Insulating Concrete Forms (ICFs) are stay-in-place form-work for energy-efficient, cast-in-place reinforced-concrete walls.

The forms are interlocking modular units that are dry-stacked (without mortar) and filled with concrete. The forms lock together somewhat like Lego bricks and serve to create a form for the structural walls of a building. Concrete is pumped into the cavity to form the structural element of the walls. Usually, reinforcing steel (rebar) is added before concrete placement to give the resulting walls flexural strength, similar to bridges and high-rise buildings made of concrete.

After the concrete has cured, or firmed up, the forms are left in place permanently for the following reasons:
1. Thermal and acoustic insulation
2. Fire protection
3. Space to run electrical conduit and plumbing
4. Backing for gypsum boards on the interior and stucco, brick, or other siding on the exterior

Benefits

This method has several advantages compared to traditional building materials, especially in residential and light commercial construction. The advantages of structures built with this method include:

a. Minimal, if any, air leaks -> comfort, less heat loss
b. Superior energy performance -> Lower energy bills
c. High sound absorption -> Peace and quiet inside
d. Time-tested structural integrity -> Resistance to forces of nature
e. Low maintenance, high durability, very long lifespan -> Higher resale values
f. When the building is constructed on a concrete slab, the walls and floors form one continuous surface. This keeps out insects.
g. Concrete does not rot when it gets wet.
h. Construction costs

The cost of using ICFs rather than conventional construction techniques is most sensitive to the price of labor, wood, and concrete. In the southern USA in 2006, a brick-clad ICF home cost around 5% more than a conventional brick-clad timber-frame home. However, the energy savings of an ICF home usually result in positive cash-flow from Day 1 compared to most conventional construction.

Machines to Mold ICFs

During the ongoing development, besides from the common packaging also high quality technical EPS parts were required. Special operating automatic machines were developed to produce ICF parts economically and without any damage during demoulding/ejection.

The mold change is easy and quick to achieve. The molds are brought in from the top by a hoist, which is common use for other machines.

The automatic molding machines are available in various sizes with various molding areas.

These machines are state-of-the-art with free programmable PLC panels, vacuum cooling, pressure filling, and mold quick-change system.

Commonly used terms industry terms (Proprietary & Non-Proprietary): EPS, Expanded Polystyrene, Expandable Polystyrene, Styrofoam, Thermocole, Thermocol, Styropor, Foam, Packing Foam, Packaging, Aluminium Molds, Aluminum Molds, Aluminium Moulds, Aluminum Moulds, Shape Moulding Machine, Shape Molding Machine, Mould, Mold, ICF, Insulated Concrete Forms.