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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]
Styrofoam insulation extruded polystyrene foam (XPS), owned and manufactured by DuPont. Styrofoam is a genericized trademarked brand of closed-cell extruded polystyrene foam (XPS), manufactured to provide continuous building insulation board used in walls, roofs, and foundations as thermal insulation and as a water barrier.
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Repeated spraying produced a five-to-six-inch-thick structurally sound shell within a few hours. Once the foam cured, the plastic balloon form was removed to be used again. Once the second dome was completed and the balloon form removed, the two rooms were joined by wire mesh which was also sprayed with foam to form a connecting gallery or hall.
"Form blowouts" also occur when under-designed formwork bends or breaks during the concrete pour (especially if filled with a high-pressure concrete pump). Consequences can vary from minor leaks, easily patched during the pour, to catastrophic form failure, even death. Concrete exerts less pressure against the forms as it hardens.
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