Styrofoam and concrete homes? Don’t laugh.
Believe it or not, advancements in product and technique have allowed homes today to be built of styrofoam. In fact, Cape Cod builder Todd LaBarge of LaBarge Homes has become a passionate advocate of Insulated Concrete Form home construction, which uses foam forms and poured concrete for stability and energy conservation. He and his wife, Lori, who own and operate their full-service business together, walk the talk too. They have built two homes for themselves with ICFs, a state-of-the-art technique that emphasizes energy-efficiency, a commitment to recycling and resistance to high winds.
LaBarge is among a growing number of builders using this technique. The forms contain reinforcing steel and concrete and provide the structural system for foundations, houses and swimming pools.
The technique is about 3 percent to 5 percent more expensive for new home construction, but with the new high wind requirements in the updated building code, it may end up being less expensive in the long run. It also begins to pay off immediately, through long-term energy savings, less maintenance, drier and higher finished basements, less risk of mold, quieter interiors and even home insurance discounts, he added.
LaBarge shared his thoughts on ICF building with our readers:
How does the process work?
It is an alternative to standard wood-frame construction. Concrete is poured into the foam forms. The exterior is coated with a peel-and-stick membrane, sort of a rubber wallpaper, below grade for waterproofing and conventional siding above grade. The interior blue board and plaster finishes are attached directly to the forms, as opposed to plain concrete, wood studs, insulation and sheetrock.
The insulated concrete forms can serve solely as a home’s foundation or can be applied to the entire structure, all the way up to the roof. It is formed, poured and insulated simultaneously.
A hot knife is then used to cut tunnels in the foam to accommodate electrical and water lines.
The forms are also very light and easy for crews to manage and install, but in the end, the result is a home as solid and durable as a thousand-year-old masonry villa in Italy.
Why is this process suddenly gaining popularity?
It is much more energy-efficient than standard wood construction. The foam provides continuous insulation, as opposed to traditional insulation with a break at every wood stud. The foam does not loose its R-value even if wet, and the concrete provides a thermal mass that retains the desired temperature. Given the rising concern about hurricanes, it presents a stronger building against high winds. Also, consumers are becoming much more green-conscious, which favors this kind of process.
Some of the advantages to consumers are an energy-efficient building envelope, structural strength and ease of construction. The forms are commonly used for all exterior walls, including the gable ends, but there are aesthetic benefits as well. The concrete walls also lend themselves to more flexibility for floor plans, as well as 12-inch walls that allow deep “antique” window sills and casings to accommodate window treatments like plantation shutters.
How does this process work for installing pools?
The foam forms are filled with concrete, then we install a vinyl liner around the interior. The reinforced concrete is extremely durable and the foam is a great insulator to the earth’s 55-degree temperature, especially if you heat the pool. We can maintain a water temperature of 78 to 80 degrees in the insulated envelope of the pool, as opposed to losing it into the cooler earth.
Homeowners are facing higher insurance rates. Do insurers provide incentives for this kind of construction?
Yes. Many discount the rate because it is classified as masonry construction. Not only is there less risk for wind, but also for fire, since it is not built with wood framing.
What about style and design?
A variety of styles can be achieved, including traditional, contemporary or Nantucket style. One of our homes had 11 gables made of concrete all the way to the roof. Another was designed as a sea captain’s gambrel. It also lends itself to an all-glass flat-roof contemporary style. One other advantage is the relative ease in constructing basements with high ceilings, a growing preference for homeowners who are installing spas and saunas as well as home theaters. An ICF basement will not harbor mold or humidity like a conventional basement.
You emphasize the energy-efficiency of this process. Can a home valued at $1 million actually make up the extra cost of construction through energy savings?
Every home is different, but we are discovering immediate and dramatic savings. One recent client used this process to double the square footage of his home by adding an addition. By using the insulated concrete forms in combination with new radiant heat, he is using less fuel to heat both the new and old sections than he did just heating the original structure.
In another case, a 6,500-square-foot Reddi-Form brand home, with a family of four living year-round at 68 to 70 degrees, has the same heating bill as a conventional wood-built home with 5,500 square feet used only by summer residents – with the heat set at 55 degrees in the winter.
Todd LaBarge can be reached at LaBarge Homes, (508) 432-6360 or info@labargerealestate.com
Published in Cape Business Health & Wealth March/April 2008
