Fossilcrete, Shasta Industries also hopes to expand into niche markets of the decorative concrete industry. For more information, visit www.fossilcrete.com or www.xcelsurfaces.com.

NRMCA Accepts Contractors The National Ready Mixed Concrete Association (NRMCA) is

now offering membership to concrete contractors.“We welcome contractors as part of NRMCA,” said Association

President Robert Garbini. “Together we can do more for the benefit of the entire industry.”

By joining the NRMCA, contractors gain access to professionals in engineering, safety, codes and standards. Members also receive discounts on a variety of association publications and technical documents. Contractor membership costs $1,000 per year.

For more information, visit www.ncrma.org.

V-Buck Founder RetiresJustin Anderson, founder of Vinyl

Technologies and inventor of the popular V-Buck window and door bracing system, has announced his retirement.

Anderson started the company 12 years ago with his daughter and two sons to address the need in the ICF industry for better, simpler window and door bucks. Over the years, Vinyl Technologies has expanded and improved its

product line. It now can custom manufacture bucks of any window or door size for every ICF block on the market.

Audrey Anderson, marketing director at Vinyl Technologies, notes, “We have enjoyed this time with all of the challenges of starting a new business and joy of being successful. Justin has been instrumental in all of the process as both father and part owner. He has now determined that it is time for him to move on to his next challenge, retirement… We love and appreciate him for all he has done with the company and wish him all the joy in the future.”

Justin will continue to work part-time for the next several months to assist in the transition.

Arxx Promotes KennawMike Kennaw has been promoted to Vice President of Sales,

North America at Arxx Walls and Foundations. Kennaw has been with Arxx for more than 9 years, most recently acting as Vice President of Sales, West Division. He will be working with the Arxx Regional Managers across North America, and build new relationships with the Arxx distributor base in the Eastern states and provinces.

Based in Cobourg, Ontario, Canada, Arxx is a leading manufacturer of Insulated Concrete Forms (ICFs).

June/July 2006 �

10 ICF BUILDER

2006 Competition to be Better than Ever

The ICF Builder Awards are back again for a second year, and the 2006 contest promises to be even better than last year’s highly successful event.

Contractors, distributors, and ICF manufacturers are encouraged to submit projects for consideration. Simply fill out the notebook request form below, or download the Entry Form and complete competition rules, at www.icfmag.com. The website also contains a short video that illustrates the entry process.

Like last year, winners will be chosen in four categories: Light

Commercial, Heavy Commercial, Custom Home, and Residential Development. A “Best Overall” project will also be selected. Last year’s winning projects can be viewed online at www.icfmag.com.

The competition is open to anyone involved with ICFs, without restriction on form type, brand, or number of entries. Competition rules are the same as last year, although several minor

changes have been made to encourage participation. For instance, there is a discount for companies that enter more than one project. See the fine print below for complete details.

Judging will be based on a project’s size, difficulty, and architecture, as well as sustainable design features incorporated into the project. The complete judging criteria is printed below.

All entries must be received no later than Friday, Oct. 13, 2006. Winners will be announced at World of Concrete 2007, to be held Jan. 23-26, 2007 in Las Vegas. We look forward to seeing you there!

A W A R D S

Entry Notebooks: Notebooks can be downloaded at www.icfmag.com/awards/notebook. They can also be ordered by mailing or faxing the completed request form below to ICF Builder magazine.

Entry Fees: Cost is $90 (U.S.) for the first Entry Notebook submitted. Entry fee for additional Notebooks is $50 (U.S.) each)

Deadline–Entry Notebooks must be postmarked no later than Friday, October 13, 2006. No Notebooks will be accepted after this date. Entry Notebooks without payment will not be considered.

Categories–Projects must use Insulating Concrete Forms (ICFs) as the primary construction method. Awards will be given in the following categories.

Light Commercial: This category encompasses all commercial construction projects with a total cost of less than $5 million (USD). Typical projects in this category would include car washes, warehouse space, restaurants, gas stations, and small retail, office, and multi-family complexes.

Heavy Commercial: This category is for

commercial construction costing more than $5 million (USD) to construct. This would include most hotels, cinema multi-plexes, large office and retail buildings, as well as major apartment, condominium, and resort-style developments.

Custom Home: Probably the largest category in terms of number of entries, this is reserved for single-family residential buildings and accompanying landscaping work. (i.e. A detached garage or shop and retaining walls made from ICFs should be included as part of the project.)

Residential Development: This is the category for any contractor building multiple ICF homes in the same development. Projects in this category are eligible if “Phase I” of the development is complete. Typically entrants in this category are developers building entire neighborhoods from ICFs.

We retain the right to re-assign a project’s category if specifications show the project is inappropriate for the category in which it is competing.

Photography Requirements–A minimum of 5 and a maximum of 20 photographs shall

be submitted with each entry. These photos should illustrate the project’s ability to address each of the judging criteria mentioned above. Each photo must be at least a 5 x 7 print or if digital, at least 5 x 7 in size at 300 dpi (digital is encouraged; see below).

All digital photography should be sent on CD or DVD to the attention of Clark Ricks, Editorial Director of ICF Builder magazine at the address below. Prints and slides will be returned only if accompanied with a self-addressed, stamped envelope.

Digital Photos vs. Prints or Slides –Digital photographs are convenient, easy to duplicate, and can be distributed to the judging committee with very little hassle. However, it is only acceptable when the size and resolution of the image is sufficient.

It is essential that images are provided in high resolution format. Since most digital cameras default to 72 dpi, unless you are confident that you can adequately change the settings, stick with a traditional film camera for your submission. Use a high quality (low compression) mode if stored as a jpeg file

(minimum quality 8). Prints and slides from film can always be scanned and modified to meet the needed resolution.

Judging Criteria–The project will be rated on a scale of 1 to 10 (10 being the highest) in each of the following categories based on how well it meets the criteria.

