Insuldeck,

A Better, Faster Way to Build Insulated Concrete Roofs & Floors

 

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.

THREE CONSTRUCTION STEPS

 

SETUP SHORING & INSUL-DECK

INSTALL REBAR, POUR CONCRETE

REMOVE SHORING & FINISH IT

What is INSUL-DECK? 

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.

 

Benefits for Homeowners and Building Operators

LOWER INSURANCE COSTS AND UTILITY BILLS

Resilient construction can reduce insurance costs by incredible amounts in many areas and elevated buildings also qualify for lower flood insurance premiums. And in wood frame homes, a large portion of the energy escapes through roofs. INSUL-DECK stops energy leakage to significantly reduce the HVAC sizing requirements and energy bills.

QUIET, COMFORTABLE INTERIOR

Minimized air infiltration leads to fewer allergens, improved indoor air quality, and no drafts or cold spots. High Sound Transmission Class (STC) ratings reduce the noise. A cozy, healthy, and peaceful indoor environment is made easy with INSUL-DECK, which also is perfect for in-floor radiant heating.

DURABLE AND LOW MAINTENANCE

INSUL-DECK buildings offer the durability of reinforced concrete - measured in centuries instead of decades - with no risk of rotting like wood. INSUL-DECK is made from inert materials that are not a food source for insects and don't support the growth of mold or mildew. Remediation of water damage is much less than wood.

 

PROTECTION AGAINST DISASTERS

INSUL-DECK Roofs and Floors can be built to withstand tornado-level winds, the impact of flying debris, and fires. Elevated buildings are easily constructed with INSUL-DECK raised slabs to minimize or eliminate flood damage. Resilient buildings keep occupants and property safe.

 
 

Benefits for Architects and Contractors

FAST & EASY BUILDS

INSUL-DECK Panels are lightweight and pre-cut at the factory to your exact specifications. Utility chases and steel furring strips are built-in. The self-reinforced forms require temporary shoring only every 4-6' and no stripping. Quick build-times reduce financing costs and earn revenue faster!

FLEXIBLE SYSTEM

Available in 7 manufactured thicknesses of 7" to 12½", up to 33' clear spans are possible (with typical residential live-loads). INSUL-DECK panels can be easily modified to exact needs on-site. INSUL-DECK is designed to integrate easily with any concrete wall system and is a popular choice for completing ICF wall building shells.

REDUCED COSTS

INSUL-DECK saves on labor (MHR of 0.04-0.06 are common) and uses upto 50% less concrete & 33% less steel compared to traditional concrete slabs. And by reducing the mass of the structure, costs for supporting elements are lower.

 

RESILIENT & SUSTAINABLE

Reinforced Concrete is strong enough for bunkers and all your resiliency requirements. Due to the insulating, thermal mass, and low air-infiltration properties, INSUL-DECK structures easily meet many energy-efficiency program requirements and are ideal for Net Zero and Green Roofs. Inert materials keep occupants healthy for the life of the building.

 

  • 3D DROPPED BEAM FORMING

  • 3D END-BEAM FORMING

  • 3D FLUSH BEAM FORMING

  • 3D REGULAR ASSEMBLY

  • 3D UTILITIES

  • 3D GREEN ROOF

  • ELEVATED BUILDING

  • TYPICAL FLOOR

Product Details

 

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.

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.

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.

INSUL-DECK is formwork for concrete floors, roofs, and tilt-up walls that stays in place as insulation, space to run utilities, and backing for finishes.

Contact us today to learn more and get a quote.