Insulated Concrete Envelope Design

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Energy Efficient Envelope Design

with Insulated Concrete
Thermomass
1000 Technology Drive Sandwich Walls
Boone, Iowa 50036 USA
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©2011, 2014 ∙ Table of Contents Slide 1 of 83

Energy Efficient Envelope Design with

Insulated Concrete Sandwich Walls
Presented By: Thermomass
1000 Technology Drive
Boone, Iowa 50036 USA
Description: Provides an overview of insulated concrete sandwich walls, their benefits, applications,
thermal and moisture resistant properties and contribution to sustainable buildings.
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Purpose and Learning Objectives
Purpose: Provides an overview of insulated concrete sandwich walls, their benefits,

applications, thermal and moisture resistant properties and contribution to sustainable
buildings.
Learning Objectives:
At the end of this program, participants will be able to:
• list the sustainable characteristics of insulated concrete sandwich panels over traditional
concrete construction
• explain the difference between material and performance R-value of an insulated
concrete sandwich wall panel
• list three options for connector materials and their life cycle impact
• relate the thermal and moisture resistance properties of sandwich wall panels and the
materials that contribute to these properties, and
• relate how designers have incorporated sustainable features into various construction
types and applications.

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Overview: LEED® Certification
The U.S. Green Building Council (USGBC) is a 501(c)(3) non profit organization composed
of leaders from every sector of the building industry working to promote buildings and
communities that are environmentally responsible, profitable and healthy places to live and
work. USGBC developed the LEED (Leadership in Energy and Environmental Design)
green building certification program, the nationally accepted benchmark for the design,
construction, and operation of high-performance green buildings.
LEED credit requirements cover the performance of materials in aggregate, not the
performance of individual products or brands. Therefore, products that meet the LEED
performance criteria can only contribute toward earning points needed for LEED
certification; they cannot earn points individually toward LEED certification.
For detailed information about the council, their principles

and programs, please visit www.usgbc.org.

Table of Contents
Introduction to Insulated Concrete Sandwich Walls 9
Types of Sandwich Walls 13
Thermal Performance 31
Types of Rigid Insulation 40
Applications 61
Summary 80
Click on title to view

Introduction to Insulated Concrete Sandwich Walls

Integrated systems, such as insulated concrete

sandwich walls, are growing in popularity because
they eliminate the necessity for multiple systems.
Concrete sandwich walls are the exterior structural
system, the architectural system, and the single
source for both thermal and moisture control.
Insulated concrete sandwich walls consist of two

layers of concrete with a layer of rigid insulation
sandwiched in between. 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. Insulated concrete sandwich walls
combine the traditional benefits of concrete with
the thermal and moisture preventive properties of
rigid insulation. This pairing optimizes the wall’s
thermal mass potential and design flexibility.

Concrete
Concrete can benefit your clients’

needs through:
• speed of construction
• integrated assembly
• limited site disturbance
• long clear spans
• durability
• fire endurance
• economical construction
• attractive appearance, and
• energy efficiency.

With a focus on energy efficiency and sustainable construction, design professionals need
to use building systems that reduce energy use, use fewer non-renewable resources, re-
use materials where possible and contribute to the health and well-being of the occupants.
In effect, a sustainable building meets the needs of not only its users, but also future
generations.
Insulated concrete sandwich walls contribute to sustainable structures: ones that are
energy efficient, are composed of highly recycled components and readily renewable, are
innovative, and are designed to last for decades.
Within this presentation, we will introduce you to the different types of insulated concrete
sandwich walls and their components, with a particular focus on sustainability.

Types of Sandwich Walls

Types of Insulated Concrete Sandwich Walls
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, and
• cast-in-place, where walls are cast vertically with removable concrete forms.

Sustainable Choice
The facility type being considered (i.e. school, hospital, correctional facility, etc.), as well as
location will determine which method is specified and which will have the biggest impact on
sustainability. For instance, in the LEED Sustainable Sites Credit 5.1: Site Development:
Protect or Restore Habitat, these aspects of each method of construction should be
considered:
• 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
• Cast-in-place requires no scaffolding or additional perimeter access.

Sustainable Choice
The use of concrete sandwich walls will also affect IEQ Credit 3.1: Construction Indoor Air
Quality Management Plan. Some insulated concrete sandwich walls do 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.
Also consider manufacturers of this type of wall who use supplementary cemetitious
materials (SCMs) in their panels and reduce the need for virgin materials. Fly ash, slag
cement, and silica fume are industrial by-products that are used as a partial replacement
for portland cement in concrete and are considered pre-consumer recycled content. This
material will contribute towards LEED MR Credits 4.1 and 4.2.