1. Size of the project (Project cost and square footage of exterior walls) 20%

2. Complexity (sets new standards or advances the industry) 15%

3. Percentage of project built with ICFs 10%

4. Sustainable Design (Structure and Landscaping) 15%

5. Energy Efficiency 10%6. Architecture (Creative and Aesthetic

Appeal) 10%7. Quality of Craftsmanship 10%8. Site and Construction Considerations

(Overcame adverse site conditions or delays) 10%

Additional Information: If you have questions or need additional information, email Clark Ricks at editor@icfmag.com.

Second Annual

12 ICF BUILDER

As a design/build custom home contractor based in Connecticut, I get opportunities to work on homes in the Northeast that have unique features.

This project started out like so many others; my client wanted to use ICFs for the usual benefits: energy efficiency, strength, quietness and a reasonable interpretation of green building practices. I selected Standard ICFs, based in Oronoco, Minn., for the project and began working my way through the specifications.

I was well underway with developing the construction documents when the client casually mentioned they really wanted a stone castle, complete with tower.

Stone veneers are becoming available at many local supply yards at a price that’s affordable for clients who want the classic look of stone without the high installation cost of the real thing. Manufactured stone is lighter than natural rock, and the ability to use manufactured stone without the foundation preparation required of real rock is a major reason to offer this product to your clients.

There are still real stone choices and applications that may never be replaced, but after using some of these manufactured stone products for everything from wall accents to fireplace surrounds to this project, I’ve become a convert.

What started out as a few stone accents on the front elevation turned into a man-made stone castle requiring 4,300 sq. ft of stone

veneer products. Not only was the complete exterior manufactured stone veneer, but we also decided to cover three interior walls of the Great Room, which stood 13’ to 18’ feet tall, and would be visible from the second floor overlook.

Well, after some design modifications, it was time to match up a manufactured stone with the ICFs. For this project, we needed real samples instead of pictures in a brochure so we visited a few masonry supply companies. We whittled our selection down and finally decided on Boulder Creek Stone Products of Minneapolis, which offered the pattern and coloring we wanted.

Several installation issues came up as we prepared for the stonework part of the project. After we installed the massive 12’ high Gothic windows, we fastened galvanized steel mesh on the ICF walls for the scratch coat.

We wanted to roughen the wall surface with one of our special flat foam rasps and skip the metal lath, but the manufacturer nixed that idea for the exterior. They indicated that it was a method acceptable for interior surfaces, but the way it was said caused us to use the mesh everywhere.

We brushed the EPS walls with a stiff broom before installing the mesh because once the walls were exposed for awhile, they developed a dust coating from UV degradation.

We had to special-order galvanized screws with a larger head to hold the mesh

Builder shows the beauty of manufactured stone on this custom ICF home Story and Photos by Jim Eggert

onto the ICF walls because regular galvanized drywall screws wouldn’t work. You can’t buy these type of screws at your local hardware store except in little one or five pound boxes, so you want to plan ahead. We ended up ordering three times and used around 40,000 screws.

Installing this stone veneer also required a different technique; it was installed from the top down. This was a foreign approach to us, but after awhile we got used to it. The main reason is so you keep the stones as clean as possible because they won’t take much abrasion from cleaning brushes. It helps to grout as you go before you move or lower the staging. We had winter conditions for a period but by tarping the staging we kept the heat on very low overnight and had no problems with freezing. A few stones that fell off from one area did so because the Type S mortar mix got too dry toward the end of the day; I recommend adding Acrylic 60 admixture solution to the mortar mix which makes it stickier and helps lengthen the working time of the mortar. The randomness of the stones provided a nicely crafted wall and we also purchased pre-made corner stones. These we used around all the windows as well as building corners. The sills were made from cut and fire-popped stone, selected to compliment the wall colors.

I believe that builders who are not even offering ICFs are missing a chance to create a niche market for themselves. A small

June/July 2006 13

The Exclusive Standard ICF™

Modified Flat Wall System is flexible and conforms to a wide variety of standard design and building practices. The strong modified flat wall form design prevents racking, withstands concrete pressure, and minimizes bracing requirements.

The project was nearing the end of the design stage when the client casually mentioned they really wanted a stone castle, complete with tower.

What started out as a few stone accents ended up requiring 4,300 sq. ft of stone veneer products. It covered the entire exterior as well as three interior walls of the Great Room, with walls reaching 18 feet.

contractor can do his own ICF projects and sub himself out to others just for the ICF portion.

It is misguided thinking that doing this for another contractor is affecting your own business. If anything you will improve it by being in the forefront and providing services which will put your company in demand.

In years past when you discussed ICFs, you’d get a blank look. Now, as more and more people have been exposed to ICFs and also other building systems, these “better” ways to build are becoming mainstream.

This is technology you can grow with!

Jim Eggert is owner of Eggert Construction LLC, a Connecticut Design/Build contractor that has worked with ICFs for the past 10 years. Prior to founding his own construction company, he spent nearly a quarter-century as a commercial superintendent and project manager. To contact Jim, visit www.ConnecticutCustomHomeBuilder.com or call 203-���-�11�.

1� ICF BUILDER

Ceilings and walls are sheathed with tongue-and-groove pine, Window sills and stair treads

are made from local rough-sawn hemlock.

Commercial construction is by far the fastest growing sector of the ICF industry. Analysts estimate commercial ICF use is growing two or three times more quickly than the rest of the industry, and will continue to do so for the foreseeable future.

ICFs will accept nearly any finish desirable, including brick, manufactured stone, and cement or vinyl siding. But by far the most popular exterior finish is the “acrylic stucco” more properly called Textured Acrylic Finish Systems (TAFS) or Textured Acrylic Surfacing Systems (TASS).

TAFS offer the architect, builder, and owner the same advantages ICFs do. Both are durable, energy-efficient, and economical. They are also simple to use, widely available, and may shorten construction timetables.

Because of these advantages, TAFS have been used on virtually every type of commercial project imaginable: retail centers, low-rise office buildings, hospitals, universities, resorts, apartment complexes, churches, and even large high rises.

Design AdvantagesThe variety of colors and textures

available with TAFS is vast. “If you ever run through our catalogs, you’ll see that we can achieve any look you can possibly think of,” says Derick Wiaderski, senior staff architect for Dryvit Systems. “TAFS can be finished to resemble granite, brick, limestone, traditional stucco, even aged Italian plaster.”

