CT en 31701 0210

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Insulated Concrete Sandwich Walls

Composite Technologies
Corporation
1000 Technology Drive
Boone, Iowa 50036 USA
Fax: (515) 433-6088
Toll-Free: (800) 232-1748
Email: bnesset@thermomass.com
Web: www.thermomass.com
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2009
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Insulated Concrete Sandwich Walls

Presented By: Brad A. Nesset
Composite Technologies Corporation
1000 Technology Drive
Boone, Iowa 50036
Description: Provides an overview of insulated concrete sandwich walls, their benefits, applications, thermal and
moisture resistant properties and contribution to sustainable buildings.
To ensure the accuracy of this program material, this course is valid only when listed on AEC Daily's Online Learning
Center. Please click here to verify the status of this course.
If the course is not displayed on the above page, it is no longer offered.
The American Institute of Architects Course No. AEC317; LUs 1.00 This program qualifies for HSW credit.
AEC Daily Corporation is a Registered Provider with the American Institute of Architects Continuing Education Systems. Credit earned on completion of this
program will be reported to CES Records for AIA members. Certificates of Completion for non-AIA members are available on request.
This program is registered with AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be
an approval or endorsement by the AIA or AEC Daily Corporation of any material or construction or any method or manner of handling, using, distributing or
dealing in any material or product. Questions related to specific materials, methods and services should be directed to the program instructor.
Construction Specifications Institute Course No. CSI-A0171; CEUs 0.1 This program qualifies for HSW credit.
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2009 Table of Contents
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Learning Objectives
Upon completing this course, you will be able to:
list the characteristic benefits of insulated concrete sandwich panels over

traditional concrete construction
explain the difference between material and performance R-value of an insulated

concrete sandwich panel wall
list three options for connector materials and their benefits and drawbacks
relate the thermal and moisture resistance properties of sandwich wall panels and
the materials that contribute to these properties, and
design and detail insulated concrete sandwich walls in a sustainable manner.
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Table of Contents
Introduction to Insulated Concrete Sandwich Walls
Thermal Performance
24
Types of Sandwich Walls
30
Types of Rigid Insulation
50
Sustainability
63
Summary
74
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Introduction to Insulated
Concrete Sandwich Walls
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Types of Insulated Concrete Sandwich Walls

Insulated concrete walls consist of two layers of concrete with a layer of rigid
insulation sandwiched in between. The three main types of insulated concrete
sandwich walls are:
precast concrete, where the walls are cast in a plant
tilt-up, where walls are cast on-site
poured-in-place, where walls are cast vertically with removable concrete forms.
The type of construction project being considered (i.e. school, hospital, correctional
facility, etc.), as well as location will determine which method is specified.
Plant Precast
Site Cast (Tilt-Up)
Poured In Place
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Fabrication of an Insulated Concrete Sandwich Wall Panel
Form panels overall

shape including
architectural features.
Place exterior concrete

layer, vibrate and level
to receive insulation &
connector.
Place interior layer of

concrete.
Install insulation &

connector while exterior
layer of concrete is still
wet.
Vibrate and level interior

layer of concrete to
smooth finish and let cure
for 24hrs.
Install lifting inserts and

interior concrete layer
reinforcing.
Remove panel from

form and prepare for
installation.
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Why Insulated Concrete Sandwich Walls?

Concrete is a tremendously durable material,
and is popular because of its relatively low cost
and high availability. However, concrete does
possess very little R-value.
Integrally-insulated concrete walls combine the
traditional benefits of concrete with the
thermal and moisture preventive properties of
rigid insulation. This pairing optimizes the walls
thermal mass potential.
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Benefits of Insulated Concrete Sandwich Walls

Throughout the course of this AIA/CES program,
you will see how concrete can benefit your
clients needs through:
speed of construction
integrated assembly
limited site disturbance
energy efficiency
increased day lighting
long clear spans
low maintenance
fire endurance
economical construction, and
attractive appearance.
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Texture Options
Concrete is often a preferred building material due to its flexibility. One of the most
widely recognized benefits of concrete construction is that through innovative uses of
colors, forming, and textures, the appearance of concrete is limitless.
The following projects demonstrate a wide variety of textural finishes, including:
inlaid thin brick

sand blasting
acid etching
colored and exposed aggregate, and
reveals and form liners.
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Retail Facility Applications

This retail center incorporates a thin-brick exterior with hand-set stone. It also
features an elastomeric stucco material that bonds directly to the concrete surface to
create a hand textured plaster type appearance along with a brick faade.
Best Buy: Liberty, Missouri

