Insul-Deck
Experience the future of construction with Insul-Deck
A revolutionary integrated floor and roof system that combines robust structural integrity with superior insulation and streamlined installation. By utilizing steel-reinforced, flame-retardant EPS panels as permanent concrete formwork, Insul-Deck creates efficient "T-beam and slab" structures, reducing concrete usage by 30-40% compared to traditional methods while accommodating impressive clear spans up to 33 feet. This innovative approach not only delivers excellent thermal and sound insulation, contributing to energy efficiency and occupant comfort, but also simplifies the building process with custom-cut panels and integrated furring strips for easy finishing, making Insul-Deck the smart choice for modern, high-performance residential and commercial projects.
EASY, QUICK WAY TO BUILD ICF ROOFS AND FLOORS
INSUL-DECK is formwork for concrete floors and roofs that stays in place as insulation. The insulated concrete forms (ICF) are made of expanded polystyrene (EPS), an insulation material of choice for many decades.
- Insulation stays in place. No need for stripping formwork.
- Fast construction with minimal shoring.
- Clear spans up to 33 feet and more.
- Produces a T-beam shape instead of a conventional flat slab, thereby reducing weight.
- Reinforced with two integral steel beams molded into the product
- Pre-formed utility chases and steel furring strips speed up construction.
- Molded-in steel beams serve as attachment points every 12” for finishes like drywall, etc.
- USA-based
1) Utility Chases can be used to install a variety of electrical, plumbing, or ducting. It’s easy to enlarge those chases by simply cutting away some of the insulation (after the concrete is poured and cured).
2) 4) Tongue-and-Groove Interlocks form the bottom of the concrete T-beams, or joists. Rebar reinforces each joist with ¾” Double-Rebar-Chairs available from Insul-Deck. Steel mesh or rebar reinforces the floor slab. Engineering guidelines and detailed design documentation is available for a wide variety of project requirements.
3) Tongue-and-Groove Interlocks form the bottom of the concrete T-beams, or joists. Rebar reinforces each joist with ¾” Double-Rebar-Chairs available from Insul-Deck. Steel mesh or rebar reinforces the floor slab. Engineering guidelines and detailed design documentation is available for a wide variety of project requirements
Building Strong: The Advantages of Sloped Concrete Roofs with Insul-Deck
Discover how Insul-Deck’s innovative ICF system is revolutionizing residential and commercial construction by enabling robust, sloped concrete roofs. This article from ICF Builder magazine explores the enhanced durability, fire resistance, and protection against natural disasters offered by these advanced roofing solutions, highlighting their cost-effectiveness and long-term benefits in the face of rising insurance rates. Learn about the structural advantages and installation techniques that make concrete roofs a smart investment for resilient building.
Insul-Deck ICF Concrete Pour
Discover the practical application of Insul-Deck with this insightful video, showcasing a live concrete pour. This demonstration provides a comprehensive look at the process and benefits of integrating Insul-Deck into construction projects.
Overview
Insul-Deck panels are steel-reinforced, foam plastic insulation boards used as permanent formwork for cast-in-place concrete floor and roof construction. They are designed to create reinforced concrete “T-beam and slab” structures, with reinforced concrete joists spaced at 24 inches (610mm) on center, poured monolithically with the slab.
For more in-depth understanding, these technical specifications and downloadable PDFs offer comprehensive details on Insul-Deck’s performance and installation:
Technical Summary
Typical Details AutoCAD 2018, 2000, or PDF
Revit BIM
Insul-Deck Top Hats
Installation Checklist
Handling Instructions
Key features and specifications of Insul-Deck include:
Material: Made from expanded polystyrene (EPS) insulation, which is treated with a flame-retardant. The average density of the EPS is 1.25 pcf [20 kg/m³].
Reinforcement: Each panel is reinforced with two continuous, galvanized steel, Z-shaped metal strips (22 gauge [0.8mm] thickness). These strips serve as furring for attaching ceiling finishes and as secondary shoring/formwork support.
Customization: Panels are custom-cut to the exact required length and are available in various thicknesses/joist-heights (7″, 8″, 9″, 10″, 11″, 12″, and 12.5″ [178mm-318mm]) to accommodate different spans and loads.
Structural Support: Insul-Deck panels themselves do not provide permanent structural support. The structural integrity is provided by the reinforced concrete joists and slab topping, which must be designed by a licensed engineer according to relevant standards like ACI 318 and ACI 301.
- Spans and Loads: Depending on the structural design, clear spans of up to 33 feet [10m] can be achieved. Greater spans or loads can be supported by increasing joist height with foam “Top Hats”, using high-strength concrete, additional reinforcing steel, stirrups, post-tensioning, or camber.
Slab Thickness: Slab sections typically range between 2 and 6 inches (50 and 150mm), leading to a 30-40% concrete savings and mass reduction compared to traditional methods. A 3-inch [75mm] slab is common for residential floors, and 5-inch [125mm] is recommended for areas with high point loads like garage floors.
Shoring: Insul-Deck panels require primary shoring, typically every 6 feet [1.8m] on center and perpendicular to the panels. The design and installation of shoring are the installer’s responsibility, in accordance with ACI 347.2R guidelines.
Thermal and Sound Insulation: The EPS material provides insulation. The system also offers sound transmission classification (STC) ratings, with examples such as 55 for a 12-inch Insul-Deck with a 4-inch concrete slab, rubber underlayment, tile flooring, and a 1/2-inch GWB ceiling finish. Fire resistance ratings can be designed using prescriptive methods based on concrete slab thickness and aggregate type.
