Man Hour Rate: Jobs to Staff For
Before starting any ICF job it’s important to understand the demands of the project. There are a variety of jobs that you’ll need to staff for. In this section we discuss the different jobs present and what they entail.
Staging of Materials
Stage all materials inside the work area and 6 feet back from the future walls. Stage and organize ICF blocks, bracing, and tools so that they are easy to find. If you are stacking the walls of a basement and then installing a flooring system, only stage the materials you need for this first portion of the job.
Stacking ICFs
Crews will stack ICF blocks beginning in a corner and working around the structure. Keep blocks in line with chalk lines that are snapped onto the footing or slab.
Placing Rebar Reinforcement
Steel rebar is used throughout the ICF build. Team members will:
- Place vertical rebar pins in the foundation
- Measure, cut, and bend rebar to create the appropriate laps in walls
- Place horizontal rebar inside the forms, alternating left and right of center every course
- Place vertical rebar inside the forms between the vertical chase created by horizontal bars
Creating and Bucking Openings
Team members will cut ICF blocks to create necessary openings for doors and windows. They will also create, install, and brace bucking for all openings.
Erect Bracing and Alignment Systems
After the third or fourth course is stacked, team members will erect and install the bracing and alignment system.
- The anchor foot should be securely fastened to the foundation or staked into the ground
- The wall should be straight and plumb
- Screws attaching the strongback to the ICF wall should be placed at the top of the slot to allow for settling
- Apply any necessary walk boards and safety rails
Aligning Walls
After the wall is poured team members should check the bracing system and adjust the wall for level. Use a string line and level or laser level to ensure the wall is level and plumb. Use the adjustment mechanism on the bracing to make slight adjustments as the concrete sets.
Create and Install Embedments
It may be necessary to cut ICF blocks for many different types of penetrations, beam pockets, and blockouts. Understand your projects needs and direct your team on how to create and install embedments.
Pouring and Consolidating Concrete
Concrete is poured into ICF walls in four foot lifts, working around the structure in a continual direction. The team member in charge of pouring should be familiar with best practices when pouring an ICF wall and be able to communicate effectively with the pump operator. A separate team member will use an internal wall vibrator to vibrate each lift of concrete into the lift below it. This temporarily returns concrete to a liquid state and helps to prevent voids and maintain the structural integrity of the wall.
Installing Flooring Systems
Three days after the concrete is poured the top plate and flooring system can be installed. If continuing up another story, you can also begin stacking additional courses.
Jobsite Cleanup
After the walls are poured the crew should spend a little time cleaning up around the jobsite. Completing these tasks immediately after the wall is poured will save great time and labor.
- Clear any garbage from the site
- Use a soft broom to clear debris from the face of the ICF wall
- Sweep the foundation clean
Loadout
After one week, the concrete will have cured enough to remove the bracing systems from the wall. They should work together to disassemble the bracing system, organize any leftover tools or materials, and load out all ICF related materials to prepare the job for other trades.