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Retail Facility Applications contd

Not all retail centers are brick. This center utilized a colored concrete/sand-blast
finish along with a series of reveals to create a very attractive appearance. The
interior was furred out with metal studs, deep enough to enclose conduit. The studs
however, require no fiber glass insulation as insulation is integral to the wall. The
cavity becomes conditioned space.
Cabelas: Lehi, Utah
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Correctional Facility Applications

This project, was constructed with plant cast or
factory cast walls for the exterior shell, precast
pre-stressed concrete beams, stairs, floors, and
interior shear walls.
The radius wall panels incorporate 2.5 of rigid
integral insulation, an exterior colored concrete
fascia and a structural grade interior mix of
concrete.
El Paso County Correctional:

Colorado Springs, Colorado
LEED Silver Building
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Correctional Facility Applications contd

Modular precast construction illustrates another
example of concrete's flexibility in correctional
facility construction. The outside wall, which is the
exterior insulated element, commonly receives a
form liner finish. When combined with the prefinished interior, modular precast construction
provides tremendous architectural flexibility.
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Spiritual Facility Applications

The design flexibility of concrete wall panels
is also evident in this spiritual center project.
The St. Sarkis Armenian Apostolic Church was
designed by architect R. Glen Stephens. The
exterior was designed to resemble an 11th
century church constructed from tufa, a stone
native to the religion's homeland in the
mountains of Eastern Europe.
Armenian Spiritual Center: Charlotte, North Carolina
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Educational Facility Applications

LEED Silver Building
South Regional Library, Broward
County Community College:
Ft. Lauderdale, Florida
The project's exterior concrete was sand blasted.

The concrete mix was specified to be sea-foam
green in color - normally an expensive option.
However, since it was a sandwich panel, the
contractor only needed to use 3" of this mix to
achieve the desired appearance. The interior
gray concrete was much less expensive and
received a paint finish.
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Educational Facility Applications contd

A great example of color, form, and texture in a higher education facility is presented
in this project at the University of North Florida. The use of thin-brick and cladding
panels also assisted in LEED Certification (which will be addressed later in this
presentation). This project combined thin-brick with a colored exterior layer of
concrete to create a very attractive exterior finish.
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Sport Venue Applications

Sport venues also use insulated precast sandwich wall panels. For Ford Field, home of
the NFLs Detroit Lions, architectural precast panels were used to match an existing
warehouse structure. This project features more than 400,000 individual pieces of thinbrick.
Ford Field: Detroit, Michigan
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Health Care Facility Applications

This is another example of a project that was
constructed with architectural cladding panels. These
spandrel cladding panels combined architectural
reveals and acid etching to create a high performance
hospital.
Cook County Hospital:

Chicago, Illinois
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Controlled Environment Applications

Structures requiring controlled environments
greatly benefit from the use of integrally
insulated concrete wall panels. Whether it is
housing food or beverage, or a high or low
humidity structure, these wall panels allow a
mechanical engineer to effectively control and
manage the HVAC system and the building as a
whole, all while providing both attractive and
durable surfaces.
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Case Study Catholic University of America Dormitory

A combination of thin-brick, acid
etching and painted interior concrete
surfaces provide an architectural faade
and durable interior for the OPUS Hall
at the Catholic University of America in
Washington, DC.
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Case Study Catholic University of America Dormitory contd

As evident in the previous photos, the construction
concept was based on durability, architectural
features, and thermal performance.
As in all of these situations, the architectural features

are maximized by the insulation being integral in the
wall. With the wall fully insulated, the interior
concrete can be left exposed, and only needs periodic
painting.
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Thermal Performance
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Thermal Performance
Thermal Efficiency - The Importance of Insulation

Adequate R-value is a key characteristic of the exterior wall in both cooling and
heating climates. In a region where heating is predominantly required, increasing wall
R-values by as little as 5 points can reduce energy use by 30% (i.e. R-5 to R-10).
Many states have adopted energy codes based on ASHRAE Standard 90.1(American
Society of Heating Refrigeration and Air Conditioning Engineers) or IECC (International
Energy Conservation Code) requirements, which specify thermal resistance in the
building shell among other energy saving measures. These requirements are defined by
the method of construction (ie. mass wall, steel stud) and geographic location.
Meeting or exceeding the R-value requirements of these codes and standards affect the
HVAC equipment sizing, contribute to points for a green building rating program (i.e.
LEED), and improve the bottom line for the owner.
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Thermal Performance
Insulating Options
Insulation position is critical: ASHRAE and the IECC provide values and requirements
based on the insulation position in a mass wall. The three locations of insulation are:
Interior: Insulation on the inside of

