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This project work consisted of developing technical data to justify, from the standpoint of material
properties (of aggregate fines and HFC), construction efficiency, cost competitiveness, and energy
performance, a basis for the use of high-fines concrete (HFC) inside ICF wall systems. Although several
aspects of the study are listed above, the report primarily concentrates on the material aspects of a limited
number of aggregate fines sources and their use in HFC relative to strength development and placeability.
Originally, emphasis was planned to be placed upon the use of a controlled low strength material (CLSM)
but due to strength requirements currently in force for ICF construction, it was determined that greater
benefit would be derived from highlighting the advantages of using aggregate fines in ICF concrete. A
framework for developing suitable HFC mixture designs for different ICF wall systems relative to placement
and strength characteristics is discussed. These guidelines were based upon results from the construction to
two residential structures using HFC and the placement of 4 trial wall systems. One of the structures
consisted of a Atest model@ that was used to investigate methods of construction and the energy efficiency of
an ICF wall system.
by
Dan G. Zollinger
Associate Research Engineer
Texas Transportation Institute
Sponsored by the
September 2001
DISCLAIMER
The contents of this report reflect the views of the authors, who are responsible for
the facts and the accuracy of the data presented herein. The contents do not necessarily
reflect the official view or policies of the International Center for Aggregate Research or
AAB Building Systems. The report does not constitute a standard, specification, or
regulation, nor is it intended for construction, bidding, or permit purposes. The engineer in
charge of this project was Dan G. Zollinger, P.E. #67129.
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ACKNOWLEDGMENTS
Research findings presented in this report are a result of a project carried out at the
Texas Transportation Institute (TTI), Texas A&M University. The authors would like to
thank the staff of the International Center for Aggregate Research or AAB Building
Systems for their support throughout this research project. The authors would also like to
recognize significant contributions made by the following organizations and individuals:
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TABLE OF CONTENTS
Page
List of Figures ........................................................................................................................ ix
List of Tables .......................................................................................................................xiii
Chapter 1 Use of Concrete in Residential Construction ...................................................... 1.1
Scope of Work ............................................................................................................... 1.4
Objectives ................................................................................................................ 1.4
Beneficial Aspects of ICF Construction ........................................................................ 1.5
Economical Considerations of ICF Construction ........................................................ 1.11
ICF Construction Practices .......................................................................................... 1.13
Chapter 2 Considerations for the Use of Fines in Concrete ............................................... 2.1
Research on Fines in Concrete....................................................................................... 2.1
Use of Fines in Concrete................................................................................................ 2.1
Implications of the Literature Review ........................................................................... 2.6
Testing Protocol Considerations.............................................................................. 2.7
Protocol for Testing Relevant to HFC ........................................................................... 2.7
Fines Classification for Use in HFC .............................................................................. 2.9
HFC Performance Considerations ......................................................................... 2.14
Application of Classification System .................................................................... 2.19
Conclusions.................................................................................................................. 2.29
Chapter 3 Properties of HFC Relative to ICF Construction ............................................... 3.1
Laboratory Test Program ............................................................................................... 3.1
Module Construction ............................................................................................... 3.7
Chapter 4 Case Study in ICF Construction.......................................................................... 4.1
Introduction.................................................................................................................... 4.1
General Features ............................................................................................................ 4.1
Specific Construction Details ........................................................................................ 4.3
Concrete Factors ...................................................................................................... 4.4
Interior Finishing ..................................................................................................... 4.5
Construction Costs ......................................................................................................... 4.9
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LIST OF FIGURES
Figure Page
1.1 ARXX=s Building Products Concrete Wall Form.............................................. 1.2
1.2 Residential Concrete Building Systems. Left to Right: Hebel
Block Rasta, ICF, and Polystyrene ICFs .......................................................... 1.3
1.3 Construction of the Thomas A. Edison Home [Collins, 1959].......................... 1.6
1.4 Completed Home of Thomas A. Edison [Collins, 1959]................................... 1.7
1.5 (a) Panel System; (b) Plank System; (c) Block System
[VanderWerf et al., 1997] ................................................................................ 1.15
1.6 (a) Flat System; (b) Grid System; (c) Post-and-Beam System
[VanderWerf et al., 1997] ................................................................................ 1.16
1.7 Examples of House Footprint Irregularities; Curved Walls, Non-90°
Angles, and Frequent Corners [VanderWerf et al., 1997] ............................... 1.17
1.8 Examples of Forming Curved Walls by Bending ICF Panels (top)
and Blocks (bottom) [VanderWerf et al., 1997] .............................................. 1.17
1.9 Curved Walls Formed by Bending the Face Shells of Units Assembled
in the Field [VanderWerf et al., 1997]............................................................. 1.18
1.10 Curved Wall Formed by Cutting the Ends of the Units at Angles
[VanderWerf et al., 1997] ................................................................................ 1.18
1.11 Placement of Opening in ICF Wall Section [VanderWerf et al., 1997] .......... 1.19
2.1 Water Demand of Reference Concrete, and Concretes Containing
10 Percent Fines............................................................................................... 2.26
2.2 Compressive Strength at 7 and 28 Days Note: LS-Limestone N-Natural ....... 2.26
2.3 Porosity of Reference Concrete, and Concretes Containing 10, 20,
and 30 Percent Siliceous Fines ........................................................................ 2.27
2.4 Porosity of Reference Concrete and Concretes Containing 10, 20,
and 30 Percent Limestone Fines ...................................................................... 2.27
2.5 Shrinkage vs. Time for Concrete Samples Containing
Limestone Fines ............................................................................................... 2.28
3.1 Aggregate Grading............................................................................................. 3.2
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LIST OF TABLES
Table Page
1.1 Sample Costs of ICF Wall Construction [VanderWerf et al., 1997] ............... 1.13
2.1 Substitution of Limestone Fines in Malhotra and Carrette Study ..................... 2.2
2.2 Influence of Aggregate Fines-Related Material Properties on
HFC Performance ........................................................................................ 2.8
2.3 Parameters to Classify Fines............................................................................ 2.10
2.4 Sand Equivalent Results .................................................................................. 2.20
2.5 Classification of Particles in Fines................................................................... 2.21
2.6 Elemental Composition (Percent by Mass) of Aggregate Fines...................... 2.24
2.7 Mixture Design for Limestone Fines Concrete................................................ 2.25
3.1 HFC Mixture Factors ......................................................................................... 3.1
3.2 Typical HFC Mix Design Material Properties................................................... 3.2
3.3 Specific Mixture Combinations ......................................................................... 3.3
3.4 W/CM vs. W/S for 400-lb HFC......................................................................... 3.4
3.5 HFC Mixture Proportions .................................................................................. 3.5
5.1 Cross Section Thermal Properties....................................................................... 54
F.1 HFC Performance Rating...................................................................................F.3
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