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[CCMC 13354-R] CCMC Canadian code compliance evaluation

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Compliance opinion

It is the opinion of the Canadian Construction Materials Centre that the evaluated product, when used as a flat insulating concrete form wall system in accordance with the conditions and limitations stated in this evaluation, complies with the following code:

National Building Code of Canada 2015

ID Code provision Solution type
03-01-05-14-00-0-003.1.5.14. Combustible InsulationAcceptable
04-01-00-00-00-0-004.1. Structural Loads and ProceduresAcceptable
04-01-01-03-04-c-004.1.1.3.(4)(c) CAN/CSA-S269.3-M, “Concrete Formwork.”Alternative
04-03-03-01-00-0-004.3.3.1. Design Basis for Plain, Reinforced and Pre-stressed ConcreteAcceptable
09-03-01-01-00-0-009.3.1.1.(4) For flat insulating concrete form walls ...Acceptable
09-10-17-10-00-0-009.10.17.10. Protection of Foamed PlasticsAcceptable
09-15-01-01-01-c-009.15.1.1.(1)(c) Flat insulating concrete form ...Acceptable
09-15-03-03-00-0-009.15.3.3. Application of Footing Width and Area RequirementsAcceptable
09-15-03-05-01-c-009.15.3.5.(1)(c) 150 mm for each storey ...Acceptable
09-15-04-01-00-0-009.15.4.1. Permanent Form MaterialAcceptable
09-15-04-02-00-0-009.15.4.2. Foundation Wall Thickness and Required Lateral SupportAcceptable
09-15-04-03-00-0-009.15.4.3.(5) Flat insulating concrete form foundation ...Acceptable
09-15-04-04-00-0-009.15.4.4. Foundation Walls Considered to be Laterally Supported at the BottomAcceptable
09-15-04-05-00-0-009.15.4.5. Reinforcement for Flat Insulating Concrete Form Foundation WallsAcceptable
09-20-01-01-01-b-009.20.1.1.(1)(b) flat insulating concrete form ...Acceptable
09-20-01-02-00-0-009.20.1.2. Earthquake ReinforcementAcceptable
09-20-15-01-00-0-009.20.15.1. Amount of ReinforcementAcceptable
09-20-17-00-00-0-009.20.17. Above-Ground Flat Insulating Concrete Form WallsAcceptable

The above opinion(s) is/are based on the evaluation by the CCMC of technical evidence provided by the evaluation holder, and is bound by the stated conditions and limitations. For the benefit of the user, a summary of the technical information that forms the basis of this evaluation has been included.

Product information

Product name

Polycrete®Big Block 1600

Product description

The product is a foldable, modular, flat insulating concrete form wall system consisting of two expanded polystyrene (EPS) panels. Embedded within the EPS panels is steel wire mesh reinforcement connected with metal ties during the manufacturing process. The forms are dry-laid and stacked in a running (staggered) configuration. The stacked units form a rectangular space, which, after being filled with concrete, forms an insulated monolithic concrete wall of uniform thickness. The polystyrene panels have a preformed interlocking mechanism along their top and bottom edges to facilitate stacking and to prevent the leakage of freshly placed concrete.

Reinforcement may be placed where required to satisfy strength requirements for above- or below-grade loadbearing walls, beams, lintels, and shear walls. The units have external dimensions of 2 440 mm in length and 305 mm, 460 mm and 610 mm in height. The polystyrene panels are 64 mm thick resulting in an overall wall thickness of 270 mm, 320 mm, 370 mm, and 420 mm. The forms are available in straight, tapered top and brick ledge forms.

Isometric and front view of the product.

Figure 1. Isometric and front view of the product

Manufacturing plant

This evaluation is valid only for products produced at the following plant:

Product nameManufacturing plant
Trois-Rivières, QC, CA
Polycrete®Big Block 1600Product evaluated by the CCMC

Product evaluated by the CCMC Indicates that the product from this manufacturing facility has been evaluated by the CCMC

  Conditions and limitations

The CCMC’s compliance opinion is bound by this product being used in accordance with the conditions and limitations set out below.

