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Technical Information

Composition

Envirolast Structures provides the Met-Rock Structural Concrete Insulated Panel (SCIP). This is a concrete sandwiched panel comprised of an EPS foam core flanked by 14-gage galvanized steel 1"x1" mesh, which is held rigid over the surface of the foam by 3/16 steel trusses spaced on 6" intervals. The mesh is fastened to the trusses with pneumatically applied steel hog rings. A structure is usually built completely in raw panels, which are joined by overlapping mesh. Next, 1" of wet-process structural shotcrete is applied over the entire exterior and interior. This creates a monolithic building, completely sealed and extremely strong. For even greater strength, 1.5" or 2" of shotcrete can be applied.

In order to ensure consistent quality, Envirolast Structures only uses pre-bagged complete mixes from established spec- mix suppliers. Currently we use Quickrete's Shotcrete MS mix, which is delivered directly to the jobsite, only water is added during mixing. The Shotcrete MS product is used in industrial concrete repair for bridges, dams, and support for mine shafts, etc and delivers 5,500 p.s.i under normal curing conditions, and can go as high as 7,000 p.s.i with wet curing. Using a certified complete mix ensures the highest level of quality and eliminates a critical variable - consistency and quality of the mix.

Click here to view the Shotcrete MS Product Spec Sheet

Load Characteristics

As a load-bearing wall, Met-Rock SCIPS are extraordinarily strong in comparison with most other wall systems available on the market. With 1.5 pounds of steel per square foot combined with the load-transferring properties of the trusses and the 5,500 p.s.i. concrete, tremendous working loads can be applied. Used as a beam, the panels can be used for foundations on caissons or even small bridges. For calculation guidelines, see the Engineering Calculations for Met-Rock panels. For a brief summary, see pages 49-59.

Click here to view the MetRock Calcs and Tables

Thermal / Acoustical Properties

Oak Ridge National Laboratory rates Sandwiched Concrete Insulated Panels (SCIPS) as the most energy efficient wall system currently available. This study was done using a very similar sandwiched panel system of a competitor, but in this aspect of energy efficiency, the Met-Rock panels will perform identically to the panels in the study.

All SCIPS, regardless of manufacturer, are so energy efficient for three main reasons:

1. They are completely sealed monolithic concrete structures that offer a very tight finished structure with virtually no possibility of air transfer.
2. The type and amount of insulation is excellent for the application, and the insulation is continuous inside the wall, it is not separated by solid wood or steel supports.
3. The thermal mass of the concrete of the wall provides a "thermal battery" that provides passive heating and cooling properties. It has a stabilizing effect on temperature throughout the day.

Met-Rock SCIPS can be made with any foam thickness from 2 to 10 inches, which given the R-value of EPS foam at R4.2 per inch, this translates into R8.4 to R42. Most other SCIP's available today from our competitors only provide 4 inches of foam due to restrictions in their automated panel making machinery.

Do not disregard the energy efficiency of your building.

Energy costs have skyrocketed in the past five years alone and there seems to be no leveling off in sight. With total energy costs increasing at over 12% annually in many areas (and the price of natural gas tripling in 6 years), the cost of energy will be a serious issue for all of us in the long run.

From an acoustical standpoint, these walls will deaden exterior sound significantly, allowing developers to utilize locations that would be otherwise undesirable. Having excellent acoustical properties in your load bearing structure eliminates the need to add acoustical control measures (and the accompanying cost) to your structure.

Resilience

Concrete, EPS and galvanized steel provide no nutritional value to mold or termites. The steel, being galvanized and then encased in concrete which is top coated with a moisture proof coating (stucco, Flex-c-ment, etc), will not be subject to any risk of rusting for hundreds of years. In the case of fire ratings, concrete provides 1 hour of protection per inch - so our Met-Rock SCIP's have a minimum of 2 hours fire rating. In applications where fire is a concern, 2 inches of concrete can be applied to both sides, yielding a 4-hour rating.

The strength of the structures is such that even with 1 inch of concrete; buildings can be designed to withstand class 5 hurricanes. Even if a building were flooded, the structure can be cleaned out, allowed to dry, and be used again indefinitely with no concerns about rot, mold or structural problems.

Design Consideration

Our panels are usually constructed in 4ft x 10 ft units, but they can be made up to 18 feet long. Wall lengths in units of 4 feet will be the most efficient utilization; the second most efficient will be in any 6-inch increment. Dimensions in "odd" units not covered in the previous statement can be accommodated as well, but with slight additional cost. Any wall height in 1-inch increments can be had. In the construction of multi-story buildings, the Met-Rock SCIP can be the load bearing structure up to five stories tall. Beyond this, it can be used as a cladding over steel superstructure. In multi-story construction, the "platform method" or "balloon method" can be used with equal results.

Windows can be formed in the panel erection stage, or can be cut out of a solid wall with a concrete saw.

None of the design restrictions common with pre-cast or tilt up panels apply to our system, particularly in regards to placement of doors and windows in relation to a panel edge. Our structures, being monolithic, have no unsightly (and leaky) seams either. Curved walls can be accommodated as well, even with a small radius.

Code Approval

IBC approval is in the final stages. Structures can be built without this approval; it usually requires a higher level of data submission to the local building authorities, which Envirolast Structures will support via its engineering partners and the Met-Rock group.

We enjoy meeting and talking with new customers, and learning more about their unique applications. Give us a call today at 803-409-8111 to find out more about us, and let us show you how easy and affordable a new Envirolast structure can be.