Fabrication of an Insulated Concrete Sandwich

Wall Panel
Form panel’s overall Place exterior concrete Install insulation and Place second layer of
shape including layer, vibrate and level to connector while exterior reinforcing.
architectural features and receive insulation and layer of concrete is still
install necessary connector. wet.
reinforcing.
Place interior layer of Vibrate and level Remove panel from

concrete. interior layer of form and prepare for
concrete to smooth installation.
finish and let cure.

Types of Sandwich Walls
There are two types of

sandwich wall panels:
• Non-Composite Sandwich
• Structurally Composite
Sandwich
We will discuss each panel

type, its design, and limitations
in detail in the following slides.
Non-Composite Wall Panel. Structurally Composite

Wall Panel.

Non-Composite Sandwich Wall Panel
With a non-composite wall:
• you can use site-cast tilt-up, plant-precast, or cast-

in-place construction methods
• the inner and outer wythes work independently of

one another to resist externally applied forces and
are allowed to move due to temperature changes
• the design is for ambient and low-temp facilities
• thermal bow is eliminated, and
• the inner wythe is the structural wythe–the outer

wythe acts only as cladding, resulting in a thicker
wall.

Non-Composite Sandwich Wall Panel
In a non-composite wall:
• the outer wythe minimum exterior

thickness is 2"
• any additional reveal depths are added

to the thickness, and
• the interior wythe is determined by the

minimum design requirements.

Structurally Composite Sandwich Wall Panel
Composite walls can be precast or site-cast tilt-up, and:
• the two layers of concrete act together to support the

loads imposed
• designed for room temperature buildings only
• panels can be cladding or support joist loads
• panels are either prestressed or mildly reinforced
• while the panels are thinner, they may be subject to

solid sections of concrete to achieve composite
action
• minimum wythe thickness is 2", and
• typical configurations include 3" or 4" of concrete.

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, or fiber-composite.

Connection Devices:
Metallic Pin
Metal ties are most common, as they are the least
expensive. These ties have inherent issues:
• They are highly conductive thermal bridges,

which results in energy loss and increases the
likelihood for moisture transmission and the
growth of mold and mildew.
• 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, and
• Once the insulation is compromised, interior

insulation will be required.

Connection Devices: Metal Truss
Trusses are also metal, but are typically used with composite panels. They transfer a lot of
shear, but they are very thermally inefficient. Not only are there solid sections of concrete,
but when there is a connector between the sheets of insulation, there is also a solid rib of
concrete created that will promote moisture migration (as we will discuss later in the
presentation).

Connection Devices: Plastic Pin
Plastic connectors have low conductivity, but they do have some drawbacks. They have a
limited factor of safety due to low levels of pull-out and shear strength. Also, concrete and
plastic (nylon or polypropylene) expand and contract at a different rate, resulting in the
potential for spalling.

Connection Devices: Carbon Fiber Grid
The fourth type of connector is a grid made of carbon fiber. As compared to other sandwich
panel connectors, this is a relatively new entry into the precast market and is designed to
create composite panels. While non-conductive, it is extremely brittle and relies heavily on
the bond between concrete and insulation, typically EPS.
When any connector is installed between the sheets of insulation, a gap is created through
which concrete matrix can penetrate and create thermal bridging. This type of thermal
bridging can be as detrimental as those detailed around panel edges and lifting inserts.

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.

Fiber-composite connectors are supplied as a system along with rigid insulation. The
insulation is provided to the job-site and cut beforehand with the connector locations
determined by means of predrilled holes. This ensures proper installation. Also, the fiber-
composite rod and overmolded collar are designed in such a way to withstand the high-
alkali content of concrete and be installed to the proper depth in the concrete. These
connectors are:
• tested in accordance with ICC AC320

• composed of E-glass fibers and E-glass/vinyl ester resin
• able to negate thermal short circuits in the wall panel, and
• similar coefficient of thermal expansion as concrete.

Connection Devices: Thermal Efficiency
These thermographic images clearly demonstrate how efficient a wall panel is with edge-
to-edge insulation and non-conductive connectors, when compared to other materials.
Metal Ties Carbon Fiber Fiber‐Composite

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 five 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, Refrigerating 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 affects the
HVAC equipment sizing, contributes to points for a green building rating program (i.e.
LEED), and improves the bottom line for the owner.