  • Use of the product is permitted in the construction of houses and small buildings up to two storeys high that fall under the provisions of Part 9 of Division B of the NBC 2015, subject to all of the conditions listed below.
  • Structural applications of the product must be in strict accordance with the design analysis as prepared for Smag Industries and included in Genivar Report, dated 25 October 2011, from which the tables in the Design requirements section have been reproduced. When the product is used in structural applications outside the scope of the referenced design analysis, a professional engineer skilled in concrete design must certify the design analysis and the design drawings for such applications. The engineer must certify that the construction conforms to Part 4 and/or Part 9 of the NBC 2015.
  • The attachment of exterior cladding and interior finishing materials has not been assessed by the present evaluation. The exterior cladding attachment must be in accordance with Section 9.27., Cladding, of Division B of the NBC 2015. The interior finishes attachment must be in accordance with Section 9.29., Interior Wall and Ceiling Finishes, of Division B of the NBC 2015.
  • The concrete compressive strength shall not be less than 20 MPa after 28 days when used with this product.
  • The maximum aggregate size to be used in conjunction with the product must be no greater than 14 mm.
  • For the wall heights indicated in the tables Vertical and horizontal steel reinforcement for below-grade walls and Vertical and horizontal steel reinforcement for above-grade walls, the pouring of concrete must be made at a rate of 1.3 m per hour in consecutive lifts where each lift is limited to a maximum height of 1.3 m.
  • The EPS insulation used in this system must comply with CAN/ULC-S701-11, “Standard for Thermal Insulation, Polystyrene, Boards and Pipe Covering,” Type 2.
  • The product's EPS insulation panels must be aged for at least three weeks from their date of manufacturing.
  • The interior face of the product panels must be protected from the inside of the building in accordance with Article 9.10.17.10., Protection of Foamed Plastics, of Division B of the NBC 2015.
  • For above-grade installations, the exterior face of the product must be protected with materials conforming to Article 9.20.6.4., Masonry Veneer, and Sections 9.27., Cladding, and/or 9.28., Stucco, of Division B of the NBC 2015.
  • The concrete must be cured a minimum of seven days before backfilling. The top of the foundation wall must be supported by the first floor prior to backfilling.
  • For below-grade installations, dampproofing material must be provided in accordance with Article 9.13.2.2., Dampproofing Materials, of Division B of the NBC 2015.
  • Where hydrostatic pressure exists, waterproofing must be provided in accordance with Article 9.13.3.2., Waterproofing Materials, of Division B of the NBC 2015.
  • For foundation-wall installations, the backfill must be placed in such a way as to avoid damaging the wall, the exterior insulation panel, and the waterproofing or dampproofing protection. The backfill material must be well-drained and a drainage system must be installed around the footing in accordance with NBC requirements.
  • Installation of the product must be in compliance with the “Polycrete Installation Manual,” Version 1.0 Revision 1.10 dated 2011-1-27.
  • The concrete wall must be constructed on a footing designed as per Article 9.15.3.4., Basic Footing Widths and Areas, of Division B of the NBC 2015.

  Technical information

This evaluation is based on demonstrated conformance with the following criteria:

Evaluation requirements
Criteria number Criteria name
CCMC-TG-031119.01-15CCCMC Technical Guide for Modular, Expanded-Polystyrene Concrete Forms

The evaluation holder has submitted technical documentation for the CCMC's evaluation. Testing was conducted at laboratories recognized by the CCMC. The corresponding technical evidence for this product is summarized below.

Material requirements

Conformance of the EPS

Compliance of the expanded polystyrene thermal insulation with the requirements of CAN/ULC-S701-11 Type 2 is covered under the Intertek Testing Services NA Ltd. certification program.

 Design requirements

Conformance of structural capacity (steel reinforcement designs)

The design analysis presented by Genivar for walls using the product provides a level of performance equivalent to that required by applicable provisions in Part 4 and/or Part 9 of Division B of the NBC 2015. The design analysis is summarized in the tables below. The tables provide steel reinforcement specifications for a number of different wall and lintel applications based on specific structural loads. The design assumptions are indicated below each table.

