Insulated Concrete Forms

For AC Schnitzer Warehouse

The cutting edge in industrial building wall systems

Value Engineering Proposal By:

Abdulkareem Alqahtani

CNST 624

Fall 2013
Introduction:

A systematic approach of the value engineering concept will be implemented in AC Schnitzer

Warehouse project, Saline, MI. this approach aims for two big major benefits of implementing
this approach.

The systematic approach is about the building type of this warehouse. The AC Schnitzer
Warehouse building will be built of insulated concrete forms. This system has two major
benefits: Construction savings, and long-term benefits.

1- Construction Savings:

- fast, easy construction

- flexibility

- light weight for easy shipping and erection

- compatibility with carpenter trades

- Ability to meet higher energy code mandates with less complicated

construction.

2- Long-Term benefits for the Owner:

- strong walls

- disaster resistance and safety

- mold, rot, mildew, and insect resistance (below grade can require
termite protection)

- sound-blocking ability

- overall comfort
 - energy efficiency and resultant cost saving

What is the insulated concrete form?

Insulating Concrete Form (ICF) is a system of formwork for reinforced

concrete that stays in place as a permanent interior and exterior substrate
for walls, floors, and roofs. The forms are interlocking modular units that are
dry-stacked (without mortar) and filled with concrete. The forms lock
together somewhat like Lego bricks and serve to create a form for the
structural walls or floors of a building. ICF construction has become
commonplace for both low rise commercial and high performance residential
construction as more stringent energy efficiency and natural disaster
resistant building codes are adopted.

Sizes, Components, Configurations, Systems:

ICF systems can vary in their design. "Flat" systems yield a continuous
thickness of concrete, like a conventionally poured wall. The wall produced
by "grid" systems has a waffle pattern where the concrete is thicker at some
points than others. "Post and beam" systems have just that – discrete
horizontal and vertical columns of concrete that are completely encapsulated
in foam insulation. Whatever their differences, all major ICF systems are
engineer-designed, code-accepted, and field-proven. The two insulating
faces are separated by some type of connector or web. Large preassembled
blocks stack quickly on site. Panels or planks ship more compactly, but must
be assembled into formwork on the job. Foam is most often EPS, expanded
polystyrene. It can be XPS, extruded polystyrene, which is stronger, but also
more costly. A few products are made with recycled foam or wood fiber in a
nod to green construction. The salvaged material is formed into blocks with
cement, making units ideal for direct application of plaster finishes. The ties
that interconnect the two layers of insulated forming material can be plastic,
metal, or additional projections of the insulation. There are advantages to
each type of material, but one current trend incorporates hinges into the ties
that allow preassembled forms to fold flat for easy, less costly shipping. The
joints between individual forms can feature interlocking teeth or a tongue
and groove configuration molded into the forming material, or simple butt
jointed seams. Many manufacturers have developed units with universal
interlocks that allow the forms to stack whether the form is flipped one way
or the other. These “reversible” forms save time during placement and
prevent improper alignment. Special units for corners, floors, and roof
assemblies round out the product lines and improve the engineering of the
system and energy efficiency of the final construction.

Characteristics:

 Energy Efficiency:

- Minimal, if any, air leaks, which improves comfort and reduces heat
loss compared to walls without a solid air barrier

- High Thermal resistance (R-value) typically above 3 K·m²/W (in

American customary units: R-17[3]); this results in saving energy
compared with uninsulated masonry (see comparison)

-Continuous Insulation without Thermal Bridges or 'insulation gaps' as

is common in framed construction

-Thermal mass, when used well and combined with passive solar
design, can play an important role in further reductions in energy use,
especially in climates where it's common to have outside temperatures
swing above inside temperatures during the day and below at night

 Strength:
 - Insulating Concrete Forms create a structural concrete wall (either
monolithic or post and beam) that is up to 10 times stronger than
wood framed structures.

- Structural integrity for better resistance to forces of nature,

compared with framed walls.

- The components of ICF systems (both the poured concrete and the
material used to make the ICF itself) do not rot when they get wet.

 Sound Absorption:

- ICF walls have much lower rates of acoustic transmission. Standard

thickness ICF walls have shown sound transmission coefficients
(STC) between 46 and 72 compared to 36 for standard fiberglass
insulation and gypsum walls. The level of sound attenuation
achieved is a function of wall thickness, mass, component materials
and air tightness.

 Fire Protection:

- ICF walls can have 4–6 hour fire resistance rating and negligible
surface burning properties

 Indoor Air Quality:

 - ICF walls can regulate humidity levels, mitigate the potential for
mold and facilitate a more comfortable interior while maintaining
high thermal performance.

 Environmentally Sensitive:

- ICF walls can be made with a variety of recycled materials that can
lower the carbon footprint of the structure and minimize the
environmental impact of the building.

ICF details section

ICF carries steel beams connection and steel or metal roofs.

The proposed insulated concrete forms for AC Schnitzer

Warehouse:

There are many advantages for the AC Schnitzer Warehouse’s owner such:

1- Reducing the construction work 30% of the normal work schedule. It

will be reduced from 26.6 weeks to 20 weeks.

2- Saving cost will be around

- Foundation:

Length 1500 l.f

Height 4 ft
 Cost $/sf 22 $/sf

Total Cost $ 132,000

- Wall

Length 532 l.f(with openings)

Height 16 ft

Cost $/sf 20 $/sf

Total Cost 170,240 $/sf

- Original Estimation:

Foundation $ 122,110.00

Wall $ 128,338.00

- Additional cost: (construction)

Foundation: 132,000 - 122,110 = $ 9,890

Wall: 170,240 - 128,338 = $ 41,902

Total: $ 51,792
3- In addition to the construction time saving, ICF will save energy by
40% reducing of the heating and cooling bills cost, according to many
studies that conducted on real building built by ICFs.

The reason ICF structures save energy dollars has to do with the
energy performance of a structure. The insulation value (R-value)
of ICF systems is R-17 to R-22.

In this case, the total cost of the energy without ICFs system will be

22,000 sf X $ 2 (average cost in Michigan/sf) = $ 44,000

With ICFs system, it will be only 60% of $44,000=$26,000

And saving 18,000 per year.

The payback period is around 3 years of saving the cost of the

energy only.

4- Moreover, ICF will reduce the nosing and the neighborhood will not be
interrupted by the noise from the warehouse.

5- The warehouse will be resistant to hurricanes, tornadoes, and

earthquakes. The benefits of this is to save the goods inside the
warehouse in case of tornadoes or hurricanes.

6- Insurance discounts are available for concrete warehouse.