PermaCrete Feature Article

     How do you eat a cream-filled sandwich cookie? Those of us who are still kids at heart go for the creamy inner filling first. Then almost reluctantly, we turn our attention to the two crunchy outer pieces.
     In an abstract way, a producer's revenue stream from selling insulating concrete forms (ICF) is akin to the way kids enjoy sandwich cookies. Many producers are earning the sweet rewards of selling the wall's inners, first as the supplier of the concrete form then they deliver the system's concrete filling.
     But when it comes to the ICF's outer surface, producers are allowing others to get in on the profits. As demand for ICF construction increases, savvy producers might want to try their luck in selling products that clad the ICF exterior.

Why make the effort?      Whether it's protecting homes from future storms or pocketbook concerns about escalating energy prices, new home buyers are considering concrete homes more often. Fortunately for ready-mixed concrete and block producers, these buyers are often selecting concrete building systems.
     In 2004, 16.3% of the single-family homes built in the United States used exterior above-grade concrete ICF wall systems, accounting for More than 226,000 homes in that year alone. Multiply this by four and that's almost 1 million walls waiting for some sort of cladding or covering.
     According to a recent Hanley Wood reader survey, 25% of producers sell contractor supplies, in addition to their main concrete products. Many producers sell building materials such as bricks and coatings. These producers might want to look at an ICF wall in a different way.

Out on the ledge      Producers who sell brick don't have to give up on cladding sales just because a project uses ICFs. That's because engineers have introduced an innovative device, that when attached to an ICF form, enables the contractor to form a supporting concrete ledge for masonry veneer. The engineers at Quad-Lock Building systems call their idea the Brick Ledge Tie (BLT).
     The idea is simple. The device doesn't require any special tools or anchors. The BLTs are inserted into the wall l2 inches on center, just like any other Quad-Lock tie. The ICF installer transitions the lower wall from a 12-inch concrete cavity to an upper 6-inch cavity when it is used with a manufacturer's R-22 panel.
     Moving the upper panel toward the building leaves a 3¾ inch solid concrete supporting ledge. After the concrete hardens, the installer can place a 2¼ inch, high-density foam panel capped by a galvanized metal track on the ledge.
     When the concrete achieves its design strength, a mason contractor can use the ledge as the veneer wall footing and create the brick wall. Some builders have found another use for the device, positioning it toward the basement so that the ledge can provide interior support for floor joists. Laying it on      In many markets, stucco or similar surfaces are more popular than brick, creating an opportunity for those producers who sell exterior coatings. PermaCrete's Cementitious Coating System recently received thermal and moisture protection International Code council approval for exterior ICF surfaces.
     The system has a 10-year track record. That's because the acrylic polymer cement compound provides the coating with up to 6,000 PSI compressive and 1,800 PSI flexural strengths when applied in additional thicknesses. The six-step system is easily applied, and it offers a wide range of surfaces and colors to choose from in coating the ICF wall.

For more information on Quad-Lock's Brick Ledge visit the company's Web site at www.quadlock.com.
For more on the PermaCrete Coating System, visit the company's Web site at www.permacrete.com.

© 2006 Hanley Wood, LLC. All rights reserved. Republication or dissemination of "More on the Outside" (The Concrete Producer, May 2006, page 22) is expressly prohibited without the written permission of Hanley Wood, LLC. Unauthorized use is prohibited. Quality Systems, Inc., is publishing "More on the Outside" under license from Hanley Wood, LLC.