Table 1.  Vertical and horizontal steel reinforcement for below-grade wallsFootnote (1)
Height of walls (m) Backfill height (m) Vertical and horizontal steel reinforcement for below-grade walls for all seismic zones
Maximum vertical steel reinforcement spacing Maximum horizontal steel reinforcement spacing
150-mm wall 200-mm wall 250-mm wall 150-mm wall 200-mm wall 250-mm wall

 

 

 

2.44

1.22 10M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.53 10M at 400 or 15M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.83 10M at 250 or 15M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
2.14 10M at 200 or 15M at 425 10M at 325 or 15M at 500 10M at 450 FI and at 500 FE or 15M at 500 FI and 10M at 500 FEFootnote (2) 15M at 600 20M at 600 10M at 600 each face

 

 

 

 

3.05

1.22 10M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.53 10M at 300 or 15M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.83 10M at 200 or 15M at 425 10M at 250 or 15M at 500 10M at 400 FI and at 500 FE or 15M at 500 each face 15M at 600 20M at 600 10M at 600 each face
2.14 10M at 150 or 15M at 325 10M at 325 or 15M at 500 10M at 350 FI and at 500 FE or 15M at 500 each face 15M at 600 20M at 600 10M at 600 each face
2.44 10M at 125 or 15M at 250 10M at 200 or 15M at 425 10M at 275 FI and at 500 FE or 15M at 500 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
2.75 10M at 100 or 15M at 200 10M at 175 or 15M at 350 10M at 225 FI and at 500 FE or 15M at 400 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face

 

 

 

 

 

 

3.66

1.22 10M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.53 10M at 275 or 15M at 425 10M at 325 or 15M at 500 10M at 500 each face 15M at 600 20M at 600 10M at 600 each face
1.83 10M at 175 or 15M at 375 10M at 300 or 15M at 500 10M at 400 FI and at 500 FE or 15M at 500 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
2.14 10M at 125 or 15M at 275 10M at 225 or 15M at 475 10M at 300 FI and at 500 FE or 15M at 500 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
2.44 10M at 100 or 15M at 200 10M at 175 or 15M at 350 10M at 250 FI and at 500 FE or 15M at 500 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
2.75 15M at 175 10M at 125 or 15M at 275 10M at 200 FI and at 500 FE or 15M at 400 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
3.05 Footnote (3) 10M at 100 or 15M at 200 10M at 150 FI and at 500 FE or 15M at 350 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
3.36 Footnote (3) Footnote (3) 10M at 125 FI and at 500 FE or 15M at 275 FI and 10M at 500 FE 15M at 600 20M at 600 10M at 600 each face
Table 2.  Vertical and horizontal steel reinforcement for above-grade wallsFootnote (1)
Wall height (m) Maximum vertical spacing for reinforcement Maximum horizontal spacing for reinforcement
150-mm wall 200-mm wall 250-mm wall 150-mm wall 200-mm wall 250-mm wall
Single storey concrete construction supporting wood truss roof
2.44 10M at 400 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
3.05 10M at 300 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
3.66 10M at 200 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
Ground floor concrete construction supporting a second storey wood frame and a wood frame roof structure
2.44 10M at 300 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
3.05 10M at 200 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
3.66 Footnote (2) 15M at 300 10M at 400 each face Footnote (2) 20M at 600 10M at 600 each face
Ground floor concrete construction supporting a second storey concrete construction and a wood frame roof structure
2.44 10M at 200 15M at 400 10M at 400 each face 15M at 600 20M at 600 10M at 600 each face
3.05 Footnote (2) 15M at 300 10M at 400 each face Footnote (2) 20M at 600 10M at 600 each face
3.66 Footnote (2) 15M at 200 10M at 400 each face Footnote (2) 20M at 600 10M at 600 each face
Table 3. Minimum steel reinforcement of lintels for 150-mm thick Polycrete® Big Block 1600Table footnote (1)
Width of openings (mm) Uniformly distributed loads (kN/m)
2.0 5 10 15 20 25 30
Lower steel bar Dist. from s/uTable footnote (2) Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u
1 000 2-10M 0 2-10M 0 2-10M 0 2-10M 0 2-10M 0 2-10M 100 2-10M 167
1 500 2-10M 0 2-10M 0 2-10M 0 2-10M 84 2-10M 250 2-15M 350 2-15M 417
2 000 2-10M 0 2-10M 0 2-10M 0 2-15M 334 2-15M 500 2-15M 600 2-15M 667
2 500 2-10M 0 2-10M 0 2-15M 250 2-15M 584 2-15M 750 2-15M 850 2-15M 917
3 000 2-10M 0 2-10M 0 2-15M 500 2-15M 834 2-15M 1 000 2-15M 1 100 Table footnote (3) Table footnote (3)
3 500 2-10M 0 2-10M 0 2-15M 750 2-15M 1 084 2-15M 1 250 Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3)
4 000 2-10M 0 2-15M 0 2-15M 1 000 2-15M 1 334 Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3)
4 500 2-10M 0 2-15M 250 2-15M 1 250 2-20M 1 584 Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3)
5 000 2-10M 0 2-15M 500 2-20M 1 500 Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3) Table footnote (3)
Table 4. Minimum steel reinforcement of lintels for 200-mm thick Polycrete® Big Block 1600Footnote (1)
Opening width (mm) Uniformly distributed loads (kN/m)
2.0 5 10 15 20 25 30
Lower steel bar Dist. from s/uFootnote (2) Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u
1 000 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 34
1 500 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 50 2-15M 190 2-15M 284
2 000 2-15M 0 2-15M 0 2-15M 0 2-15M 67 2-15M 300 2-15M 440 2-15M 534
2 500 2-15M 0 2-15M 0 2-15M 0 2-15M 317 2-15M 550 2-15M 690 2-15M 784
3 000 2-15M 0 2-15M 0 2-15M 100 2-15M 567 2-15M 800 2-15M 940 2-20M 1 034
3 500 2-15M 0 2-15M 0 2-15M 350 2-15M 817 2-15M 1 050 2-20M 1 190 2-20M 1 284
4 000 2-15M 0 2-15M 0 2-15M 600 2-15M 1 067 2-20M 1 300 2-25M 1 440 Footnote (3) Footnote (3)
4 500 2-15M 0 2-15M 0 2-15M 850 2-15M 1 317 2-25M 1 550 Footnote (3) Footnote (3) Footnote (3) Footnote (3)
5 000 2-15M 0 2-15M 0 2-20M 1 100 2-25 1 567 (3) (3) (3) (3) (3) (3)
Table 5. Minimum steel reinforcement of lintels for 250-mm thick Polycrete® Big Block 1600Footnote (1)
Opening width (mm) Uniformly distributed loads (kN/m)
2.0 5 10 15 20 25 30
Lower steel bar Dist. from s/uFootnote (2) Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u Lower steel bar Dist. from s/u
1 000 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0
1 500 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 50 2-15M 167
2 000 2-15M 0 2-15M 0 2-15M 0 2-15M 0 2-15M 125 2-15M 300 2-15M 417
2 500 2-15M 0 2-15M 0 2-15M 0 2-15M 84 2-15M 375 2-15M 550 2-15M 667
3 000 2-15M 0 2-15M 0 2-15M 0 2-15M 334 2-15M 625 2-15M 800 2-20M 917
3 500 2-15M 0 2-15M 0 2-15M 0 2-15M 584 2-20M 875 2-20M 1 050 2-20M 1 167
4 000 2-15M 0 2-15M 0 2-15M 250 2-15M 834 2-20M 1 125 2-25M 1 300 2-25M 1 417
4 500 2-15M 0 2-15M 0 2-15M 500 2-20M 1 084 2-25M 1 375 2-25M 1 550 Footnote (3) Footnote (3)
5 000 2-15M 0 2-15M 0 2-20M 750 2-25M 1 334 2-25M 1 625 Footnote (3) Footnote (3) Footnote (3) Footnote (3)

