Project Profile: A Missouri Hospital Builds Stronger with EPS

A Montana

A Missouri hospital rebuilds stronger after a tornado largely destroyed most of the health care facility.

Mercy Hospital  |  Joplin, MO.  |  View Project Profile (pdf)

After a force five tornado destroyed St. John’s Regional Medical Center on May 22, 2011, the Joplin, MO. hospital rebuilt with a new stronger facility designed to stand up to devastating wind forces.  After the destruction, architects and engineers analyzed how the nine-story structure reacted to the storm.  Today, a new facility stands stronger with a big tornado in mind….Mercy Hospital.

One of the largest changes to the hospital was the roof in an effort to harden the hospital’s building envelope.  More than any other part of a building, its roof system components must complement each other.  Insulation is a crucial component, because it contributes to a roof system’s thermal performance and overall durability while providing a substrate for the roof membrane.  Tapered Insulfoam was used to help the new hospital roof combat strength, water absorption, stability, stable R-Value and excellent performance.

By using Insulfoam 15″ InsulRoof Taper EPS as part of the roof system on the new hospital, the resulting structure is 30% STRONGER than the requirements for the old hospital.

THE PROBLEM

In the old facility, the design team learned that the metal with insulation on top was removed by the tornado and exposed the inside of the building.  The roof is all concrete decks with a double roof system and a waterproof membrane.  The result, if the hospital loses the roof system, there will still be a watertight and concrete-sealed building.

THE SOLUTION

Mercy

Mercy Hospital, Insulfoam EPS installation

Pre-cut tapered EPS blocks were used to increase roof slope for additional drainage, while offering a long term, stable R-Value, excellent dimensional stability, compressive strength and water resistant properties that meet or exceed the requirements of ASTM C578.  The thick blocks can be factory-cut into single-layer tapered pieces that eliminate the labor of stacking multiple insulation panels.  Tapered EPS can be adapted to accommodate any roof drainage system and roof configuration.

Labor Savings:  There are no complicated filler panel systems.  Tapered InsulFoam can be installed in a single layer for thicknesses up to 40″, making it significantly more cost effective than comparable rigid-insulation tapered systems.  The ultra lightweight nature of Insulfoam EPS further allowed for fast installation.

Promoted Positive Drainage:  Tapered InsulFoam is the ideal insulation for both new construction and re-roofing projects in which positive slope is desired or ponded water is a concern.

Hospital rebuilding

Mercy Hospital, Insulfoam EPS installation

Environmentally Friendly:  100% recyclable if ever removed or replaced.

Stable R-Value:  EPS’s thermal properties will remain stable over its entire service life.  There is no thermal drift, so the product is also eligible for an Insulfoam 20-year thermal performance warranty.

Proven Performance:  The same fundamental EPS chemistry has been in use since the mid-1950’s so the actual performance of the product is well known.

Water Resistance:  Tapered Insulfoam does not readily absorb moisture from the environment.

Code Approvals:  Tapered Insulfoam is recognized by the ICC-ES, and has numerous Underwriters Laboratory and Factory Mutual approvals.

 

 

Project Profile: Target Retail Store Saves 25% Cost Savings in Insulation with EPS

Target  |  King of Prussia, PA  |  View Project Profile (Pdf)

R-Tech Below Grade provided 25% cost savings in insulation on the project without sacrificing performance.

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The Target store located in King of Prussia, PA was constructed different than most and was not built as a slab on grade.  The bottom level of the building is a parking garage while the retail space is located on the second level.  Target used InsulGrade R-Tech as a between slab insulation as a way of insulating the floor of the retail space and providing a thermal barrier between the concrete planks and the floor slab.

DOW XPS was initially specified on the Target project, however; R-Tech was substituted and provided a substantial cost savings while providing both long-term stable and non-degrading R-Value.

PROBLEM & SOLUTION

Space was a challenge for this Target project as the parking garage is on the ground level and the actual retail floor is on the second level.  Concrete planks were installed as the base substrate.  R-Tech was then installed over the plank to insulate the interior of the retail space from the open parking garage underneath.  A topping slab was then poured over the R-Tech to create the retail floor.  The R-Tech insulation has a long-term stable R-Value and is eligible for an Insulfoam 20-Year Thermal Performance Warranty … a warranty that’s not prorated or limited to a percentage of the published R-Value.

InsulGrade R-Tech features a premium factory-applied laminate polymeric facer that is virtually impervious to moisture, keeps water from entering the insulation, and away from concrete foundations and slabs.  Available in 4′ x 8′ panels and thicknesses starting at 3/8″, with compressive strengths from 10-50 psi.

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View Project Profile (Pdf)

PROJECT DETAILS:

EPS vs. XPS

  • Both EPS and XPS are closed-cell insulations
  • EPS and XPS below grade insulations are covered under the same standard- ASTM C578
  • EPS has a more stable R-value and less long-term moisture retention than XPS
  • XPS is 20-40% more expensive for the same compressive strength

Cost Effective

  • Highest R-value per dollar
  • 100%, 20 year R-value warranty
  • 10-30% less than XPS insulations

Green From the Start

  • Up to 20 LEED points possible
  • 100% recyclable
  • contains up to 15% recycled content
  • Minimal job site waste
  • No thermal drift
  • Helps preserve energy and fossil fuels

R-Tech Uses

R-Tech has been used successfully for numerous commercial, industrial and residential applications:

  • Below grade insulation
  • Waterproofing protection board
  • Cavity walls
  • Interior walls
  • Cold storage & freezers
  • Sheathing
  • Concrete panel insulation
  • Concrete slabs
  • Radiant heated floors

PROJECT OR EPS QUESTIONS

Jason Myers

Jason Myers, Insulfoam Territory Sales Manager

Contact Jason Myers, Insulfoam Territory Sales Manager

Cell:  609-385-8930

Email:  Jason.Myers@insulfoam.com

Connect with Jason on LinkedIn  |  Follow Insulfoam on LinkedIn

 

Project Profile: Idaho Bridge Expansion & Replacement

Topaz Bridge Expansion & Replacement  |  McCammon, Idaho  |  View Project Profile (pdf)

Idaho’s heavily used trucking route and bridge (circa 1940) expands from 2 to 4 lanes to increase safety and capacity using InsulFoam Geofoam.

Geofoam blocks were used to construct a new 500 foot long, 30 foot tall EPS block embankment.  The new embankment supports the US-30 road expansion and its approach to the new Topaz bridge - notably the longest span in the state of Idaho.

Geofoam blocks were used to construct a new 500 foot long, 30 foot tall EPS block embankment. The new embankment supports the US-30 road expansion and its approach to the new Topaz bridge – notably the longest span in the state of Idaho.

Topaz Bridge

The pavement section is constructed on top of the 45 foot tall combined soil & Geofoam block approach fill

Idaho Transportation Department’s first EPS Geofoam project was designed by Terracon Engineers and JUB Engineers of Boise.  EPS was specified as a soil replacing embankment fill material due to poor foundation soils and 2 steel fish culverts that could not bear the weight of traditional soil fill.  A new three-span, bridge replaced the existing bridge (from the 1940’s) crossing rail road tracks and expanding the highway to 4 instead of 2 lanes.  23,000 cubic yards of large block EPS was installed by Scarsella Brother Inc. and supplied by Insulfoam.

THE PROBLEM

The expansion of the US-30 and bridge replacement required a new fill embankment to support the new roadway and bridge approach on a very steep side slope.

The new (600 ft long) expanded bridge clears The Pontneuf River as well as the Union Pacific Railroad tracks, and required a new higher grade of both the bridge structure and the existing roadway to support the new wide and long center spans.

EPS

EPS block fill is partially installed, during bridge construction.

As a result the new bridge approach embankment would be 45-50 feet high, too costly to be retained by conventional concrete cantilever or MSE wall, and raised concerns about global stability.

Further challenges to the project design were the site conditions.  Located adjacent to the Portneuf River, shallow bedrock and loose or soft sediments underlie the new approach embankment.  This both challenged the new roadway embankment’s strength and stability, and limited deep foundation designs required with concrete walls.

THE EPS GEOFOAM FILL SOLUTION

To reach the new bridge’s approach embankment height of 45 feet, engineers chose a combined fill solution.  The lowest 15 feet was a small earthen embankment, while InsulFoam GF constituted the upper 30 feet.  4 1/2 feet of granular fill retained in wire gab ions and an asphalt pavement section were installed directly on top of the EPS blocks to complete the full height of the new embankment.

Custom fabricated "tongs" grip the large EPS blocks without damaging them.

Custom fabricated “tongs” grip the large EPS blocks without damaging them.

The exposed vertical face of the EPS is eventually covered with a protective shotcrete facing.

The exposed vertical face of the EPS is eventually covered with a protective shotcrete facing.

 

 

 

 

 

 

 

 

 

The soft sediments underlying the site required the lower earthen embankment to settle (80 days), but the InsulFoam GF block fill required no additional surcharge time or secondary compaction by the contractor.  Traffic moved on the existing roadway throughout the installation of the upper embankment, which was a key factor for the expansion to finish when weather conditions permitted.

Net

Near “Net-Zero” surcharge loads.  The void in between the blocks and the native slope was filled with sand.

The ultra lightweight nature of EPS allowed the total design weight of the tall embankment to be week under the bearing capacity of the poor foundation soils which aided ITD in successfully completing their first EPS Geofoam project.