“We do color matching as well. If you send in a chip, we can match it at the factory and send you the product, premixed and ready-to-go, with no variation in color,” he says.

Kent Stumpe, director of marketing communications at Degussa Wall Systems and member of the ICFA’s board of directors, lists the reasons TAFS are a perfect match for ICFs. “Color selection, variety of textures, integral designs, aesthetics that are economically attainable, and it complements other claddings.”

One of the most unique advantages of TAFS is that it can accommodate all sorts of integral designs. Shawn Kashou, lead architect at GreenTech, says, “You can make any shape in the foam, any thing you can do with stucco, but it’s a stronger material, and it’s easier to use.”

The bas-relief dinosaurs on the outside of the Museum of Ancient Life near Salt Lake City, Utah, are an extreme example. A more common example are the built-up cornerstones, or quoins, on light commercial structures.

Construction AdvantagesIn addition to design flexibility, the

coating system offers jobsite advantages as well.

TAFS is perhaps the easiest cladding to apply to an ICF wall. It is self-leveling, self gauging, and adheres readily to the ICF.

“Basically, you’re just troweling a finish over the existing veneer,” says Wiaderski. “It’s the same as an EIFS application but the foam is already in place. With many of the other choices out there, there is much more field work that needs to be taken into consideration.”

That ease of application translates into higher production rates for crews. “Experienced and organized crews reach high production rates,” confirms Stumpe. “It’s possible to apply base coat one day and finish the wall the next.”

And if the wall features unusual details, such as the integral designs discussed earlier, those advantages become even more marked. “Nothing else gets close to the economy of adding acrylic coated shapes and detailing,” says Stumpe.

Maintenance AdvantagesEven after the building is completed, a

TAFS exterior will provide benefits for years to come. “There’s an element of reduced maintenance because it’s a permanent finish,” says Mike Meierer at Grailcoat. “It’s a long-lasting breathable, waterproof, flexible coating.”

for Commercial Construction

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Meierer says, “Our product was used on the World Trade Center in Los Angeles when it was built in 1972, and there are no cracks after more than 30 years.” He admits that the building has been painted, but other projects and other brands of TAFS finishes can boast of similar longevity.

One of the reasons the finish is so crack resistant is because its acrylic composition keeps it flexible even at low temperatures. Also, the EPS foam doesn’t move with temperature changes, and helps insulate the finish from thermal shock.

“You could apply 39,000 sq. ft of TAFS without an expansion joint because it just doesn’t expand,” says Dean Seibert.

For a highly impact-resistant finish, consider using a heavyweight mesh on first-story walls. Degussa’s high-impact and ultra high-impact mesh provides protection from abuse in excess of 200 inch-pounds of force.

PermaCrete claims to have a compressive strength of over 6,000 psi, and is ICC

approved for both vertical and horizontal finishes.

Also, primers can improve durability. They reduce the possibility of efflorescence, and alleviate “shadowing,” slight changes in the color of the finish due to dry times. Primers, like the finish, are available in any color.

Environmental AdvantagesTAFS is an excellent choice for builders

and designers concerned about energy efficiency

and sustainability. It can reduce energy costs and will contribute to LEED certification.

Here’s why: For TAFS to work, the foam substrate must be exceptionally tight. The entire exterior must be covered in EPS, including any framed portions of the building, and all gaps larger than 1/8” must be filled. This creates what Stumpe calls a “monolithic blanket of insulation.” The acrylic base coat finish further reduces air infiltration.

June/July 2006 1�

Textured acrylic finishes are durable, easy to apply, and remarkably adaptable. Acrylic finishes can also imitate granite, brick, limestone, or traditional stucco.

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Practical ConsiderationWith all the installation and performance advantages TAFS offer, the finished look of

the building is paramount. Whether the final look is one of brick, stone, plaster, or stucco, the color and texture

of the finish should match the style of the building. Stumpe says designers and building owners should be aware that dark-colored

finishes contain more pigment, and will fade more noticeably than lighter shades. TASS manufacturers are also careful to alert designers that dark colors reflect less light and can contribute to heat build up on and in the wall that can melt the underlying EPS insulation.

Kashou, the GreenTech architect, says, “The scale of the building should really determine the finish. If the finish will usually be seen from a distance, use a coarse finish. If the finish will be seen up close, use something smoother, like a sponge float finish.”

There are, however, practical considerations for texturing. Imperfections in the base coat are difficult to hide with smooth finishes. A “worm-holed” or rilled appearance is more forgiving of blemishes, and the most forgiving are the coarse finishes that use large aggregates.

Textured Acrylic Finishes and Insulating Concrete Forms are a great match, especially for commercial construction. TAFS complements the energy-efficiency and durability of ICF walls, and is one of the easiest and most cost-effective finishes to apply.

The wide variety of colors, textures, and looks that can be achieved with TAFS means that one of them will probably be right for your project.

June/July 2006 1�

This dinosaur museum, built out of ICFs, highlights the flexibility of acrylic finishes. The building

entrance uses a variety of colors and textures to simulate the layers

in the earth’s crust.

The TAFS finish on the San Marcos Mall in Texas draws visitors for hundreds of miles. Designers used Dryvit’s Tuscan Glaze on

sculpted EPS foam to recreate the look and feel of old Venice.

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20 ICF BUILDER

How To…

Textured Acrylic Surfacing Systems (TASS) are perhaps the most popular exterior finish for ICF construction. They are easy to apply, relatively inexpensive, and available in a wide range of colors and textures. But getting the details right—especially around windows and doors—can present challenges in the field.

TASS are often incorrectly called “stucco,” or “EIFS” (Exterior Insulation Systems), but there are significant differences between these systems. True stucco is a mixture of cement, sand, and lime, and must be applied over metal lath. It

is quite thick—3/8” to ¾” is common—and is much less flexible that TASS.

EIFS more closely resembles TASS, since both are applied over Expanded Polystyrene (EPS) foam. However, on EIFS walls, the EPS is non-structural and non-load-bearing. Additionally, EIFS walls often contain moisture-sensitive components, such as wood studs and sheathing, which can create problems when cracking occurs.