Administrative information

Use of Canadian Construction Materials Centre (CCMC) assessments

This assessment must be read in the context of the entire CCMC Registry of Product Assessments, any applicable building code or by-law requirements, and/or any other regulatory requirements (for example, the Canada Consumer Product Safety Act, the Canadian Environmental Protection Act, etc.).

It is the responsibility of the user to confirm that the assessment they are using is current and has not been withdrawn or superseded by a later version on the CCMC Registry of Product Assessments.

Disclaimer

The National Research Council of Canada (NRC) has evaluated only the characteristics of the specific product described herein. The information and opinions in this evaluation are directed to those who have the appropriate degree of experience to use and apply its contents (such as authorities having jurisdiction, design professionals and specifiers). This evaluation is valid when the product is used as part of permitted construction, respecting all conditions and limitations stated in the evaluation, and in accordance with applicable building codes and by-laws.

This evaluation is provided without representation, warranty or guarantee of any kind, expressed or implied, and the NRC provides no endorsement for any evaluated product. The NRC accepts no responsibility whatsoever arising in any way from any and all use of or reliance on the information contained herein or the use of any evaluated product. The NRC is not undertaking to render professional or other services on behalf of any person or entity nor to perform any duty owed by any person or entity to another person or entity.

Language

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Copyright

© His Majesty the King in Right of Canada, as represented by the National Research Council of Canada, 2024

All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the CCMC.

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