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 Exterior: Outside of the bulk Integral: Sandwiched
the bulk mass of the wall system. mass of the wall system. between substantial
1. Insulate the mass to the exterior, 1. Limits the architectural features amounts of mass.
defeating the benefit of thermal mass possible (as we will show later in 1. Mass is in correct location
2. Must be covered with drywall, which the presentation) 2. Insulation is protected
defeats the benefit of durable, interior 2. Secondary trade must install the 3. Architectural exterior concrete
concrete insulation, slowing construction
4. Durable interior concrete
3. Secondary trade must install the
5. No additional trades
insulation, slowing construction

Effective R-Value
In the drawing at right are the materials

that make up a thin brick-finished
sandwich wall. The majority of the
material R-value comes from the 2" of
insulation. The assembly material R-value
is only part of the overall sandwich wall
performance.
R-value of the wall area will impact the

Energy & Atmosphere (EA Credit 1)
portion of LEED®.

Effective R-Value
In the table at right are the wall

section R-values of the materials in Panel of 3.5" Exterior Concrete / 2" XPS
the previous slide. Insulation / 3" Interior Concrete
Component R‐value
Interior Air Film 0.68
3" Concrete 0.24
2" Continuous Insulation 10.00
3" Concrete 0.24
½" Thin Brick 0.10

Effective R-Value
There are two insulating values tied to high-mass sandwich wall panels: Material R-value
and 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%.
INSULATED CONCRETE CONVENTIONAL

WALL BUILDING INSULATED BUILDING
DAY 1 DAY 2 DAY 3

Performance Analysis: ASHRAE 90.1
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 wall’s heat capacity, insulation position,
building location, occupancy type and floor-to-wall ratio.

Performance Analysis: ASHRAE 90.1

ASHRAE 90.1-2001 Compliant Building Envelope
For this project–a high school in Ohio–the Performance Study. Provided for: New Logan High
sandwich wall panel performs equivalent School. Logan, OH
to an R-value of R-25.69. This is the R-
value a wall without mass would need to
have in order to perform equally to the
insulated concrete sandwich wall.
Historically, buildings constructed with
insulated concrete sandwich walls have
contributed towards a tonnage reduction of
up to 37%.
Calculations will show at what R-

value an integrally insulated high-
mass wall panel will perform.

LEED EA Credit and R-Value
As we have seen, insulated sandwich wall panels not only have an integral insulation but
also high thermal mass, a property that helps concrete to store heat and moderate daily
temperature swings. Insulated concrete sandwich wall panels can achieve high R-values
and lower HVAC demands.
In addition, large concrete walls have fewer, better sealed joints, reducing uncontrolled air
infiltration. These attributes can help a project earn many of the LEED credits in the
Optimize Energy Performance category.

Types of Rigid Insulation

GHG Abatement Strategies
In 2007, McKinsey & Company studied the costs of implementing various greenhouse gas
(GHG) abatement options, including within the building industry. “Insulation improvements”
were among the more economical measures that provided the fastest payback. As the
graph shows, “insulation improvements” are by far the best measure within the negative
marginal cost items. This graph represents only a few of the abatement options
researched. For the graph in its entirety, visit:
http://www.mckinsey.com/en/Client_Service/Sustainability/Latest_thinking/Reducing_US_gr
eenhouse_gas_emissions.aspx (Accessed September 2011)

Types of Rigid Integral Insulation
Rigid or foamed plastic insulation is a plastic in which 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, and extruded polystyrene.
Expanded Polystyrene. Polyisocyanurate. Extruded Polystyrene.

Expanded Polystyrene (EPS)
Expanded polystyrene or bead board, as it Closed Cell.

is commonly known, is the type of
insulating material used for portable
coolers and cups and has a characteristic Voids.
fusion between its resin beads. In this type
of insulation, the voids in the foam allow
the migration of air and moisture.
Bead Board – Molded Polystyrene.

Overall, this type of insulation needs to be
thoroughly evaluated in sandwich panels,
as:
• at 2" of thickness, it does not typically
qualify as a vapor retarder
• it loses R-value as it gets wet and
absorbs water, and
• there are many variables that need to
be specified (density, R-value, etc.).