EIFS has endured an undeserved bad reputation, ever since a 1995 study of 100 homes with EIFS in Wilmington, North Carolina found that a significant portion had moisture damage.

This same study found that nearly half of all moisture-related problems could be traced to improperly detailed windows. ICFs, of course, have a negligible sensitivity to moisture, but that doesn’t mean it’s not important to detail windows correctly. For instance, nearly all visible cracking in acrylic finishes can be traced to poor detailing. T h e key to avoiding cracks and the problems they can create, is to ensure that your windows and doors are detailed correctly.

Structural StressCracks are caused by a number of

factors; most can be traced to structural or thermal stress.

Differential settling is a common cause of structural stress. One part of the building settles faster than another—like one end of the foundation, or one side of the window header. The resulting stress will cause cracking at the weakest part of the wall, which is usually a window or door opening.

Cracks that run vaguely perpendicular to the opening are almost always caused by structural stress.

One solution, says Kent Stumpe, director of brand strategy and communications at Degussa Wall Systems, is to use extra mesh. In addition to the regular trim mesh used around the windows, place an extra piece over each corner at a 45° angle.

“Window corners are an area of stress and movement,” says Stumpe. “Without the double reinforcement, cracking is likely.”

Thermal StressAll objects expand when heated

and shrink as they cool—driveways and sidewalks have expansion joints to accommodate this movement. The problem is that every material moves differently as the temperature changes, so when TASS are applied over two different materials, this movement is powerful enough to crack the exterior finish.

“Vinyl or wood will expand or contract considerably,” says Dean Seibert, of Wind-Lock. “But the coefficient of expansion for EPS is almost zero. So if you apply your finish over dissimilar substrates, cracking is going to occur.”

Bruce Anderson, general manager for Vinyl Technologies, which makes the Vbuck, agrees. “It’s not a Vbuck issue,” he says. “It’s

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June/July 2006 21

a dissimilar materials issue.” Incidentally, thermal cracking can

occur anytime TASS is applied over dissimilar materials, such as on ICF blocks with exposed ties. The plastic tie will move more than the surrounding foam and eventually cause the finish to crack. It can also occur in areas where local building codes require a “concrete inspection strip” on the exterior wall 6” to 8” above grade. The concrete moves, the foam doesn’t.

Fortunately, an easy solution exists that looks good and is fairly foolproof.

“The easiest solution is to install aesthetic bands around the window,” says Derick Wiaderski, senior staff architect at Dryvit Systems. “By installing EPS trim around openings, you’re covering the dissimilar materials, which will keep the finish from cracking,” he says.

This trim around windows and doors is extremely popular in most areas, and is the only guaranteed way to avoid cracking due to thermal resistance.

The “pop-out” or trim pieces are attached to the ICF blocks with specialized screws. Wind-Lock’s “Wind Devils” are by far the most popular. They come in a variety of lengths with large, 2”- diameter nylon baskets near the head to hold the foam in place.

“It’s crucial that the heads of the fasteners are beneath the surface of the foam,” says Seibert. “TASS and EIFS coating are resilient, and if the fasteners aren’t recessed, you’re going to have cracking.

Difficult ApplicationsIf your building plan or architect

requires the TASS finish to extend flush to the window flange, detailing just got a lot more complicated. Sometimes called the “New Mexico,” “Spanish Colonial” or “modern” style, this look presents numerous challenges.

The problem, of course, is that it will probably involve bridging dissimilar sub-strates, which will inevitably create cracks.

Anderson calls it “one of the last unsolved challenges of ICF construction.”

“It really is a very difficult problem,” he says. “When homeowners want a nice smooth finish on the ICFs, we can’t warranty it, because there are two dissimilar systems—wood or vinyl. Have there been any installations? Yes, it happens all the time. But it invalidates the warranty because it will crack.”

EPS window trim is the best way to avoid cracking due to thermal resistance.

Option 1: One solution is to use an ICF brand that offers EPS endcaps and lintels, such as Smartblock, Greenblock, or IntegraSpec. By forming the openings with foam, the dissimilar materials issue disappears.

Option 2: Other solutions also exist. Wind-Lock, Dow, and others sell a butyl-based, cloth-backed tape that claims to reduce cracking, although none will guarantee

it. “We always caution buyers about the aesthetic cracking,” says Seibert.

Called transition wrap, the tape is applied over the dissimilar materials to help absorb some of the movement. “The tape has a high modulus of elasticity,” Seibert says. It stretches to three times its thickness.

“What you’re trying to do is to get it to move all at once. And when there’s a hairline crack, it prevents the water from migrating

into the building around the window,” he says.

Option 3: A more reliable solution is to use “internal” window bucks. By recessing the wood into the concrete cavity, the builder has shifted the area of thermal stress to the inside

of the wall where movement won’t affect the finish. For this approach to work, the window must be installed close to the exterior of the wall, where the flange can cover the transition from foam to window buck.

David Bowen, supervisor, in-house technical services at Degussa Wall Systems, says, “Our standard recommendation is a flange. There are questions about the long-term adhesion of transition wraps. We haven’t tested it, so I can’t verify or deny. I just don’t see it lasting long term.”

Bowen admits that there will be some movement between the EPS and the window

These before-and-after photos show how foam was used to detail

the complex window openings of this colonial-style home.

22 ICF BUILDER

flange, which can be reduced by installing a foam band between the window and the buck.

Anderson, at Vinyl Technologies, cautions that internal bucks may allow termites to tunnel into the structure, since the finished window bridges the gap from exterior foam to interior finishes.

Option 4: A final suggestion is to use an acrylic finish that adheres well to the buck material and is flexible enough to absorb the movement. At least two such products are on the market. Grailcoat is a genuine concrete coating that offers an incredible degree of flexibility and adhesion. “A lot of products don’t stick well to vinyl, says Mike Meierer, technical director at Grailcoat, “but our product adheres better, and can go right to the flange. Our combination of different sizes of aggregates allows it to fit tighter together, and the polymer gives it the flexibility.”