the bulk mass of the wall system.
Exterior: Outside of the bulk

mass of the wall system.
Integral: Sandwiched between

substantial amounts of mass.
1. Insulate the mass to the exterior,

defeating the benefit of thermal mass
2. Must be covered with drywall, which
defeats the benefit of durable, interior
concrete
3. Secondary trade must install the
insulation, slowing construction
1. Defeats the benefit of the

architectural features displayed
in the introduction
2. Secondary trade must install
the insulation, slowing
construction
1. Mass is in correct location

2. Insulation is protected
3. Architectural exterior concrete
4. Durable interior concrete
5. No additional trades
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Thermal Performance
Effective R-Value
Material R-Value
Outlined below are the materials that make up a sandwich wall and their respective
R-values. The assembly shown here is an 8.5 thick sandwich wall. The majority of the
material R-value comes from the 2 of insulation.
As will soon be illustrated, the assembly material R-Value is only part of the overall
sandwich wall performance.
3.5 Exterior Concrete / 2 XPS Insulation / 3 Interior Concrete
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Thermal Performance
Effective R-Value contd

There are two insulating values tied
to high mass sandwich wall panels:
Material R-Value
Performance R-Value
The ability of concrete to store energy and dampen the effect of temperature change
on heating and cooling systems is known as the thermal mass effect.
Due to the mass effect of insulated concrete walls, the performance R-value of the
high performance wall system can be two to three times greater than that of the
material R-value, resulting in energy cost savings up to or exceeding 50%.
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Thermal Performance
Performance Analysis ASHRAE 90.1 - 1989

To determine the performance R-value, ASHRAE established a method of calculation
called System Performance Criteria located in ASHRAE 90.1. The criteria was first
detailed in the 1989 version of the Compliant Building Envelope Performance Study.
This study calculates the R-Value as a result of
effectively using the thermal mass of concrete. The
effective R-value is dependent upon the walls heat
capacity, insulation position, buildings location,
occupancy type and floor to wall ratio.
ASHRAE 90.1-2001 Compliant Building Envelope

Performance Study
Study Provided For: New Logan High School. Logan, OH
For this project - a high school in Ohio - the sandwich

wall panel performs equivalent to an R-value of R25.69. This is the R-value used when sizing HVAC
components and the R-value that would be used in
code compliance and/or LEED certification processes.
Historically, this has resulted in a tonnage reduction
of up to 37%.
Calculations will show at what R-value an integrally
insulated high mass wall panel will perform.
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Types of
Sandwich Walls
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Insulated Concrete Walls

There are three types of sandwich wall panels:
1) Non-Composite
2) Composite
3) Partially Composite
NON-COMPOSITE
SANDWICH PANEL
COMPOSITE
SANDWICH PANEL
PARTIALLY COMPOSITE
SANDWICH PANEL
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Non-Composite Sandwich Wall Panels

the inner and outer wythes work
independently of one another to resist
externally applied forces and are
allowed to move due to temperature
changes
designed for ambient and low temp
facilities
thermal bow is eliminated
the inner wythe is the structural wythe the outer wythe acts only as cladding,
resulting in a thicker wall
minimum exterior wythe thickness is 2
any additional reveal depths are added
to the thickness
the interior wythe is determined by the
minimum design requirements
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Connection Devices
Over the years there have been a variety of wythe connectors or fasteners used in
the industry. They are metal, plastic, either in a pin or ladder geometry, and fibercomposite.
Metallic
Plastic
FiberComposite
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Connection Devices - Metallic

Metal ties are most common, as they are the least
expensive. These ties have inherent issues.
Metallic Pin Connector:

Thermally Inefficient
They corrode when exposed to the elements. This

is very important with architectural precast.
Solid sections of concrete are commonly
incorporated in the panels to increase the bond
between the two layers of concrete. When this is
done, the panel loses some of its insulating value.
Solid Zones
They are highly conductive thermal bridges which

results in energy loss and increase the likelihood
for moisture transmission and the growth of mold
and mildew, and
Once the insulation is compromised, interior
insulation will be required.
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Connection Devices Metallic contd

Photos of metal ties and the associated solid sections in a typical sandwich wall panel.
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Connection Devices Metallic contd