Expanded Polystyrene (EPS)
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:
• R-value – as the density goes up, the R-

value increases
• Compressive Strength – as the density
goes up, so does the compressive
strength
• Water Vapor Permeance (WVP,
measured in perms) – as the density
goes up, the WVP goes down. The
lower the number, the better, and
• Water Absorption Percentage – EPS
has the highest % when compared to
the next two types of rigid insulation.

Polyisocyanurate
Most designers are familiar with

polyisocyanurate insulation in roofing
applications, as it has a high R-value per
inch. In sandwich wall applications,
polyiso with impermeable facers should
always be used. Common impermeable
facers include poly and aluminum.
Impermeable facers provide greater

perm ratings and aid in the retention of
R-value. For sandwich panels, this
insulation requires a poly facer, as it will
not negatively react with the alkalinity of
the concrete.

Polyisocyanurate
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
• has a perm rating less than 0.02, which is the same as a 10-mil poly sheeting
• very high heat tolerance of 250°F = ideal for steam curing

Polyisocyanurate Facer Sheet
The addition of the facer sheet provides the insulation with a very low perm rating, allowing
it to qualify as a vapor retarder, 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
Type I I II
Class I II
Facer Triplex aluminum poly facer Foil Felt or Glass Fiber Mat
R‐value/inch @ 75°F 6.5 6.5 5.6
Compressive strength minimum psi 25 25 16
WVP, max perm for 1" <0.02 <0.03 1
Water Absorption max, %/vol 0.05 0.05 1.50

Extruded Polystyrene (XPS)
The third and final type of insulation is

extruded polystyrene or XPS insulation.
What is unique about XPS foam is that at
1.5" thick, it qualifies as a vapor retarder
and does not absorb water. In fact, this
type of insulation was initially developed for
use as buoyancy billets for docks.
The most common is Type IV EPS, which

has an R-value/inch of 5.0 and a
compressive strength of 25 psi.

Extruded Polystyrene (XPS)
The following characteristics make XPS the ideal choice for insulating wall panels:
• Steady R-value • Does not absorb water

• High compressive value • 100% recyclable
• Vapor retarder
Type X IV VI VII V
Density, min pcf 1.35 1.60 1.80 2.20 3.00
R‐value/inch @75°F 5.00 5.00 5.00 5.00 5.00
Compressive Strength, min psi 15 25 40 60 100
WVP, max, perm for 1.5" 0.55 0.55 0.55 0.55 0.55
Water Absorption, max, % by vol. 0.3 0.3 0.3 0.3 0.3

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 insulation’s
thermal performance is extreme! Insulation
must stay DRY to perform.
In general…
“for every 1%
Water conducts
heat 24 times
water absorption
faster than air there is a
reduction in
R-value of about
5%!”

LEED MR Credits
The type of insulation and the type and amount of recycled content can impact the
Materials & Resources Credits 4 and 5 concerning recycled content and regional materials
(Credits 5.1 and 5.2) and the Recycled Content (Credits 4.1 and 4.2) sections of LEED.
Insulation within an insulated concrete wall can be made with partially recycled material:
XPS - Extruded Polystyrene

10%-40% post-industrial recycled
ISO - Polyisocyanurate
11%-18% post-consumer recycled

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.
Since the insulation is the single source of

thermal and moisture control, specifying the
correct thickness and type is critical.

Air and Moisture Management
In the next few slides, we’ll take a look at how the concrete sandwich wall contributes to
reducing both vapor diffusion and air infiltration.
Vapor diffusion is the process by which water vapor migrates through a wall system. Each
component of the wall system has a perm rating. According to the American Society for
Testing and Materials (ASTM), a material must have a Water Vapor Permeance (units are
perms) or perm rating of 1.0 or less to qualify as a vapor retarder. As we saw earlier, XPS
has a perm rating of 0.55 and ISO has a perm rating of 0.02‒both are vapor retarders.
EPS is not a vapor retarder, with a perm rating of 3. In comparison, gypsum, concrete, and
plastic sheets span the spectrum of perm ratings.
Average Perm Ratings for Different Wall Materials
Gypsum 12 – 50 perms

Plastic Sheet Barriers (2‐10 mil) .16 – .03 perms
Rigid Insulation 5.8 – .03 perms
Concrete 3.2 perms

Air Infiltration
Air infiltration has significant effects on the amount of energy required to heat and cool a
building. It may also result in reduced thermal comfort, interference with the proper
operation of mechanical ventilation systems, and damage of building envelope components.
• 15% to 20% of air leakage in buildings occurs at doors and windows.

