KVandyke and Associates

Essays

SIPs, PTFs, ICFs, & PICs: Our Experience In Innovative Construction Methods

• Ken VanDyke • Essays

After working a decade in substantial reconstruction of existing homes and commercial buildings I had a lot of good insights into why buildings failed or endured over time, and how the materials and structure of a building interacted with the lives and behaviors of the occupants. Working for not-for-profit housing developers, I became interested in the construction of new homes that were affordable, durable and efficient, what today we call “sustainable.” With a desire to try some innovative approaches with new technologies, I started a general contracting company in 1986.

Structural Insulated Panels (SIP) were just coming into the market, and our first SIPs project was the Murray Lake House. This custom-built small retirement home was a K. VanDyke design/build project, and was constructed on the foundation of a former summer cottage, on a hill overlooking the lake.

SIP Unloaded
Structural insulated panels being delivered to the jobsite. Wall panels have a 3.5 inch expanded polystyrene core, roof panels have a 7.5 inch EPS core.

The Joan Avenue House, also a K. VanDyke design/build, was another SIPs project, constructed in 1987.  Photos of SIPs being used in the construction of this home are shown below.

Wall sections going up. The front wall as seen from the interior.
Wall sections going up. The front wall as seen from the interior.
The front wall as seen from the exterior. Note that the interior is oriented strand board (OSB) and the exterior is wood siding.
The front wall as seen from the exterior. Note that the interior is oriented strand board (OSB) and the exterior is wood siding.
The first roof panel set in place. Additional window openings in the side wall will be cut out later.
The first roof panel set in place. Additional window openings in the side wall will be cut out later.
Front elevation of the house when completed.
Front elevation of the house when completed.
The first two wall panels are placed.
The first two wall panels are placed.
Additional wall panels being set. Cut-outs have been made for window openings.
Additional wall panels being set. Cut-outs have been made for window openings.
All wall panels in place.
Setting the roof beam.
Setting the roof panels, starting in the center and working each side equally toward the end walls.
Setting the roof panels, starting in the center and working each side equally toward the end walls.
The last roof panel goes down.
The last roof panel goes down.
The building with windows and skylights in place and roofing in process.
The building with windows and skylights in place and roofing in process.
Exterior view of the pressure-treated wood foundation wall. Note the 2x12 bottom plate and extended gravel bed. The wall will be wrapped in a moisture-barrier membrane before backfill.
Exterior view of the pressure-treated wood foundation wall. Note the 2×12 bottom plate and extended gravel bed. The wall will be wrapped in a moisture-barrier membrane before backfill.
The project 23 years later.
The project 23 years later.

A Pressured-treated Wood Foundation,(PWF) was used for the Joan Avenue House, because the lower level was designed to be living space.  It was clear from the outset that an empty, poorly insulated basement has no place in our residential design perspective; we believe that the below-grade portion of every home should be as habitable and well-insulated as the rest of the home.  This approach reduces the home’s overall footprint and cost per square foot of living space.  A Pressure-treated Wood Foundation was also used for the Springdale House, and other projects.

A bed of crushed stone is placed in the footing trenches and under the entire “basement” floor area. The boxed out areas are for interior structural footings.
A bed of crushed stone is placed in the footing trenches and under the entire “basement” floor area. The boxed out areas are for interior structural footings.
Pressure treated lumber framed foundation walls, as seen from the interior. These are placed directly on the stone, using a 2x12 bottom plate.
Pressure treated lumber framed foundation walls, as seen from the interior. These are placed directly on the stone, using a 2×12 bottom plate.
The lower-level living space, before pouring the concrete floor.
A vapor barrier of 6 mill poly and a layer of two inch foam insulation board are placed over the stone in the future lower- level living area.
An insulated concrete form foundation under construction.
An insulated concrete form foundation under construction.
A precast insulated concrete wall foundation under construction.
A precast insulated concrete wall foundation under construction.

In 1987 Insulated Concrete Forms (ICF) were introduced to our local market, and we did a residential addition with them late that year.  We built our first ICF home foundation in 1988 doing all the work with our crew as there were yet no concrete contractors experienced with the product.  Today there are a wide variety of ICF products available and we use contractors we specialize in this construction.

Developed in the early 1980’s and introduced to our market area in 1997,  Precast Insulated Concrete walls (PIC),  use a crushed stone base similar to that of a wood foundation system. These walls come with an R-5 insulation value and are set up so that adding additional insulation, wiring, plumbing, and drywall finish can all be done with standard field techniques. This foundation system is manufactured and installed locally by Great Lakes Superior Walls Systems.    This is system is another very attractive option for foundations, especially when time or working space is limited.  We have used these in both single-family and multi-family residential construction.  (See www.greatlakessuperiorwalls.com)

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