These images demonstrate the thermal and moisture related issues that highly
conductive thermal bridges present.
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Connection Devices Plastic

Plastic connectors are non-conductive but they
do have some drawbacks.
Plastic Pin Connector
They have a limited factor of safety due to

low levels of pull-out and shear strength,
and
Concrete and plastic expand and contract at
a different rate resulting in the potential for
spalling.
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Connection Devices - Plastic contd

Thermal images show pronounced thermal bridges due to solid through sections of
concrete interrupting the insulation layer.
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Connection Devices Fiber-Composite

Fiber-composite connectors were designed to solve the deficiencies inherent in metal
and plastic connectors:
- Load Capacity
- Compatibility
- Quality Control
- Thermal Efficiency
Fiber-composite ties have been used since 1980. They possess superior strength (2600
lbs pull-out and 450 lbs shear) and have a coefficient of thermal expansion compatible
with that of concrete. As the exterior concrete expands and contracts, the tie will
allow it to do so independently of the interior wythe of concrete. Additionally, because
of the connector's strength, there is no need for solid sections of concrete, removing
any thermal bridges and allowing the panel to behave as a 100% non composite panel.
Fiber-composite connectors are supplied as a system along with rigid insulation. The
insulation is provided to the job-site, cut beforehand, with the connector locations
determined by means of pre-drilled holes. This ensures proper installation. Also, the
fiber composite rod and plastic, overmolded collar of the tie is such that it withstands
the high-alkali content of concrete and is installed to the proper depth in the
concrete.
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Connection Devices Fiber-Composite contd

Fiber-Composite Connector:
tested in accordance with ICC AC320
76,000 E-glass fibers
composed of E-glass/vinyl ester
resin
negates thermal short circuits in the
wall panel
twice the strength of 60-grade steel
(#3 bar)
similar coefficient of thermal
expansion as concrete
Pullout Capacity = 2,600 lbs

Shear Strength = 450 lbs
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Connection Devices Fiber-Composite contd

This thermographic image clearly demonstrates how efficient a wall panel is with
edge-to-edge insulation and non-conductive connectors.
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Composite Sandwich Wall Panels

The second type of sandwich wall panel is a composite wall. This design provides for a
thinner wall section where both wythes of concrete act together to resist external
loads.
Both wythes act together to resist external
loads.
Continuous ties or solid concrete sections
accomplish the necessary horizontal shear
transfer.
The composite action allows the panels to be
thinner and span greater lengths (to 50+ feet),
and
The issues affecting composite panels are:
thermal bow and thermal bridging.
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Connection Devices
Historically, connection devices available on the market included:
wire trusses
continuous bars, and
carbon fiber mesh.
All are rigid and transfer shear
from layer to layer, but all are
subject to consideration when
determining the correct
amount of shear transfer
required to allow the panel to
behave as 100% composite.
Wire Trusses
Continuous Bar
Carbon Fiber Mesh
To transfer shear, you need solid zones of concrete.

These zones are at the top and the bottom of the
panel (commonly 18), at the lifting pick points (up to
16 per panel) and around window and door openings.
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Connection Devices contd

In this image, the wire truss is installed between the sheets of insulation and there is a
significant amount of solid concrete in the panel. As will be addressed later, this is a
very poor design in terms of thermal efficiency.
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Connection Devices - Thermally Inefficient

Using thermographic images, we can see the
effect that solid zones of concrete have on the
building. There are two areas where the
thermal resistance of the building envelope is
lower; an un-insulated area where the floor
systems are tied in and at solid zones around
the window openings.
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Partially Composite Sandwich Wall Panels

The third type of sandwich wall panel is a partially composite
wall. These panels are designed similar to a composite wall
panel, only with edge-to-edge insulation.
panels will be partially composite enough to resist external
loads
partial composite action allows the panels to be thinner and
span greater lengths (to 40+ feet)
they are thermally efficient when non-metallic connectors
are used
they have a reduced thermal bow
when compared to conventionally
composite panel
they provide continuous insulation
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Connection Devices Fiber-Composite

In addition to non-composite walls, when
necessary to transfer shear loads, a fiber
composite connector with a more robust
geometry can be utilized. This maintains the
thermal and moisture prevention efficiencies
in the wall assembly while providing superior
strength to develop composite action.
Fiber-Composite Connector:
E-glass / vinyl ester resin
over 426,000 E-glass fibers
design represents a vierendeel
truss - chords and web members
Properties of this type of connector include:
non-conductive
non-corrosive
compatible coefficient of thermal expansion
connectors have pre-determined locations, and
the insulation is edge-to-edge.
Pullout Capacity = 3,400 lbs.
Shear Strength = 3,300 lbs.
180mm (l) / 40mm (w) / 8mm (t)
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Connection Devices Thermally Efficient

