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The first expanded polystyrene ICF Wall forms were developed in the late 1960s with the expiration of the original patent and the advent of modern foam plastics by BASF. [citation needed] Canadian contractor Werner Gregori filed the first patent for a foam concrete form in 1966 with a block "measuring 16 inches high by 48 inches long with a tongue-and-groove interlock, metal ties, and a waffle ...
Foam concrete, also known as Lightweight Cellular Concrete (LCC) and Low Density Cellular Concrete (LDCC), and by other names, is defined as a cement-based slurry, with a minimum of 20% (per volume) foam entrained into the plastic mortar. [1]
It is easy to produce but time-consuming for larger structures, and the plywood facing has a relatively short lifespan. It is still used extensively where the labour costs are lower than the costs for procuring reusable formwork. It is also the most flexible type of formwork, so even where other systems are in use, complicated sections may use it.
For example, a 1-inch layer of closed-cell foam provides about the same insulation factor as 2 inches of open-cell foam. Closed-cell foam is very strong, and structurally reinforces the insulated surface. By contrast, open-cell foam is soft when cured, with little structural strength.
SIPs are most commonly made of OSB panels sandwiched around a foam core made of polystyrene. A structural insulated panel, or structural insulating panel, (SIP), is a form of sandwich panel used as a building material in the construction industry.
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In a typical 8-inch wall panel the concrete wythes are each 2-3/8 inches thick), sandwiching 3-1/4 inches of high R-value insulating foam. The interior and exterior wythes of concrete are held together (through the insulation) with some form of connecting system that is able to provide the needed structural integrity.
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