Hollow Core Planks

You can specify and integrate any commonly used floor system with ICF walls. It all depends on the needs of the project. While there are ICF floor systems, hollow core planks were utilized here for their slim profile, only 10", including 8" planks and 2" topping of concrete. It was also selected for speed.

Utility Penetrations Are Easy...

...if timed correctly! It's not always a matter of simply removing foam. It is with the smaller penetrations, but this building has some big ones, which means removing some of the ties in the forms.

These special made utility sleeves have a water stop ring that sets inside the form.

A large enough hole must be cut on one side of the forms in order for the water stop ring to fit in.

Then, it sits flush against the inside face of the other side of the form.

The forms here are reinforced with OSB screwed to the ties and foam glued around the opening to seal if for concrete placement.

Liquid concrete consolidates well even around tightly arranged small openings.

This bank of electrical conduit comes through the ICF wall (below).

Joints are prepared with waterproofing ahead of time, before the overall coat is applied.

Prefab rebar

I helped build many homes with PolySteel ICFs up in Harrisonburg, VA with Glen Stoltzfus Builders, and Virginia PolySteel, and we always had to bend and cut our own rebar to fit our needs. For such a large and intricate project as this residence hall, pretty well the only cutting that needs to take place are for the proper length of straight pieces. All bending and cutting and bending of stirrups, corners, and other unique pieces is done by Rockingham Steel at their facility. What many folks don't realize is that rebar fabricators will do the same even for residential projects. Make sure to inquire where you source your rebar.

Similar Project in Ethiopia (though not ICF)

I thought this would be an interesting comparison. My folks were in Ethiopia last year and got to witness the construction of a new dormitory on the campus of an institution there. We are so dependent upon technology, so it's amazing to see what can be done with two very standard pieces of power equipment, and a bunch of people. Granted, time is a different story there... Enjoy!

Getting gravel to the mixer.

All concrete for this entire project mixed in a mortar mixer.

The mortar mixer and hoist are the only power equipment utilized, and even the latter was only used when the ramp (see below) was out of reach of the very top of the building.

Concrete bucket hoisted up through the intricate scaffolding assembly.

Would you wheelbarrow a full load of concrete up this ramp...barefoot?

This man and woman haul concrete up the scaffold ramp at a nearby building.

The entire structure is reinforced concrete alone. It will be infilled with handmade concrete blocks (below).

Hand made cinder blocks laid out to dry.

Each cast-in-place slab is shored up with small tree trunks.

Central triangular atrium.

This dormitory will house 400 students, just a few less than our project in Durham.

Pour Day 2

Pour day pictures are pretty self explanatory. But, they amaze me every time. What we're able to do in a matter of a handful of hours, without too much exertion, is remarkable with pump and concrete truck technology. In contrast, consider a building in Ethiopia my folks saw under construction last year during a visit. As soon as I get the photos and details from them, I'll post them, too. For now, enjoy these shots of a well-orchestrated pour day...