This thermographic image demonstrates the
thermal efficiency of a partially composite
sandwich wall panel designed with nonconductive fiber-composite connectors and
edge-to-edge insulation.
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Selecting Insulation Systems

Insulation System Selection Matrix For Precast (PC) /Prestressed (PS) /Post-tensioned (PT) Sandwich Wall Panel Construction
System Type
Building Type
Load Bearing
or Non Load
Bearing
Max. Unsupp.
Wall Length
(ft)
Min.
Insulation
Thickness in.
Max.
Insulation
Thickness in.
Wall
Type
NonComposite
System
Partially
Composite
System
Remarks: ETE=Edge-to-Edge Ins.

NTB=No Thermal Bow
PTB=Possible Thermal Bow
LB
Per Design
PC/PS/PT
LB
37
1.5
PS
ETE Insulation, PTB
LB
29
1.5
PC
ETE Insulation, PTB
LB
37+
1.5
PS
Solid Sections Top + Bottom, PTB
NLB
Per Design
PC/PS/PT
NLB
37
1.5
PS
ETE Insulation, PTB
NLB
32
1.5
PS
ETE Insulation, PTB
NLB
29
1.5
PC
ETE Insulation, PTB
NLB
37+
1.5
PS
Solid Sections Top + Bottom, PTB
LB
Per Design
PC/PS/PT
NLB
Per Design
PC/PS/PT
LB/NLB
Per Design
4 min.
12
PC/PS/PT
ETE Insulation, NTB
LB/NLB
Per Design
6 min.
12
PC/PS/PT
ETE, NTB, Vapor Barrier Rec.
Ambient Temp. Facilities
Single Story and Multistory (including schools,

office buildings,
manufacturing facilities,
warehouse/distribution,
retail, institutional
excluding correctional)
Correctional
ETE Insulation, NTB
ETE Insulation, NTB
Low Temp. Facilities

Coolers
28F to 50F
Freezers
28F to (-40F)
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Types of Rigid Integral Insulation

Foamed Plastic
A plastic where density has been decreased by the presence of cells throughout its mass.
The gas used to decrease its mass is usually distributed in the cells giving it its R-value
and moisture resistant properties.
There are three main types of foamed plastic rigid insulation used in insulated concrete
sandwich wall construction:
Expanded Polystyrene
Polyisocyanurate
Extruded Polystyrene
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Expanded Polystyrene EPS Bead Board

Expanded polystyrene is the type of insulating
material used for portable coolers and cups and
has a characteristic fusion between its resin
beads. In this type of insulation the voids in the
foam allow the migration of air and moisture.
Overall, this type of insulation needs to be
thoroughly evaluated in sandwich panels as:
Bead Board Molded Polystyrene
at 2 of thickness, it does not typically

qualify as a vapor retarder
loses R-value as it gets wet and absorbs
water, and
there are many variables that need to be
specified (density, r-value, etc).
Molded polystyrene in a sandwich panel
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Expanded Polystyrene EPS Bead Board contd

The R value of EPS insulation is based on its density. Individual resin beads are steamed
and vacuumed together to mold the insulation. How densely the beads are bonded
together will determine:
1)
2)
3)
4)
R-Value as the density goes up, the Rvalue increases

Compressive Strength as the density
goes up, so does the compressive
strength
Water Vapor Permeance the lower
the number the better but all are
greater than one so it does not qualify
as a vapor retarder according to the
International Building Code (more on
this later in this presentation), and
Water Absorption Percentage has the
highest % when compared to the next
two types of rigid insulation.
ASTM C578 Standard Specification for Preformed

Cellular Polystyrene Thermal Insulation - EPS
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Polyisocyanurate
Most designers are familiar with polyisocyanurate insulation in roofing applications as it
has a high R-value per inch.
In sandwich wall applications, ISO's with impermeable facers should always be used.
Common impermeable facers include plastic and aluminum. Impermeable facers
provide greater perm ratings and aid in the retention of R-value.
Sandwich panels require a poly facer as it does not negatively react with the alkalinity
inherent in concrete.
Type 1 Polyisocyanurate:
R-value of 6.5 / inch
special triplex aluminum/poly facer
aluminum facer is completely covered by
the poly laminate
no reaction of the concrete with the
aluminum when using poly facer
acts as a vapor barrier as the perm rating
is less than 0.04
very high heat tolerance of 250F = ideal
for steam curing
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Polyisocyanurate POLY ISO contd