GreenTech, maker of TruWall finishes, also claims to be able to bridge dissimilar substrates without problems. “If you want the finish to be flush—a modern or simpler look—you can apply TruWall without any problems,” says Shawn Kashou, lead architect

at GreenTech. “We recommend applying the finish before installing the window, and installing wire mesh in the corners of the openings to reinforce. Installed correctly, the product has experienced no cracking.”

Wiaderski, the staff architect at Dryvit, cautions that manufacturer warranties typically don’t cover cracking. “The thing you have to realize is that the warranty is on the finish. The form manufacturer is

responsible for the warranty on cracks.” Bowen, at Degussa, points out that it’s

possible that even if the lamina does crack, the damage may only be aesthetic. “With ICFs and moisture issues, it’s a whole different ball game because the wall components are not as moisture sensitive as they are with stick frame.”

Just one more reason ICFs are a better building technology.

June/July 2006 23

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2� ICF BUILDER

As the demand for durable, energy-efficient housing and office space has increased, ICF use has skyrocketed. This rapid growth has created business opportunities at all levels of the industry, but many entrepreneurs have found the greatest success in the middle of the supply chain as form distributors and dealers.

“If you’re willing to work hard, and you market accessory products in con-junction with the foam, you’re going to see above average profits,” says Eric Williams, national sales manager at BuildBlock Building Systems.

Market growth means there’s still plenty of opportunities available. Most companies interviewed said that even with dozens of dealers being trained this year, they are still far short of achieving the market coverage they want. (See the sidebar “Dealerships Available” on the left to discover nearby opportunities.)

Necessary SkillsDave Watson, national sales manager at

American Polysteel, estimates about half of his distributors were formerly contractors. The rest have backgrounds in business, marketing, or sales.

But distributors with other backgrounds can be successful, too. “It’s hard to pinpoint a typical distributor,” says Rhyno Stinchfield, Director of North American Sales for Quad-Lock Building Systems. “I think that of all our distributors, I could only get 4 or 5 to fit into any one classification.”

Many ready-mix concrete suppliers have discovered that an ICF distributorship fits well with their existing business, and has generated significant profits. Some regional building supply centers have experienced similar results. On the other end of the spectrum, many of the most successful dealerships are husband-and-wife teams. “In some ways they [smaller dealers] get more exposure, because they’re out there hustling 24-7,” says Stinchfield.

Quad-Lock recently honored the husband-wife team of Real and Lyne Gagne of Grande Prairie, Alberta, Canada, as their top distributor worldwide. Mike and Robin Hanes, another husband-wife team, have positioned themselves as a leading distributor in the highly competitive Michigan market.

“The most important thing is that they have to understand the industry and have a passion for it,” says Stinchfield. “If a general manager comes and says we’ll take it on, and the salesman don’t have any excitement for the product, it won’t move.”

Williams agrees. “The first and foremost quality is, ‘What have you already done in the ICF industry; are you familiar with the ICFs.”

“This industry is growing but still has tons of work to do to educate builders, homeowners, architects etc., and that takes enthusiasm and passion.” says Sherri Bebee, marketing director at Arxx. “It all comes down to how much fire they have in their belly.”

The ideal distributor is not a category, says Bebee, “He’s a person with a passion for Arxx who proactively communicates that throughout his community...That

person could be at a lumberyard, a ready mix company or an entrepreneur.”

CautionsMany manufacturers say that some of

their most successful distributors have a contractor background, but contractors who are considering becoming distributors just to obtain better pricing are in for a shock.

Most of the largest companies won’t let contractors become distributors at all.

The reason? “It’s basic Economics 101,” says Williams. “Contractors have disincentive to sell blocks at a good price to their competitors, and buyers are never sure they are receiving the best value.”

“A contractor will not buy from a contractor,” agrees Stinchfield. “They’ll pay more to buy from a dealer, because they don’t want to give money to their competition.”

“If a contractor is truly interested in becoming a distributor,” says Watson, “we require an exit plan to get out of the [contracting] business or they have to set up a completely separate company.”

Many programs allow the same indi-vidual to own both a contracting firm and a distributorship, but all transactions have to be made at ‘arms-length.’ That means you’ll be buying block at the same price as your compet-itors—and running two separate companies.

by Clark Ricks

Make sure you have ample space to warehouse the forms, bracing,

and other materials dealers are expected to keep in stock.

The most important thing is to understand the industry and have a passion for it. The amount you make depends on how much effort you put into it.

June/July 2006 25

What it TakesStill interested? Regardless of which ICF

brand you choose to work with, expectations for new dealers are fairly similar. You will be expected to provide what Williams calls “value added services and materials.” That means inventory, expertise, and outstanding customer service.

Inventory: A good inventory and warehouse space is basic. “Contractors don’t want to wait for a week for their forms to be shipped across the country,” says Stinchfield. “They expect the dealer to have extra supplies if they’ve miscalculated and come up short, or they’ll want to return stuff if it’s unused and still in good condition.”

Most programs also expect dealers to carry a good selection of accessories as well. Watson explains, “Starting out, we require them to have on hand an inventory of forms, a bracing package, and the accessories used in ICF construction—hot knives, rebar cutters/benders, etc.—or if they don’t stock it, to have it readily available. Ideally they will stock accessory materials, bucks, waterproofing, windows, and exterior finishes. All of those provide additional profit opportunities for the dealer.”

Stinchfield adds, “The more mainstream builders that get into ICFs, the more they’re going to expect that level of service, the same that they’ve been getting from the local lumberyards.”

Technical Support: A second common requirement is the ability to provide local, on-site expertise. “They can’t be a drop-and-run dealer,” says Stinchfield. “Every dealer needs

Contractors expect building materials to be delivered to the jobsite. This truck is usually busy hauling supplies in the Reno, Nev. area.

