Professionals in the building industry know that a key part of designing and constructing any building is making sure it meets all current fire and safety codes. Fire-resistant insulation can improve safety and a building’s ability to withstand a fire. However, ICF blocks (Insulated Concrete Forms) themselves already provide superior fire resistance and thermal insulation, significantly enhancing a building’s fire safety and energy efficiency by reducing thermal bridging.
Understanding Fire Resistance and Insulation with ICF
ICF blocks are made from expanded polystyrene (EPS) beads that expand when heated with high-pressure steam, forming a dense cellular structure. This structure provides excellent insulation properties, keeping a building well-thermally insulated. The concrete core inside the ICF blocks provides enhanced fire resistance. Once the concrete is poured and fully cured, it offers a fire rating of up to 4 hours, making it far superior to traditional wood-framed walls, which offer only 15-20 minutes of fire resistance.
Unlike many other insulation materials that require additional treatments for fire resistance, EPS used in ICF blocks is inherently fire-resistant. The insulation value and fire protection are integrated into the ICF system itself, meaning there is no need to add extra fireproof insulation.
Standards and Regulations
Different agencies oversee the safety regulations that architects must follow when designing a building. Architects must ensure that their projects comply with the International Building Code (IBC) and National Fire Protection Association (NFPA) standards, particularly regarding fire-resistance ratings.
With ICF construction, no additional fireproof insulation is needed, as the concrete core of the ICF blocks already provides significant fire resistance — up to a 4-hour fire rating once the concrete is poured and cured. The EPS foam used in ICF blocks is naturally fire-resistant and contributes to the overall fire protection of the building.
However, for traditional construction methods or projects not using ICFs, architects must ensure the selected insulation materials meet the required flame spread and smoke development ratings, and incorporate fire-resistant materials, such as mineral wool, fiberglass, or calcium silicate, to meet safety requirements.
For projects aiming to meet LEED or BREEAM sustainability certifications, it’s essential that all materials, including those used in insulation, meet the organizations’ environmental and fire safety standards. The installation process must also follow manufacturer guidelines to ensure the fire-resistant properties of the materials are maintained.
Integrating Fireproof Insulation With ICF
ICF blocks provide a dual purpose of insulation and fire resistance in one system. The EPS foam creates a dense cellular structure that enhances thermal insulation, while the concrete core ensures up to a 4-hour fire rating. This integrated system eliminates the need for extra fireproof insulation.
Comparison to Traditional Wood or Concrete Builds
When architects use traditional wood or concrete in construction, thermal bridging can significantly increase heat loss, reducing fire protection and efficiency. Traditional wood-framed walls typically have a fire-resistance rating of 15 to 20 minutes, but ICF provides 6 to 8 times greater fire resistance, thanks to the concrete core. The concrete core’s 4-hour fire protection rating far exceeds traditional methods.
Quality Control and Inspection
During manufacturing, ICFs are monitored and inspected at every stage for quality and adherence to building regulations. They are checked for:
- Dimensional accuracy
- Density and strength testing
- Bonding of ties and webs
- Thermal performance
- Fire resistance and safety
Once manufactured, the ICF blocks are inspected for cracks, voids, and misalignment to ensure optimal performance on the construction site.
Planning and Design Considerations
Choosing the right insulation material is essential for ensuring the building has the best possible fire resistance, thermal efficiency, environmental sustainability and cost-effectiveness.
The most significant planning and design considerations architects face when choosing building materials like fireproof insulation are:
- Compliance with fire safety codes: The insulation used in the construction of the building must meet the required fire resistance, flame spread and smoke development ratings.
- Performance of the insulation material: Architects need to choose insulation materials based on their fire resistance, moisture resistance and durability.
- Building use and location: Architects must consider the types of extreme weather the building will be subject to based on its region.
- Sustainability and environmental impact: For LEED certification, architects must consider the ecological footprint and recyclability of the materials.
- Ease of installation and maintenance: Part of keeping the budget low is using materials that can be easily installed to keep labor costs down.
Installation Techniques
ICFs are quick and easy to assemble, making them a cost-effective way to get superior fire resistance and stay on budget.
ICF blocks are light and stackable, so they’re easy to transport. With the light, stackable design, ICF forms are incredibly easy to assemble. Being much easier to handle makes them a better alternative to traditional forms.
This ease of use saves time on construction projects and reduces the possibility of errors. It also makes the project more efficient by reducing labor needs.
They are manufactured to the specifications needed for the job, resulting in almost no material waste because there is no need for adjustments or trimming on site. They also connect with precise interlocking mechanisms, meaning entire walls can be assembled quickly and securely.
Best Practices for Installers
When installing ICFs during the construction of a building, construction crews should use these best practices to make the installation quick and successful:
- Pre-installation planning
- Proper foundation setup
- Accurate block installation
- Correct rebar placement
- Bracing and wall support during pouring
- Consistent concrete pouring
- Allowing for proper curing and set-up time
- Properly finishing the interior and exterior
- Safety and quality control
Tools and Equipment
Using the right tools and equipment is essential to smoothly install fire-resistant ICFs. The tools and equipment builders will need include:
- Measuring and alignment tools
- Cutting and shaping tools
- Bracing and wall support equipment
- Reinforcement tools
- Safety equipment
- Plumbing, electrical, and utility integration tools
- Finishing tools
- Transportation equipment
Common Challenges and Solutions
While ICFs are typically easy to install, there are some challenges that architects and builders should be aware of. Planning for the following challenges can make the installation go smoother:
- Alignment and leveling issues
- Bracing and wall stability during concrete pour
- Concrete pouring and air pockets
- Improper mixing
- Cutting ICF blocks
- Managing window and door openings
- Cold joints and concrete set issues
- Thermal bridging and insulation gaps
SuperForm Is Leading the Way
SuperForm’s EPS ICF blocks are redefining industry standards for fire-resistant and insulation.
Commonly referred to as “1,000-year homes,” structures built with our ICF blocks can resist fires for up to 4 hours. In fact, in a firewall test (ATSM E119), SuperForm ICF withstood exposure to intense flame without structural failure.
This allows occupants more time to evacuate the building and more time for emergency personnel to arrive on site and address the fire.
Ready to increase your project’s fire safety? Discover the best ICF options for upcoming jobs. To learn more about the revolutionary way that SuperForm ICFs are making buildings safer, contact our team today.