The addition of the facer sheet provides a very low perm rating and will qualify as a
vapor barrier according to the IBC (International Building Code). This type of insulation
is ideal for high humidity applications.
ASTM C1289 Standard Specification for Faced Rigid
Cellular Polyisocyanurate Thermal Insulation Board
1) Highest R-value per inch

2) Lowest perm rating
3) Tri-plex facer
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Extruded Polystyrene - XPS

The third and final type of insulation is extruded polystyrene or XPS insulation. The
most common is Type 4, which has an R-value/inch of five and a compressive strength
of 25 psi.
What is unique about XPS foam is that at 1.5 thick, it qualifies as vapor retarder and
does not absorb water. In fact, this type of insulation was initially developed for use as
buoyancy billets for Navy docks.
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Extruded Polystyrene XPS contd

The following characteristics make XPS the ideal choice for insulating wall panels:
1)
2)
3)
4)
5)
Steady R-value
High compressive value
Vapor retarder
Does not absorb water
100% recyclable
Please remember the exam password INSULATING. You will be required to enter it in order
to proceed with the online examination.
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Specifying Insulation
The manufacture of insulated concrete walls exposes the
insulation to significant volumes of water.
The insulation must resist water and avoid absorption.
The following chart demonstrates why specifying the
correct type of insulation is so critical.
Water is a high conductor of heat. Its negative effect on an
insulations thermal performance is extreme! Insulation must stay
DRY to perform.
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Effect of Moisture on Insulation
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Specifying Insulation
The type of insulation selected and its
continuity will determine how
effective the wall assembly is at:
maintaining its R-value, and
preventing water vapor from
condensing within the wall.
This is because the manufacturing of
sandwich panels itself subjects the
insulation to a significant amount of
water. This can have a detrimental
effect on the long-term R-value of the
insulation.
Since the insulation is the single source
of thermal and moisture control,
specifying the correct thickness and type
is critical.
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Moisture Management
To confirm that a wall assembly will not have moisture issues, designers should insist
that a a dew-point analysis be performed and included in the concrete contractors
submittal package. In the case of a sandwich wall panel, where closed cell (every air
pocket is completely sealed from the next) extruded polystyrene or polyisocyanurate
insulation are used, it is best for the dew-point to occur in the core of the insulation or
in the exterior wythe of concrete, where it will exfiltrate over time.
Dew-point theory predicts condensation in a

system at any point where the actual and
dew-point temperature lines cross.
Indoor Temp = 70F

Outdoor Temp = 14F
Insulation = R-10
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Moisture Management contd
One of the benefits of concrete sandwich wall

assemblies is that there are no cavities in which
moisture can collect. Additionally, any dew-point
occurs in the foam and not within a wall cavity so
there is no condensation. There are also no
thermal bridges in the wall or convection
looping in the insulation. The walls are resistant
to moisture and the closed cell insulation impedes
the growth of mold and mildew.
Exfiltration
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Sustainability
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Sustainability
Sustainable Design
With a renewed focus on energy efficiency and
sustainable construction, design professionals
are constantly searching for building systems
that help contribute to a building that not only
meets current days needs, but also keeps future
generations in mind.
Insulated concrete sandwich walls contribute
greatly to sustainable structures; ones that are
energy efficient, are comprised of highly recycled
components and readily renewable, are
innovative, and are designed to last for decades.
The next few slides focus on some sustainable
attributes of concrete; specifically when judged
by the United States Green Building Council's
(USGBC) Leadership in Energy and Environmental
Design (LEED) rating program.
1 Sustainable
Building Industry Council. High Performance School Buildings. 2005, Second Edition.
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Sustainability
Possible LEED NC Version 2.2 Points with Insulated Concrete Sandwich Panels
The following are categories where designers and LEED Accredited Professionals
commonly rely on insulated concrete wall systems for points towards LEED Certification.
Sustainable Sites
Credit 5.1
Site Development, Protect or Restore Habitat
Points
1
Materials & Resources

