INSUL-DECK is a fast, versatile joist construction system for concrete Floors, Roofs and Elevated Buildings. The stay-in-place insulated concrete forms (ICFs) are made of Expanded Polystyrene (EPS), an insulation material of choice for many decades. Integrated steel beams are molded into each Insul-Deck panel creating formwork for the support of concrete, reinforcement, and construction loads with minimal shoring. The forms are lightweight so that two people can handle each panel. Insul-Deck also reduces the floors’ weight, producing a T-beam shape instead of a conventional flat slab. Ceiling finishes, such as drywall, can be attached directly to the Insul-Deck forms. To speed up job-site installation, Insul-Deck concrete forms are made-to-order in whatever lengths & thicknesses required using a patented continuous molding process. The system is the result of years of research, design, and practical field experience.
Three Construction Steps
Each INSUL-DECK panel is supported and reinforced with two integral steel beams molded into the product from end to end. The result is a self-supporting joist and deck forming system that provides the maximum strength of a reinforced concrete deck with a minimum of materials and installation labor.
Molded-In Steel Beams (extended for illustration purposes) are continuous providing the strength for Self-Supporting Concrete Forms, which greatly reduces shoring and labor. They also serve as Attachment Points for Finishes every 12″. For example, drywall can be screwed directly to the exposed steel furring strips at the bottom of each panel.
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).
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.
Wide Range of Spans and R-Values
INSUL-DECK is available in 7 different thicknesses (7″, 8″, 9″, 10″, 11″, 12″ and 12.5″), creating concrete joist heights of 5″ to 10.5″. The R-values range from R-18 to R-40 between the joists and R-16 to R-25 for completed assemblies. The 2′ wide Insul-Deck panels are custom-made at the factory to the lengths required for your construction project, eliminating waste in labor and materials. You can achieve up to 33 foot clear spans with residential live-loads and regular construction methods. For longer spans or higher loads, special techniques or secondary structural support may be required, see Technical Summary.
Reduced Shoring during Construction
During construction INSUL-DECK needs to be supported underneath with temporary supports called “shoring”, usually about 6 feet apart. The structural engineer or shoring engineer is responsible for the correct layout and shoring specifications, often provided for free with shoring rentals from scaffolding providers. INSUL-DECK acts as its own formwork so no additional plywood/stringers are required between primary shoring beams, making INSUL-DECK quick to install with no stripping labor nor bond-breaker chemicals.
Top Hat Options
Top Hats increase INSUL-DECK’s effective joist height which in turn increases live load capacity and free span of the floor system. Top Hats are made from modified Expanded Polystyrene – EPS that includes a fire retardant. They can be custom ordered in any thickness for project-specific requirements.