Sandwiching foam in concrete rather than the other way around (ICF)?
Last Post 05 May 2022 12:49 PM by Alton. 2 Replies.
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tronUser is Offline
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04 May 2022 08:43 PM
The foam in ICF can't be used as a durable surface for either the exterior or interior of the house. So, sandwiching foam in between two layers of concrete sounds like a better idea since concrete provides a durable surface that can simply be painted, perhaps with minimal stucco or plaster for cosmetics if desired.

It seems many country in Asian countries including cold countries like South Korea and hot countries like India are building walls with a foam core sandwiched by two layers of concrete. Why aren't we doing this in the US? It seems more functional and avoids the need for surface finishes or water/vapor barrier on both sides.

Is it possible to do this in the US?
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04 May 2022 08:48 PM
Here's a CNBC news segment on this construction method- https://www.youtube.com/watch?v=xRCIhgNTi8c

Here's an animation of the building process. They stack the styrofoam panels covered in wire mesh and then shoot shotcrete (like a swimming pool) and finish the surface on both sides. https://www.youtube.com/watch?v=gx6Rqv6tV2s

A video of the technique that shows how wall, floors and roofs (flat or pitched) are all built in one go. Plumbing and electricals are done in one go also. https://www.youtube.com/watch?v=wa7dS2YSNvM

Real construction and explanation of the technique in a typhoon-prone area in the Philippines: https://www.youtube.com/watch?v=4us3pBg187A

A video of the fire test: https://www.youtube.com/watch?v=oGlCXbnlyaY

They call it 3D cementitious sandwich panel or EPS sandwich panel or EPS sandwich wiremesh panel. Seems better than ICF for fire/termite/water/severe weather resistance to have concrete surfaces rather than foam surfaces that are covered up.

I'm looking to build my next home and very interested in this technology if there are builders who can do this. I'd love to hear everyone's thoughts around pros, cons, feasibility, concerns, etc.
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05 May 2022 12:49 PM
I believe the alternative building system you are describing is called Structural Concrete Insulated Panels (SCIPs). I can think of three companies that make these panels available for walls, floors, and roofs. I have experience with SCIPs from Insteel (I think it is called Tridipanel now) and Gulf Concrete Technology.
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Construction Technology Consultant -- E-mail: Alton at Auburn dot Edu Use email format with @ and period .
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