• 20% to 50% of air leakage occurs through the walls.
Moisture will move into or across a wall by vapor diffusion and/or air movement.
Condensation resulting from air infiltration can be greater than condensation from vapor
diffusion. Concrete walls qualify as air barriers because they are low air permeable
materials when joints are properly sealed, whereas concrete block, acoustic insulation,
open cell polystyrene insulation or fiberboard would not qualify.
Examples of Average Air Leakage, cfm/ft2 of Surface at 0.3 in. H2O
½" Fiberboard Sheathing 0.31
Expanded Polystyrene 0.93
Extruded Polystyrene No measurable leakage

Air and Moisture Considerations
Why would a building have moisture problems?
• Poor sealing of the wall-air barrier and vapor retarder

at window joints within the wall
• Penetration of rainwater into the wall at a joint
• Condensation of moisture or frost formation on the
inside of windows
• Excessive leakage of warm, moist air either inside
during summer or outside during winter
• Solid areas of permeable concrete
• Thermal short circuits
To eliminate many of these potential causes of moisture

infiltration, joints need to be detailed properly, and the
insulation needs to be continuous.

In a cold/mixed climate, the wall will cool from

the outside through thermally conductive
sections. Insulation is critical in preventing the
warm, moisture-laden, interior air from coming
in contact with these cold surfaces.
These surfaces are the locations where

condensation will occur, especially if the perm
rating of the devising material is
greater than 1.0.

In a hot/mixed climate, it is also common

for diffusion to occur from the exterior
side of the wall. Not only can wind-driven
rain be absorbed in the exterior and
stored, but high humidity levels can also
promote moisture migration.
Moisture will again diffuse and become

condensation, especially if the material
perm rating is greater than 1.0.

Dew-Point
Dew-point theory predicts condensation in a system at any point where the actual and
dew-point temperature lines cross. To confirm that a wall assembly will not have moisture
issues, ask that a dew-point analysis is performed and be included in the concrete
contractors submittal package. A dew-point analysis can show what the wetting potential
may be for certain wall systems under specific climate conditions. This will also allow the
concrete contractor to predict the proper thickness and type of insulation.
Please remember the exam password INSULATING. You will be required to enter it in order to proceed with
the on-line examination.

Dew-Point
Extruded insulation and polyiso are both

closed-cell products. Using the proper
thickness of these types on insulation allows
the dew-point to occur in the core of the
insulation or in the exterior wythe of the
concrete, where it will exfiltrate.

With concrete sandwich wall there is

no “cavity” in which moisture can
collect. The wall can be designed for
the dew-point to occur in the
foam/insulation layer or the exterior
wythe.
When designed properly, this type of

wall doesn’t have thermal bridges, and
the wall is resistant to moisture.
Closed-cell insulation does not
support the growth of mold and
mildew.
Finally, edge-to-edge detailing

prevents vapor diffusion and air
infiltration.

Applications

Applications
Design professionals are constantly searching for

building systems that provide energy efficiency and
contribute to sustainable construction‒that is, buildings
that are energy efficient, are composed of highly
recycled and readily renewable components and are
innovative and designed to last for decades.
Throughout the course, we have seen a number of

ways insulated concrete sandwich walls contribute to
the LEED rating system and energy savings. Let’s take
a further look at some applications for insulated
concrete sandwich walls.

Retail Center Applications
Retail centers aren’t typically designed to be sustainable, but some owners recognize that
sustainable sites and recycled materials can impact ROI. In this case, a thin brick exterior
saved on clay material, and the site-cast construction limited site impact.

Not all retail centers are brick or have panels cast on-site. 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 fiberglass insulation as insulation is integral to the wall. The cavity
becomes conditioned space. This design created better indoor air quality and utilized
regional materials.

Correctional Facility Applications
This project was constructed with plant-cast or

factory-cast walls for the exterior shell, and precast
prestressed 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. The envelope’s high
R-value and regional materials contributed to LEED
Silver Certification.
El Paso County Correctional:

Colorado Springs, Colorado
LEED® Silver Building

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.

This also creates a very durable structure,

designed to last 100 years. All new Federal
Correctional Institutes must be designed to
achieve LEED Silver Certification.

Spiritual Facility Applications
By not using natural stone, one saves

tremendously on raw materials, and
shipping of materials. This is very
innovative.

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.