2� ICF BUILDER

Opportunities Available The ICF manufacturers below are currently seeking distributors in select areas:

American Polysteel www.polysteel.com • 800-977-3676 See ad on p. 25

Amvic Building Systems www.amvicsystem.com • 877-470 9991 Alam Suleman All regions in Canada and the US See ad on p. 27

Arxx Building Products www.arxxwalls.com • 800-293-3210 Mike Kennaw All regions in Canada and the US See ad on p. 17

BuildBlock Building Systems www.buildblock.com • 866-222-2575 Eric Williams • All enquiries welcome See ad on p. 21

E-Rated Walls www.hobbsbuildingsystems.com 515-720-1252 Andrew Hobbs • All regions See our ad on p. 29

Lite-Form Technologies www.foldform.com www.liteform.com • www.litedeck.com 800-551-3313 • Wayne Fenton Select Regions in the U.S. and Canada See ad on p. 31

Quad-Lock Building Systems www.quadlock.com • 888-711-5625 See ad on p. 15

Reddi-Wall www.reddi-wall.com • 586-752-9161 See ad on p. 18

Standard ICF www.standardICF.com • 800-925-3676 See ad on p. 13

In addition to these ICF manufacturers, many other advertisers in this magazine are also seeking distributors for their products. They can be contacted directly through the phone number on their ad.

a product champion that knows the product very well. He provides training, visits job sites, and answers whatever questions arise.”

Watson advises small dealerships to separate the roles of business manager and technical expert. “We like our distributors to have installer resource,” he says. “What happens is that a guy will sell two or three projects, but he doesn’t keep the pipeline full. They really need to have somebody else that can visit the jobsites and do the training so that they [the dealer] can concentrate on selling and promoting the business.”

Outstanding Service: “Here’s the bottom line,” says Stinchfield. “Somebody has to act as the dealer. Shipping in from far way, you never have the right amount. You have to have local training; you have to have a technical expert. Usually they’ll want someone there for the pour and to answer questions as the job progresses. You have to commit to cover the territory and to do so on short notice.”

Manufacturers also expect a realistic business plan, financial stability, and a commitment to stick to pricing guidelines.

Program DifferencesForm makers generally have high expectations of their

dealers, but they are also very committed to helping them succeed. National sales managers travel thousands of miles every month to teach new distributor seminars and offer individualized help. Companies produce high-quality marketing brochures and technical bulletins. They spend tens of thousands of dollars annually to promote the product through trade shows and national publications like this one.

Every company has also developed specialized tools to help their distributors succeed.

American Polysteel, for instance, has developed specific programs to help distributors market ICFs to commercial contractors, custom home builders, owner-builders, and architect/designers. They also provide an in-house financing program. Like Quad-Lock, they provide dealers with protected territories if they meet certain annual volume requirements.

Arxx does not offer protected territories, but their training and support are legendary. “The Arxx system, Arxx representatives [and] Arxx educational seminars [were] a complete support team that could be relied on,” says Ron Albright of Hanover Concrete, a Pennsylvania ready-mix and ICF dealer.

BuildBlock has devised a complex, five-level system that gives distributors better wholesale prices and other benefits as sales volumes increase.

Every dealer needs a product champion. He provides training, visits job sites, and answers whatever questions arise.

June/July 2006 2�

BuildBlock is one of the few companies that will sell factory-direct to qualified installers. Nearly every other brand requires them to go through the local distributor. “We miss some sales because of that,” says Watson, at Polysteel, “but we’ve made a commitment to the distributor.”

The ProcessThe process of becoming an ICF distributor is fairly

straightforward: Find out which manufacturers have dealer opportunities in

your area and contact those you are most interested in. The sidebar on pg. 26 lists some of the manufacturers currently looking for distributors, with their contact information and website.

The company will probably send you an information packet outlining the company, the ICF industry as a whole, and the requirements for becoming a distributor. If you meet those requirements, fill out the application and send it in.

The company will review your application in a timely manner. They may also conduct a credit check or ask for additional information. If you qualify, the company will contact you to work out your assigned territory, give you pricing details, and sign a distributor agreement.

At some point during this process, usually after the agreement is signed, you will receive in-depth, dealer-specific training to help you get your new business started off right.

That training—combined with business knowledge, construction skills, and the willingness to work hard—is a solid recipe for success. “The amount you make depends on how much effort you put into it,” says Williams.

Most manufacturers expect dealers to keep at least one or two truckloads of ICFs on hand at all times.

As mainstream builders get into ICFs, they’re going to expect the same level of service they’ve been getting from local lumberyards.

2� ICF BUILDER2� ICF BUILDER

Quadlock Introduces Two New TiesQuad-Lock Building Systems

has released a new brick ledge tie that allows contractors to easily construct this popular feature. First seen at the World of Concrete, the new tie can be used to create a concrete ledge for brick or stone, or as an interior support for floor

joists. The tie transitions from a 12” cavity to a 6” one, leaving a 3 ¾” solid concrete supporting ledge, plus a 2 ¼” high density foam panel capped by a galvanized steel track.

Quadlock’s new Extender Tie will allow builders to create walls of almost any desired concrete thickness. Extender ties are designed

to interlock with regular Quadlock ties to add exactly 12” (305mm) to the concrete cavity width. Multiple Extender Ties can be combined to create concrete cavities larger than 24”. For more information on Quad-Lock and its products visit www.quadlock.

com, email info@quadlock.com or call 1-888-711-5625.

New Footing System Saves Time, MoneyThe Jiffy reusable steel footing

form saves time and money while improving quality and safety in ICF foundation work.

Jiffy forms allow the builder to pour the footings and ICF walls simultaneously, eliminating the cost of a pump truck, or about $500 per job.

Inventor Jim Spartz says it is also very easy to correct the footing after the first two courses of ICFs are placed. The builder can make a simple up or down ½” adjustment in minutes to insure a perfect wall system after it is poured.

Neal Lesmeister, a Minnesota-based concrete contractor, has built more than 20 buildings over 3 years and says he’ll never go back to wooden forms again. He says Jiffy forms create a wall perfectly centered over the footing, and says he saves time on set-up as well.

Architects and inspectors like the Jiffy forms because there is no cold joint on the footing, creating walls that are not only stronger and more waterproof, but also avoid the danger of exposed vertical rebar sticking out of the footings.

A set of forms comes with 45° and 90° corners and can create any length or width wall. Wall braces fit right on to the steel forms for quick set up. A video of how the system works is available at Weathershieldhomes.com. For additional

information, or to request a DVD, call 1-800-123-4567 or visit the aforementioned website.

New Windlock CatalogWind-lock, a leading supplier

of tools and equipment for the ICF industry, has published its 2006 catalog. The new book includes illustrated instructions for using the Wind-lock Hot Knife, Groove Tool, and Foam Gun.

Illustrated with color photographs and diagrams, the catalog includes important technical data, dimensions and pricing information for ease of ordering.

In addition to hot knives, cutting tips, and foam guns, the company also sells mesh, screws, trowels and other equipment for applying exterior finishes to ICF walls.

To request a copy of the 2006 catalog, call 1-800-872-5625 or visit www.wind-lock.com.

Backpack Vibrator from STOWSTOW Construction Equipment’s new backpack vibrator

is perfect for ICF construction. The compact system allows contractors to carry the unit around the jobsite—or on scaffolding—without the inconvenience of dragging electrical cords that can become tangled.

The lightweight, flex-shaft BP25H is ideal for medium- to high-slump concrete applications,

including footings, stem walls, and ICFs.Powered by a 2.5-hp Honda

gasoline engine, the unit weighs only 24 pounds (11 kilograms). The

backpack vibrator is compatible with eleven heads —

seven steel and four rubber

— ranging from 7/8” to 2¾” (2-

7 centimeters) in diameter. Flexible shafts are from 2 to 21 feet (2/3-7 meters) long.

For more information, call 877/BUY-STOW (289-7869) or visit www.stowmfg.com.

New Products

June/July 2006 2�

New Brace for V-BucksVinyl Technologies

Inc. has improved its corner bracing system, replacing the stamped steel braces of various sizes with a stronger, lighter V-Brace. Made out of ABS (acrylonitrile butadiene styrene), the 18”x18” V-Brace can be combined with the Yoke & Tie to brace virtually any window opening.

The ABS brace is far lighter than the old galvanized bracing and is ten times stronger. Based on a “king truss” configuration, the new brace will out-perform steel. Vertical supports, such as the Powerbrace, are still necessary.

“We are very excited about this whole bracing package,” states Bruce Anderson, General Manger of VTI. “Now a builder can brace openings for an entire structure and not use any wood.”

For more information, call 1-888-578-2825 or visit www.vbuck.com.

Wall Finish perfect for ICFTruWall Extend is a

cement-based vertical coating formulated exclusively for ICF construction. Installed at ½” thickness, TruWall Extend is applied directly to ICF block without mesh, adhesives or rasping. This versatile coating can be applied in a single coat by hand or pump like a traditional plaster, or by the conventional scratch and brown process.

TruWall Extend offers an economic advantage over other coatings narrowing the cost gap of ICF construction. The dry concentrate is designed to be blended with sand at the

job site to meet any project’s needs. TruWall Extend is incredibly strong as well, ranging from 4000 psi to 9000 psi, depending on the amount of sand added.

TruWall Extend is the official coating of the BASF Near- Zero Energy Home in Paterson, N.J. and the Better Home Better Planet initiative.

For more information, call 1-866-444-ICFS or visit www.greentechcoatings.com.

30 ICF BUILDER

Green Building

Choosing a window these days is much like going to a restaurant and ordering off an a la carte menu. The options are tempting and endless. The good news is that in today’s marketplace of vast possibilities, you can create custom window packages for every job you do. Understanding the options available to you becomes the key to ordering window packages that fit your personal construction styles and needs.

Glass OptionsWith all the options available these days, it’s important to have a

good understanding of energy efficient choices. By specifying windows with one or more options, you can help your homeowners find strong savings on their energy bills throughout the year.

To begin, Low E glass is very popular because it helps reduce the radiant heat transfer through the glass. Low E stands for low emissivity, which means the glass reflects heat well. The lower the E-value, the higher the reflection. Low E glass has become almost a standard in the industry and is a “must have” for any location subjected to constant sun and warm weather. During the winter months, Low E glass reflects heat back into the home to help with energy savings.

In addition, Low E glass also helps block UV rays from entering the home damaging carpeting, window treatments, furniture and plants.

You can request Low E glass with a harmless gas filling (such as Argon) between two panes of glass. This odorless, colorless, non-toxic gas is six times denser than air. When used between the glass panes in a window, it helps reduce temperature transfer, keeping a home’s interior cooler in the summer and warmer in the winter. An insulated glass unit (IGU) with argon gas is one of the most energy efficient options available in the marketplace today.

In many coastal areas, impact resistant glass is required by local or regional building codes. This glass features an invisible, shatterproof layer—usually heavy plastic—sandwiched between two pieces of

double-strength glass. Impact resistant glass can help a home stand up to severe weather, reduce the sound penetration into the home and is a strong deterrent to solar rays, so the home is more energy efficient.

What type of glass is right for your project? That depends on the specific needs of the job. In most situations, however, homes are best served with glass packages featuring Low E glass and argon gas for superior energy efficiency.

Energy-Star® Compliant Windows One of the best ways to assure

the windows you select are energy efficient is to request them to be Energy-Star compliant for your geographical area. Energy-Star, a program coordinated by the U.S. Department of Energy, identifies four climate zones in the country. To be eligible for the Energy-Star rating, products must be certified, rated and labeled for both U-Factor and Solar Heat Gain Coefficient (SHGC) and meet the Energy-Star qualifications for one or more climate zones.

Visit www.energystar.org to learn about the ENERGY STAR compliant windows and glass packages suitable for your geographic area. And, if you need more energy saving ideas, visit www.homeenergysaver.lbl.gov, www.energyideas.org, www.simonton.com or www.efficientwindows.org.

Selecting a FrameChoosing a glass package is only

half your mission when selecting a window. Your frame selection—wood, aluminum, vinyl, fiberglass

or composite—can have a great impact on the energy efficiency and maintenance of your windows.

The growing trend in the industry these days is toward vinyl frames, which are easy to maintain and offer good insulating value. Vinyl is an excellent insulator, and when combined with other energy-smart features, such as Low E glass, the efficiency of the window unit increases dramatically.

In selecting a vinyl window, look for fusion-welded sashes and

Selecting Energy-Efficient Windows

by Jody Garrett

The zero-energy Raritan Inn complex includes 92 double paned, argon-gas-filled energy-efficient windows from Simonton.

frames to ensure solid construction. Seek out windows with multi-chambered profiles, which offer high-insulating dead-air spaces. Search for unique construction elements, such as sills that are sloped to promote water runoff and sashes that tilt in to allow for easy cleaning.

In addition to being energy efficient, vinyl frames are considered a healthy product for the home. First, vinyl-framed windows help save energy by reducing heating and cooling loads, especially when the windows are Energy-Star compliant. Second, vinyl windows contribute to a safe, healthy indoor environment by not releasing significant pollutants into the structure.

At Simonton, where we operate our own vinyl extrusion facility, our vinyl windows meet the following five GreenSpec criteria, making them exceptionally environmentally friendly.

1. Windows are made with pre-consumer recycled vinyl generated within our own extrusion process and at our window manufacturing facilities.

2. Our windows are exceptionally durable and have low maintenance requirements.

3. The windows help reduce heating and cooling loads.4. The windows do not release significant pollutants into a

structure.5. Some windows (such as impact resistant windows) help with

noise control.When you take into account that vinyl windows require no finishing, are virtually maintenance-free and permit the homeowners to use less energy to heat and cool their homes, vinyl windows shine out as environmentally friendly.

Jody Garrett is vice president of manufacturing for Simonton Windows. For more information on their product line, visit www.simonton.com.

April/May 2006 31

32 ICF BUILDER

In talking with builders and homebuyers, I’ve learned that many still perceive that ICFs limit design flexibility. They assume ICF homes will somehow be less attractive than framed

homes, and have ruled out ICF construction. We at Design Basics have found the best way to overcome that objection is to take the offensive—to show that ICFs can increase design flexibility, not decrease it! A home plan we call the Kingwood Showcase illustrates this point well. This is a “brake-light”

home—meaning as people first drive by this home, it’s not uncommon to see the brake lights come on as they slow to stare. Usually it’s the symmetry in the center massing of the home—with its bayed study and dining area flanking an elegant covered porch—that captures their attention.

The Beauty of Radius WallsIn adapting this popular home for ICF construction, our designers

capitalized on the opportunity to replace those traditionally-framed bays with smooth radius walls. Here, ICFs create an absolutely

stunning look for a fraction of the cost of trying to build true curved exterior walls with other materials. Continuing this theme, rear-facing exterior walls in both the master suite and the family room were treated to

the same smooth curving wall design. Imagine standing in the entry of this home, transfixed by the beauty of these curved walls in every direction.

Creating Distinction With Inset WindowsRather than setting windows flush with the exterior and having

deep window jambs on the inside, award-winning ICF home designer Marshall Wallman loves the shadow lines created when insetting windows in an ICF wall. “We can achieve a historical architectural look and add interest by insetting the windows,” says Wallman. This is especially effective when the exterior finish material has a masonry look such as stucco or limestone.

Achieving an Old-World

Facade is Easy With ICFs

Old-world architectural styles are becoming increasingly popular, and ICFs are well-suited to take advantage of this. In authentically replicating their European predecessors, the unique characteristics of various masonry materials are artfully combined to create these timeless exteriors. We’ll use the Balleroy home plan to illustrate (yes that ICF home plan is “just” 3��� sq. ft.)

TruWall is an ultra-high strength cementious coating specifically designed to bond directly to EPS foam. No wire mesh or other materials are required for it to adhere to ICFs, making it easy to create a stucco-like finish while the 10,000 psi TruWall coating protects the softer EPS foam from the impact of hail, golf balls or the occasional Weed Eater®.

Stone architectural highlights and details for ICF homes are an ideal application for ArcusStone , a crushed limestone coating which can also be applied directly onto EPS foam to achieve the durability and finish of quarried stone.

These are just a few of the opportunities that await ICF builders and their fortunate homeowners, in terms of making good elevations even better. So, rather than having to defend ICF construction’s design flexibility, let’s tout the applications where ICFs are the obvious choice for a beautiful home.

Paul Foresman is Director of Business Development for Design Basics, a residential design firm headquartered in Omaha, Nebraska, which has adapted more than 100 of the company’s home plans for ICF building. Paul can be reached via e-mail at pforesman@designbasics.com.

Make Good Elevations Even Better

by Paul ForesmanDesign Perspectives

June/July 2006 33

Durable ConcreteFrom hurricanes to drunken

drivers, ICF homes can protect their occupants from the dangers that surround them. The can also protect against wildfire, earthquake, and tornado.

On the Job: Installing Floor JoistsA realistic look at the best

ways to attach floor joists and ledgers to ICF walls. We’ll examine the leading brands as well as brick ledges and other structural solutions.

Project Profile: Megaplex 20The largest ICF project in the country is

nearing completion. This 20-screen theater has walls reaching over 50 ft. high, and used more that 35,000 blocks. The installer had to design his own bracing system to insure the job was done right.

Design PerspectivesA leading architectural firm talks

about designing hurricane-proof homes in Florida. The Fortified For Safer Living program may boost ICF construction in hurricane-prone regions.

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Take a look at what’s on deck in the

Next Issue of ICF Builder

Ad Index June 06American Polysteel, LLC 25

Amvic 27

Arxx Building Products 17

BuildBlock Building Products 21

Cell Crete Corp. 29

Certainteed (Form-A-Drain) 34

Dryvit Systems, Inc. BC

Epro Waterproofing Systems IBC

Exaktime, Inc. 5

Fine Line Footing Forms, Inc. 6

FossilCrete 8

GreenTech Coatings (TruWall) 3

Hambro 33

HOBBS Building Systems, LLC 29

Koncrete Pump Sales & Service 10

Lite-Form Technologies (Lite-Deck) 31

Metwood Building Solutions 10

Mono-Brace 22

Northwest Ohio Foam Products (The Barrier) 31

Perma Crete IFC

Plumwall, Ltd. 13

Quadlock Building Systems, Inc 15

Reddi-Wall, Inc. 18

Simpson Strong-Tie 23

Standard ICF Corp. 13

The Barrier Insulation.com 9

Vinyl Technologies (V-Buck) 19

Wind-Lock Corp. 25

3� ICF BUILDER