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Insulated Concrete Forms for Floors, Roofs and Elevated Buildings

Ideal for residential, commercial, and institutional construction, INSUL-DECK buildings are not only more comfortable, quieter and super energy efficient, but can also provide safety from hurricane level winds, fire and floods.

 

A Better, Faster Way to Build Insulated Concrete Roofs & Floors

INSUL-DECK is a fast, versatile joist construction system for concrete FloorsRoofs and Elevated Buildings. The stay-in-place insulated concrete forms (ICFs) are made of Expanded Polystyrene (EPS), an insulation material of choice for many decades. Integrated steel beams are molded into each Insul-Deck panel creating formwork for the support of concrete, reinforcement, and construction loads with minimal shoring. The forms are lightweight so that two people can handle each panel. Insul-Deck also reduces the floors’ weight, producing a T-beam shape instead of a conventional flat slab. Ceiling finishes, such as drywall, can be attached directly to the Insul-Deck forms. To speed up job-site installation, Insul-Deck concrete forms are made-to-order in whatever lengths & thicknesses required using a patented continuous molding process. The system is the result of years of research, design, and practical field experience.

Three Construction Steps

  1. SETUP SHORING & INSUL-DECK

  2. INSTALL REBAR, POUR CONCRETE

  3. REMOVE SHORING & FINISH IT

Product Details

Each INSUL-DECK panel is supported and reinforced with two integral steel beams molded into the product from end to end. The result is a self-supporting joist and deck forming system that provides the maximum strength of a reinforced concrete deck with a minimum of materials and installation labor.

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Molded-In Steel Beams (extended for illustration purposes) are continuous providing the strength for Self-Supporting Concrete Forms, which greatly reduces shoring and labor. They also serve as Attachment Points for Finishes every 12″. For example, drywall can be screwed directly to the exposed steel furring strips at the bottom of each panel.

Utility Chases can be used to install a variety of electrical, plumbing, or ducting. It’s easy to enlarge those chases by simply cutting away some of the insulation (after the concrete is poured and cured).

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Tongue-and-Groove Interlocks form the bottom of the concrete T-beams, or joists. Rebar reinforces each joist with ¾” Double-Rebar-Chairs available from Insul-Deck. Steel mesh or rebar reinforces the floor slab. Engineering guidelines and detailed design documentation is available for a wide variety of project requirements.

Wide Range of Spans and R-Values

INSUL-DECK is available in 7 different thicknesses (7″, 8″, 9″, 10″, 11″, 12″ and 12.5″), creating concrete joist heights of 5″ to 10.5″. The R-values range from R-18 to R-40 between the joists and R-16 to R-25 for completed assemblies. The 2′ wide Insul-Deck panels are custom-made at the factory to the lengths required for your construction project, eliminating waste in labor and materials. You can achieve up to 33 foot clear spans with residential live-loads and regular construction methods. For longer spans or higher loads, special techniques or secondary structural support may be required, see Technical Summary.

Reduced Shoring during Construction

During construction INSUL-DECK needs to be supported underneath with temporary supports called “shoring”, usually about 6 feet apart. The structural engineer or shoring engineer is responsible for the correct layout and shoring specifications, often provided for free with shoring rentals from scaffolding providers. INSUL-DECK acts as its own formwork so no additional plywood/stringers are required between primary shoring beams, making INSUL-DECK quick to install with no stripping labor nor bond-breaker chemicals.

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Architects and Contractors

 

A Better, Faster Way to Build Insulated Concrete Roofs & Floors

INSUL-DECK is a fast, versatile joist construction system for concrete FloorsRoofs and Elevated Buildings. The stay-in-place insulated concrete forms (ICFs) are made of Expanded Polystyrene (EPS), an insulation material of choice for many decades. Integrated steel beams are molded into each Insul-Deck panel creating formwork for the support of concrete, reinforcement, and construction loads with minimal shoring. The forms are lightweight so that two people can handle each panel. Insul-Deck also reduces the floors’ weight, producing a T-beam shape instead of a conventional flat slab. Ceiling finishes, such as drywall, can be attached directly to the Insul-Deck forms. To speed up job-site installation, Insul-Deck concrete forms are made-to-order in whatever lengths & thicknesses required using a patented continuous molding process. The system is the result of years of research, design, and practical field experience.

Three Construction Steps

  1. SETUP SHORING & INSUL-DECK

  2. INSTALL REBAR, POUR CONCRETE

  3. REMOVE SHORING & FINISH IT

Product Details

Each INSUL-DECK panel is supported and reinforced with two integral steel beams molded into the product from end to end. The result is a self-supporting joist and deck forming system that provides the maximum strength of a reinforced concrete deck with a minimum of materials and installation labor.