Educational Facility Applications
In some cases, to get the finish needed, a

design team needs to make some
sacrifices. In this LEED Silver Building in
South Florida, the designers wanted a
“sea-foam green” concrete color, but the
pigment did not contribute to LEED.
However, since they used a non-
composite sandwich wall, which is cast in
two steps with two different concrete
mixes, only the thin exterior concrete had
to use the portland cement concrete
mixture. The thicker interior layer of
concrete was able to use a large portion
of fly ash, which is very sustainable and
contributed towards LEED.
LEED Silver Building

South Regional Library, Broward
County Community College:
Ft. Lauderdale, Florida

Educational Facility Applications
A great example of color, form, and texture in a higher education facility is presented in this
project at the University of North Florida. Thin brick uses much less material and energy to
make than traditional brick. This, along with the simulated stone, contributed towards LEED
and created a very attractive finish.

Sport Venue Applications
Sport venues also use insulated precast sandwich wall panels. For Ford Field, home of the
NFL’s Detroit Lions, architectural precast panels were used to match an existing
warehouse structure. By using thin brick, this project reduced the amount of clay needed to
accomplish the desired appearance and created a durable, highly efficient structure in
Detroit, capable of meeting ASHRAE 90.1.

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.

Health Care Facility Applications
This method of construction will positively impact indoor air quality, as the interior concrete
will not provide nutrients for mold growth and will also reduce the need for drywall.

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.
This beer distribution

facility in Kentucky
was the first LEED
Certified structure of
its kind.
KY Eagle Beer:
Lexington, KY

Case Study: Catholic University of America

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


Dormitory
The construction concept was based on durability, thermal performance and architectural
features.


Dormitory
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.

Summary

Summary
The characteristic benefits of insulated concrete sandwich panels over traditional concrete
construction are sustainability, speed of construction, an integrated assembly, limited site
disturbance, long clear spans, low maintenance, fire endurance factors, economical
factors, and its attractive appearance.
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. To determine the performance R-value, ASHRAE established a method of
calculation called System Performance Criteria, located in ASHRAE 90.1.

Summary
Fiber-composite connection devices are evaluated by ICC-ES, are non-conductive, non-

corrosive, and 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 a concrete sandwich wall 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.

Conclusion
If you desire AIA/CES and/or state licensing
continuing education credits, please click on the
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Certificate of Completion. researched, assembled, and produced by Thermomass and remains its
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AEC Daily Corporation has met the standards and requirements of

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Purpose and Learning Objectives

Purpose: Provides an overview of insulated concrete sandwich walls, their benefits,

©2011, 2014 ∙ Table of Contents Slide 5 of 83

How to use this On-line Learning Course

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Overview: LEED® Certification

For detailed information about the council, their principles

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Introduction to Insulated Concrete Sandwich Walls 9

Types of Sandwich Walls 13

Types of Rigid Insulation 40

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Introduction to Insulated Concrete Sandwich Walls

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Insulated Concrete Sandwich Walls

Integrated systems, such as insulated concrete

Insulated concrete sandwich walls consist of two

©2011, 2014 ∙ Table of Contents Slide 10 of 83

Concrete can benefit your clients’

©2011, 2014 ∙ Table of Contents Slide 11 of 83

Insulated Concrete Sandwich Walls

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Types of Sandwich Walls

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Types of Insulated Concrete Sandwich Walls

The three main types of insulated concrete sandwich walls are:

©2011, 2014 ∙ Table of Contents Slide 14 of 83

• Insulated concrete walls require very little perimeter access, if any.

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Fabrication of an Insulated Concrete Sandwich

Place interior layer of Vibrate and level Remove panel from

©2011, 2014 ∙ Table of Contents Slide 17 of 83

Types of Sandwich Walls

There are two types of

We will discuss each panel

Non-Composite Wall Panel. Structurally Composite

©2011, 2014 ∙ Table of Contents Slide 18 of 83

Non-Composite Sandwich Wall Panel

With a non-composite wall:

• you can use site-cast tilt-up, plant-precast, or cast-

• the inner and outer wythes work independently of

• the design is for ambient and low-temp facilities

• thermal bow is eliminated, and

• the inner wythe is the structural wythe–the outer

©2011, 2014 ∙ Table of Contents Slide 19 of 83

Non-Composite Sandwich Wall Panel

• the outer wythe minimum exterior

• any additional reveal depths are added

• the interior wythe is determined by the

©2011, 2014 ∙ Table of Contents Slide 20 of 83

Structurally Composite Sandwich Wall Panel

Composite walls can be precast or site-cast tilt-up, and: