Secure Buildings

Polycrete® Insulated Concrete Forms Are Chosen For Secure Government Buildings

Polycrete® Big Block™ commercial grade insulated concrete form (ICF) system is an ideal construction method for secure buildings like data centers, communication facilities, police stations and other buildings requiring a high degree of security. This system has been selected for constructing secure U. S. Federal Government buildings.

There is currently one secure building project under construction that is using Big BlockTM, and we’re collaborating on others still in the design phase. The illustrated project was designed by Cornerstone Architects of Richmond, VA. Due to the sensitive nature of the structures, we aren’t permitted to disclose exact locations or specific U.S. Government Agencies involved.

Polycrete® Big Block™ is uniquely suited for constructing these secure buildings because it has patented steel wire cross tie system.  The blocks are fully assembled in the factory, and the .16 inch steel wire cross ties fold flat for shipping. Material for over 6,000 sqft of wall is carried on each truckload – about 50% more than other ICFs.  

The real beauty of the cross ties system is that it makes managing walls with large amounts of reinforcing steel (rebar) a piece of cake. 

First, the unique cross tie system can be easily disassembled and reassembled around the rebar cage. In cases where it is necessary to cut one or more of the 48 cross ties on each 16 sqft form, replacement ties can be reattached. Once reconnected, the system allows the concrete to flow freely through the form and around the rebar. 

Here are some examples of how the system is used. We'll update this page as permitted during construction, but for security purposes will not be able to show the completed building. In these illustrations, workers are installing an eight square foot Big Block form.

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On this project, the footing has a two foot step and the overall foundation wall height ranges from three to five feet. Walls above the slab will be eighteen feet.

The contractor has chosen to start with a two foot tall Big BlockTM on the lower portion of the footing and then start with a one foot Big BlockTM on the upper section of footing. 

Here the starter base has been affixed to the footing and you can see the pairs of #5 vertical rebar dowels extending from the footing on 6”centers. 

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Workers in this photo lower the eight square foot form over the dowels. It was necessary to cut a couple of the .16" steel wire cross ties in order to properly position the Big BlockTM form on the footing. 

They're using the one foot tall form because it saves labor. It eliminates the need to rip the standard two-foot forms on the job site.

The first course is the most time consuming because the rebar is quite inflexible at the footing. On upper courses, it is possible to move the vertical reinforcing steel slightly in order to get the cross ties past it. 
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In the photos above, you can clearly see that some of the steel wire cross ties were cut in order to properly position the Big BlockTM form around the rebar. These cross ties will be re-attached using extra single wire ties that were supplied to the contractor. The reattachment takes only seconds and leaves the form's strength unchanged.  
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The photo at left gives you a perspective on the structure of the wall of this secure building. Notice the step down in the footing at the lower left section of the photo. The first course on the lowest portion of the wall consists of standard two-foot Big BlockTM with an eight inch concrete cavity. 

The one foot tall Big BlockTM course starts at the upper level of the footing and continues across the lower portion. This assures that the top course of Big BlockTM on the foundation wall will be a full two feet tall and that will be most stable during the pour. 







  
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These pictures show an eight square foot (1 foot tall) Big Block™ form with cross ties that have been disconnected from one panel in the field. This process takes only a few seconds. The two panels are placed in position on the starter base and the ties are then reattached through the rebar cage. 

It's also possible to order the forms shipped from the factory with cross ties attached on only one side.That'll save you the effort of dis-assembling them in the field. 


PolycreteUSA, LLC  is the United States Importer and Distributor of Polycrete® ICF Systems
6802 Paragon Place, Suite 410, Richmond, VA 23230     804.441.6234
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