Geofoam Lightweight Geo-synthetic Fill:

  • Soft Soil Remediation
  • Lateral Load Reduction
  • Slope Stabilization
  • Buried Utility Protection
  • Structural Void Fill
  • Predictable Elastic Modulus
  • Exceptional Strength & Stability
  • Exceeds 75 year Design Life
  • Weather, Insect & Mold Resistant
  • 100% Recyclable

 

MORE GEOFOAM SOLUTIONS IN HIGHWAY CONSTRUCTION

View Project Profile (pdf)

INSULFOAM GEOFOAM QUESTIONS:

 

Nico Sutmoller, Insulfoam Geofoam Specialist

Nico Sutmoller, Insulfoam Geofoam Specialist

Contact Nico Sutmoller, Below-Grade & Geofoam Specialist

nico.sutmoller@insulfoam.com

Connect with Nico on LinkedIn

Read more on Insulfoam.com

Project Profile: Arizona Deep Residential Retrofit

 Deep Residential Retrofit  |  Phoenix, Arizona  |  View Project Profile (pdf)

1951 abandoned house is transformed into an energy-efficient home.

Arizona

Using strategies including the R-Tech Wall System, the home was able to achieve a high Gold rating certified under the Phoenix Green Construction Code.

Before

Before Retrofit

This Arizona residential retrofit became the first project to be certified under the Phoenix Green Construction Code, receiving a Gold rating from the program. The deep retrofit project aimed to conserve water and energy, on an existing 1,000 square-foot, abandoned house originally built in 1951, and transformed it into a cutting-edge, energy-efficient home with 1,970 square feet, four bedrooms, and two bathrooms. Using strategies including Insulfoam’s R-Tech in the wall assembly the home was able to achieve a high Gold rating. The R-Tech insulation panels are large and can be assembled in the wall system continuously to reduce the amount of gaps in insulation for cold air to escape, or warm air to come in. Reducing gaps and increasing insulation was key to this home being able to reach its energy goals.

THE PROBLEM

During Construction

During Retrofit

The project started with a 1951 home that was stripped and abandoned for over 5 years when it was acquired. The project team’s goals were to turn this 50’s style home into a sustainable residence of strategies on a budget of $95 per square foot, all while in the Arizona heat. The project team took the 1,000 square foot ranch style home and completely renovated the existing living space top to bottom, while adding another 900 square feet of living space. Insulfoam R-Tech was chosen to reach its goals of large reductions in energy use and reduce landfill waste during the construction process.

The R-Tech insulation panels are large and can be assembled in the wall system continuously to reach the following goals:  air infiltration and moisture penetration are eliminated, thermal bridging and thermal shock is greatly reduced, surface cracking is minimized, and the EPS material does not sustain mold and mildew growth. These benefits lead to lowered operating costs to improved occupant comfort. 

THE SOLUTION: R-Tech Wall System

R-Tech has no thermal drift.  Designers are well served knowing the R-Tech thermal properties will remain stable over its entire service life.

R-Tech has no thermal drift. Designers are well served knowing the R-Tech thermal properties will remain stable over its entire service life.

Environmentally Friendly: R-Tech contains no dyes, may contain recycled material and the foam core is 100% recyclable.

User Friendly: R-Tech can be ordered with the InsulSnap feature which scores the product longitudinally at any pre-ordered interval (commonly 16” or 24” o.c.). The InsulSnap feature minimizes labor by enabling the installer to cleanly break the product at the desired width while also minimizing product breakage and waste.

Insect and Mold Resistant: R-Tech is manufactured with an inert additive that deters termites and carpenter ants. R-Tech does not sustain mold and mildew growth.

Water Resistance: R-Tech facers provide a surface that is virtually impervious to moisture.

Jobsite Durability: With a polymeric facer on either side of the R-Tech, it is an extremely flexible and durable insulation.

Stable R-Value: R-Tech has no thermal drift. Designers are well served knowing the R-Tech thermal properties will remain stable over its entire service life. R-Tech is eligible for an Insulfoam 20-Year Thermal Performance Warranty – a warranty that’s not prorated or limited to a percentage of the published R-Value.

Cost Effective: R-Tech is typically less expensive than other comparable insulation products.

Proven Performance: The same fundamental chemistry has been in use since the mid-1950’s, so the actual performance of the product is well known. 

Insulfoam EPS:
From foundation to roof and everything in between

High Performance.  Lower Cost.  Most R-Value Per Dollar.  Many architects and contractors are familiar with EPS insulation as a cost-effective option for roof applications; however, EPS’ benefits expand a wide range making it easier than ever for designers to create an energy efficient building project.  InsulFoam EPS rigid foam insulation has been used for decades by smart industry professionals looking to achieve high thermal properties for a cost-effective price.  In fact, EPS offers more cost savings and higher R-Values than any other rigid insulation.  The benefit of lightweight EPS goes far beyond price, since it also helps contractors significantly decrease material and labor expenses.  View all EPS project profiles:  Roofing, Below Grade, Walls, Geofoam, Premier SIPs.

  • Roof Insulation Systems
  • Below Grade & Under Slab Insulation
  • Wall Insulation
  • Geofoam – Transportation & Earthworks
  • SIPS: Structural Insulated Panels
  • Building Envelope Insulation Systems
  • Architectural & Specialty Shapes
  • O.E.M.: Garage Doors, RVs, Cold Storage & More
  • Commercial & Residential

View Project Profile (pdf)