Prereq 1
Storage and Collection of Recyclables
Required
Credit 1.1
Building Reuse, Maintain 75% of Existing Walls, Floors & Roof
1
Credit 1.2
Building Reuse, Maintain 95% of Existing Walls, Floors & Roof
1
Credit 4.1
Recycled Content, Use 10% (Post-Consumer + Half Pre-Consumer)
1
Credit 4.2
Recycled Content, Use 20% (Post-Consumer + Half Pre-Consumer)
1
Credit 5.1
Regional Materials, 10% Extracted, Processed and Manufactured Regionally 1
Credit 5.2
Regional Materials, 20% Extracted, Processed and Manufactured Regionally 1
Indoor Environmental Quality
Credit 3.1
Construction IAQ Management Plan, During Construction
Innovation & Design Process
Credit 1.1
Innovation in Design, Use of High Volume
Supplementary Cementitious Materials.
Credit 1.2-1.4
Apply for other credits demonstrating exceptional perform
Credit 2.1
LEEDTM Accredited Professional
Credit 7.1
Thermal Comfort
Energy & Atmosphere
Prereq 2
Minimum Energy Performance
Credit 1
Optimize Energy Performance 15% to 60%
1
+3
1
1
Required
2-10
Let's look at each point in detail.
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Sustainability
Sustainable Sites: Credit 5.1

The intent is the conservation of natural areas on
the site and the restoration of damaged ones.
The requirements of this credit can be met by
limited site disturbance to prescribed distances.
Insulated concrete walls require very little
perimeter access, if any.
Precast concrete is cast entirely off-site and
trucked in around the building perimeter.
Tilt-up concrete is cast directly on the floor
slab, and
Poured-in-place requires no scaffolding or
additional perimeter access.
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Sustainability
Materials and Resources: Credits 5.1 & 5.2

Credit is granted for the use of building
materials or products that have been
extracted, harvested or recovered, as well as
manufactured within 500 miles of the project
site for a minimum of 10% (based on cost) of
the total material value.
Aggregate cement, supplementary materials,
reinforcing steel, and insulation are all
typically made within the area, and
Reducing shipping distances for materials
and products to the project minimizes fuel
requirements for transportation and
handling.
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Sustainability
Recycled Content: Credits 4.1 & 4.2

Most reinforcing bars and mesh are
manufactured from recycled steel.
Rebar
Manufactured/melted 100% scrap;
5% post-industrial; 95% post-consumer
Wire Mesh
Manufactured with greater than 10% of postconsumer recycled content and/or greater
than 10% of post-industrial recycled content
Insulation within an insulated concrete wall
system is made up of partially recycled
material.
XPS - Extruded Polystyrene
10%-40% post-industrial recycled
ISO - Polyisocyanurate
11%-18% post-consumer recycled
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Sustainability
IEQ: Credit 3.1

This credit is attainable by preventing indoor
air quality problems resulting during the
construction process; the reduction and
containment of dust and particles during
construction; and, reducing moisture
absorption by materials that are damaged
by moisture.
Using insulated concrete sandwich walls
can help meet requirements because it
does not require fabrication, processing or
cutting on-site, thereby reducing airborne
contaminants.
Concrete is not damaged by moisture and
does not provide nutrients for mold growth,
and
An insulated concrete wall system will
reduce the use of steel studs and drywall.
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Sustainability
Thermal Comfort: Credit 7.1

USGBC encourages thermally comfortable
environments that support productivity and
the well-being of building occupants.
The use of insulated concrete can help meet
these requirements because it effectively
manages moisture and maintains a constant
internal temperature.
Concrete sandwich walls with edge-to-edge
insulation and non-conductive connectors do
not have thermal bridges.
Any sections of solid concrete create cold-spots
on the wall and increase the likelihood for
mold and mildew growth.
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Sustainability
Innovation in Design: Credits 1.1 - 1.4

Insulated concrete sandwich wall systems are
resource efficient and use modest amounts of
energy to construct and maintain.
Concrete contractors who construct sandwich
walls commonly have LEED experienced
professionals available to assist teams with
strategies to maximize points.
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Sustainability
Energy and Atmosphere: Credit 1

