The Polycrete® insulating form is composed of type 3 expanded polystyrene panels, fastened together by T-shaped polymer fixtures that are inserted into end grooves on adjoining panels.
Once poured, the concrete adheres perfectly to the surface of the forms creating a concrete and expanded polystyrene sandwich completely free of air pockets. The result: a load-bearing wall with far greater strength than conventional structures.
The Polycrete® FLEX 850 is perfect for any type of building design, and can be easily adapted to suite the construction of columns, beams or polygonal curves. In addition to more common types of facing materials, Polycrete® also lends itself to the application of highly resistant exterior finishes that can be fixed directly to the expanded polystyrene.
Installation Overview
Rigid expanded polystyrene panels are ultralight, allowing easy moving and on-site handling.
The 2 parallel panels that make up the insulating form are held together by tie rods to which the reinforcing steel bars are attached. Door and window frameworks are installed between the panels before the concrete is poured.
The insulating Polycrete® forms require no exterior support, reducing both handling time and material costs.
Concrete is poured into the permanent insulating form using a concrete pump. In winter, heat generated by the setting concrete in the forms is sufficient to prevent freezing, even at temperatures as low as -22°F (-30°C)
The poured concrete adheres perfectly to the panels, creating a "sandwich" wall. The strength of this load-bearing wall is far superior to that of conventional structures. Inlaid polymer "Ts" facilitate fitting of the panels, electrical installation and interior/exterior finishing.
Inlaid polymer "Ts" facilitate fitting of the panels, electrical installation and interior/exterior finishing.
Features & Benefits
Respecting the environment
Conventional Formwork
Easy to install
High Insulating Value (R-28)
A more comfortable home
Better temperature control
Healthier air quality
Superior sound insulation
Savings
Energy saving
Upkeep savings
Savings on initial investment
Reduced construction costs
Peace of mind
An assurance of quality
High fire resistance
A long-term investment
Will resist to a pressure of concrete during pouring of 850 pounds per square foot (40 kPa)
The assembly ties system doesn’t obstruct the flow of concrete during pouring
Offers no limit in design, height or thickness of wall
Designed to be used for residential, commercial, industrial and institutional buildings
Accept all exterior siding types such as stucco, acrylic system, brick veneer, vinyl and aluminum
Product Specifications
The specifications are for 6" concrete walls.
Thermal efficiency : R-28
Soundproofing : STC-60
Fire resistance : 3 hours
Durability : Reinforced concrete construction
Type III Polystyrene
2 pound density
Plastic T profile on top edge for attachment
Coverage per panel : 8 square feet (0,74 square meter)
Packaging : 6 per bundle
Polycrete® scaffolding and corners for installation
Available sizes
Panel height: 12" (30 cm)
Panel length: 96" (244cm)
Concrete thickness:
5 ⅝" (14,3cm)
7 ⅝" (19,4cm)
9 ⅝" (24,5cm)
Custom thickness based on assembly ties
EPS thickness: 2 ½" (6,4cm)
Technical data: Typical physical properties of EPS insulation Physical properties
Physical properties
Imperial S.
SI System
ASTM Test
EPS Type III
Thermal resistance: R value at 75°F (24°C) for 1 inch thickness (25 mm)
sq.ft. °F hre BTU
m² °C W
C-518 C-177
4,2 min. (0,74)min.
Compressive strength (min) at 10% distortion
lb/sq.in. or psi
(kPa)
D-1621
20,4 140
Bending strength (min)
lb/sq.in. or psi
(kPa)
C-203
43,6 300
Dimensional stability: % of linear change (max)
%
%
D-2126
1,5
Coefficient of thermal expansion (max)
in./in./°F
(mm/mm/°C)
D-696
3,5 x 10-5 (6 x 10-5C-1)
Water vapor permeability (max)
Perm
(ng/Pa.s.m²)
E-96
2,25 130
Water absorption (max)
%
%
D-2842
2
Effective temperature range: Continuous Intermittent
