|
|
 |
ENERGY BUILDING SYSTEMS, LLC
2435 E. Pecan Rd.
Phoenix, AZ 85040 |
|
602.438.8002 |
602.305.6996 (fax) |
CastleFoam™ Product & Construction Details
Material & Construction
Process Description
CastleFoam™ is an innovative,
highly insulative, modular, panelized building material with a
combination of structural strengths that make it ideal for
residential and light commercial construction projects.
CastleFoam™ can be used for load bearing walls, floors, and
roofs, in addition to interior partition walls.
The CastleFoam™ system
derives its strength from an integral frame system of concrete cells
which are reinforced with steel rebar. The EPS composite material
also has compressive and shear properties, as well as excellent
flexural strength.
CastleFoam™ construction
methods provide a unitized building envelope that is proven to be
hurricane and tornado proof. This is achieved by structurally
connecting the foundation, floor system and wall system directly to
the roof system with continuous steel connections.
-
Maximum material dimensions:
monolithic EPS (styrofoam) panelized wall sections
-
Height: up to 16' above grade
-
Width: up to 50" (includes tongue)
-
Thickness: up to 26"
NOTE: Basement construction is
also superior and faster utilizing CastleFoam™.
-
CastleFoam™ forms a
monolithic wall system with superior strength, insulative, and sound
attenuation characteristics, when the vertical tongue & groove
(t&g) joints are adhesive sealed and the cores are reinforced*
and grouted**.
* The steel reinforced support
cores can be pump-grouted with materials ranging from ordinary
structural concrete to our lightweight, high-strength structural
"SmartCrete™" products.
** The grouted cores represent the
structural strength of the bearing wall system and, when properly
specified, are superior in structural characteristics to any
conventional framed wall method.
-
An entire building envelope,
including exterior and interior walls in CastleFoam™, plus the
roof, can be field erected in 1 to 2 days, depending on the
complexity of the structure. (This time frame is based upon the floor
slab being already in place at the time the CastleFoam™ is
delivered to the site.)
-
With submission of complete
building plans, wall and corner billets with grouting cores and
t&g connections are prepared with precut door and window
openings, ready for grouting and insertion of energy efficient, noise
abating pre-hung metal framed doors and metal and vinyl framed windows.
(The window and door frame package
can be ordered and also site delivered with the CastleFoam™
building envelope package)
-
The roof can also be specified
with galvanized steel trusses and corrugated sheet metal roof decking
as a substrate for the "SmartCrete™" lightweight,
insulative and fire proof composite, thus providing a structure built
without wood products.
-
Walls, depending on thickness, can
have R rating in multiples of conventional wall construction values
with superior structural strength and increased resistance to high
winds and seismic events.
-
Exterior walls are sprayed
directly with smooth or textured pre-pigmented (colored) synthetic
stucco in conjunction with a wire mesh or scrim, or can be covered in
any number of architectural finishes such as wood or vinyl siding,
brick or masonry veneers, etc.
-
Interior walls are sprayed with
pre-pigmented synthetic interior wall surfacing compounds resembling
plaster, without wire mesh or scrim, thus eliminating the need for
drywall installation, taping, texturing and painting, while providing
a fire resistant barrier. Conventional drywall may also be used, if desired.
-
Floors and decks can be
"SmartCrete™" site-cast pours over corrugated metal sub-flooring.
* The products provide design
flexibility for use in floor systems for single story, two story and multi-story
structures with full basements.
|