All buildings must comply with certain sections on
building energy efficiency and performance as
required by ANSI/ASHRAE/IESNA 90.1-2004, Energy
Standard for Buildings. Local energy codes can be
used for compliance if they can be shown to be
equivalent or exceed the ASHRAE standard.
Credit is allowed if energy cost savings can be shown
compared to a base building that meets the
requirements of ANSI/ASHRAE/IESNA 90.1-2004,
Energy Standard for Buildings.
Insulated sandwich walls concrete systems used in
conjunction with other energy-saving measures will
mostly likely be eligible for points.
Points are awarded depending on building, climate,
fuel cost, and minimum requirements of the standard.
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Sustainability
Energy Savings
Currently, 36% of ALL energy consumed in the U.S. is consumed by buildings and
natural gas prices are expected to increase from 30% to 70% compared to one year ago.
Future versions of LEED and various green building rating systems have an increased
focus on energy efficiency. Below is a clear example of the energy efficiency of
insulated concrete sandwich walls when compared to a more 'traditional', brick/block
assembly.
This school is constructed with conventional
brick/masonry construction. It took 8 months
to construct.
This school is actually 4,000 sq.ft. larger but was

constructed with an integrally insulated sandwich
wall panel. Construction time was only 5 months!
School Comparison
Electrical Cost
Natural Gas Cost
Traditional School
$118.89 per day
$100.78 per day
Sandwich Panel School
$91.02 per day
$65.95 per day
Percent Savings
31%
52%
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Summary
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Summary
Summary
The characteristic benefits of insulated concrete sandwich panels over traditional
concrete construction are the speed of construction, integrated assembly, limited site
disturbance, increased day lighting, long clear spans, low maintenance, fire endurance
factors, economical factors, and its attractive appearance.
To determine the performance R-value, ASHRAE established a method of calculation
called System Performance Criteria located in ASHRAE 90.1. Due to the mass effect of
insulated concrete walls, the performance R-value of the high performance wall
system can be two to three times greater than that of the material R-value.
Fiber-composite connection devices are non-conductive, non-corrosive, have a
coefficient of thermal expansion compatible with concrete. The systems allow for predetermined hole location and edge-to-edge insulation, solving many of the inherent
issues that arise when using metal or plastic connection devices.
One of the benefits of concrete sandwich wall assemblies is that there are no
cavities in which moisture can collect. Additionally, any dew-point occurs in the
foam and not within a wall cavity so there is no condensation. There are also no
thermal bridges in the wall or convection looping in the insulation. The walls are
resistant to moisture and the closed cell insulation impedes the growth of mold and
mildew.
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Summary
References and Resources

ASHRAE /ANSI Standard 90.1-2004: Energy Standard for Buildings Except Low-Rise
Residential Buildings Energy Efficiency
Manual for Quality Control For Plants and Production of Structural Precast Concrete
Products, Fourth Edition, MNL-116, Precast/Prestressed Concrete Institute
The Tilt-Up Design and Construction Manual, Fourth Edition, Tilt-Up Concrete
Association
State-of-the-Art of Precast/Prestressed Sandwich Wall Panels prepared by PCI
Committee on Precast Sandwich Wall Panels
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Conclusion of This Program

If you desire AIA/CES, CSI and/or state licensing continuing
education credits, please click on the button below to
commence your online examination. Upon successful (80% or
better) completion of the exam, please print your Certificate
of Completion.
For additional knowledge and post-seminar assistance, please
visit the Ask an Expert forum (click on the link above and
bookmark it in your browser).
If you have colleagues that might benefit from this seminar,
please let them know. Feel free to revisit the AEC Daily web
site to download additional programs from the Online Learning
Center.
2009 Composite Technologies

Corporation. The material contained in
this course was researched, assembled,
and produced by Composite Technologies
Corporation and remains their property.
Questions or concerns about this course
should be directed to the instructor.
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Insulated Concrete Sandwich Walls

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Insulated Concrete Sandwich Walls

2009 Table of Contents

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How to use this Online Learning Course

2009 Table of Contents

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list the characteristic benefits of insulated concrete sandwich panels over

explain the difference between material and performance R-value of an insulated

design and detail insulated concrete sandwich walls in a sustainable manner.

2009 Table of Contents

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Types of Sandwich Walls

Types of Rigid Insulation

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2009 Table of Contents

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Introduction to Insulated Concrete Sandwich Walls

Types of Insulated Concrete Sandwich Walls

Site Cast (Tilt-Up)

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Introduction to Insulated Concrete Sandwich Walls

Fabrication of an Insulated Concrete Sandwich Wall Panel

Form panels overall

Place exterior concrete

Place interior layer of

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Install insulation &

Vibrate and level interior

Install lifting inserts and

Remove panel from

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Why Insulated Concrete Sandwich Walls?

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Benefits of Insulated Concrete Sandwich Walls

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Introduction to Insulated Concrete Sandwich Walls

inlaid thin brick

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Retail Facility Applications

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