1.gif
2.gif
4.gif

Molded-In Steel Beams (extended for illustration purposes) are continuous providing the strength for Self-Supporting Concrete Forms, which greatly reduces shoring and labor. They also serve as Attachment Points for Finishes every 12″. For example, drywall can be screwed directly to the exposed steel furring strips at the bottom of each panel.

Utility Chases can be used to install a variety of electrical, plumbing, or ducting. It’s easy to enlarge those chases by simply cutting away some of the insulation (after the concrete is poured and cured).

3.gif

Tongue-and-Groove Interlocks form the bottom of the concrete T-beams, or joists. Rebar reinforces each joist with ¾” Double-Rebar-Chairs available from Insul-Deck. Steel mesh or rebar reinforces the floor slab. Engineering guidelines and detailed design documentation is available for a wide variety of project requirements.

Wide Range of Spans and R-Values

INSUL-DECK is available in 7 different thicknesses (7″, 8″, 9″, 10″, 11″, 12″ and 12.5″), creating concrete joist heights of 5″ to 10.5″. The R-values range from R-18 to R-40 between the joists and R-16 to R-25 for completed assemblies. The 2′ wide Insul-Deck panels are custom-made at the factory to the lengths required for your construction project, eliminating waste in labor and materials. You can achieve up to 33 foot clear spans with residential live-loads and regular construction methods. For longer spans or higher loads, special techniques or secondary structural support may be required, see Technical Summary.

Reduced Shoring during Construction

During construction INSUL-DECK needs to be supported underneath with temporary supports called “shoring”, usually about 6 feet apart. The structural engineer or shoring engineer is responsible for the correct layout and shoring specifications, often provided for free with shoring rentals from scaffolding providers. INSUL-DECK acts as its own formwork so no additional plywood/stringers are required between primary shoring beams, making INSUL-DECK quick to install with no stripping labor nor bond-breaker chemicals.

Architects and Contractors

FAST AND EASY BUILDS

INSUL-DECK Panels are lightweight and pre-cut at the factory to your exact specifications. Utility chases and steel furring strips are built-in. The self-reinforced forms require temporary shoring only every 4-6' and no stripping. Quick build-times reduce financing costs and earn revenue faster!

FLEXIBLE SYSTEM

Available in 7 manufactured thicknesses of 7" to 12½", up to 33' clear spans are possible (with typical residential live-loads). INSUL-DECK panels can be easily modified to exact needs on-site. INSUL-DECK is designed to integrate easily with any concrete wall system and is a popular choice for completing ICF wall building shells.

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FAST AND EASY BUILDS

INSUL-DECK saves on labor (MHR of 0.04-0.06 are common) and uses upto 50% less concrete & 33% less steel compared to traditional concrete slabs. And by reducing the mass of the structure, costs for supporting elements are lower.

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RESILIENT AND SUSTAINABLE

Reinforced Concrete is strong enough for bunkers and all your resiliency requirements. Due to the insulating, thermal mass, and low air-infiltration properties, INSUL-DECK structures easily meet many energy-efficiency program requirements and are ideal for Net Zero and Green Roofs. Inert materials keep occupants healthy for the life of the building.

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Home Owners and Building Operators

QUIEST, COMFORTABLE INTERIOR

Minimized air infiltration leads to fewer allergens, improved indoor air quality, and no drafts or cold spots. High Sound Transmission Class (STC) ratings reduce the noise. A cozy, healthy, and peaceful indoor environment is made easy with INSUL-DECK, which also is perfect for in-floor radiant heating.

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LOWER INSURANCE COSTSAND UTILITY BILLS

Resilient construction can reduce insurance costs by incredible amounts in many areas and elevated buildings also qualify for lower flood insurance premiums. And in wood frame homes, a large portion of the energy escapes through roofs. INSUL-DECK stops energy leakage to significantly reduce the HVAC sizing requirements and energy bills.

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PROTECTION AGAINST DISASTERS

INSUL-DECK Roofs and Floors can be built to withstand tornado-level winds, the impact of flying debris, and fires. Elevated buildings are easily constructed with INSUL-DECK raised slabs to minimize or eliminate flood damage. Resilient buildings keep occupants and property safe.

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DURABLE AND LOW MAINTANANCE

INSUL-DECK buildings offer the durability of reinforced concrete - measured in centuries instead of decades - with no risk of rotting like wood. INSUL-DECK is made from inert materials that are not a food source for insects and don't support the growth of mold or mildew. Remediation of water damage is much less than wood.

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Tremco waterproofing and sealants, Professional Building Supply Austin Texas Dealer Distributor

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