There’s Now a Better, Faster, Easier, and Greener Way to Build Foundations.
Introducing The 1 Day Foundation
Build With a Durable, Waterproof, Insulated, Framed, and More Efficient Turnkey Foundation System that is Installed in 1 Day, Square and Level. With No Concrete.
We Combine: the Foundation Footings, Foundation Walls, Insulation (R-16.5), Waterproofing, Stud Framing 16″ O.C., and a Double Top Plate INTO 1 STEP IN THE BUILDING CYCLE Creating MASSIVE Time Savings for Builders while Eliminating Multiple Steps AND CONCRETE from the Foundation Construction Process.
Why We Use Fiberglass Composites (FRPs) to Build Foundations
Bridge Made from FRPs
Boeing 787 Dreamliner Made from FRPs
Underground Storage Tanks Made of FRPs
Composites, and more specifically fibre-reinforced polymers or FRPs (which is what our panels are) have become extremely popular within the aerospace, marine, automotive, and construction industries. And for good reason. FRPs are extremely durable, strong, corrosion resistant, and reliable building materials that prevent the growth of mold, and will not rust or corrode.
FRPs can be seen in harsh and corrosive environments like chemical processing plants, power plants, sewers, wastewater piping, and acid storage tanks. In fact, they are used in mineral piping systems to protect the pipes from “hydrochloric acid, sulfuric acid, phosphoric acid, chlorine gas (wet and dry), chlorine dioxide, sodium hydroxide, sodium hypochlorite, solvent extraction solutions, brines, slurries, and more” (source).
They are also used to make boat hulls, bulkheads, and other components for military, commercial and recreational boats, ships, and superyachts. Jets, like the Boeing 787 Dreamliner, are comprised of almost 50% composites. FRPs are used for beams, columns, bridge decks, seawalls, piles, piers, and cladding for roofs and walls.. They are even used to strengthen and reinforce old concrete structures, and new ones, to extend the lifespan by 50+ years. The list of uses and applications goes on.
The reason FRPs are so popular, is because they have these defining characteristics (source):
- Highly Corrosion Resistant
- High Durability
- High Flexibility
- High Impact Resistance
- High Strength-to-Weight Ratio
- High Thermal Stability
- Low Maintenance
- Long Lasting and Sustainable
These are all MAJOR benefits when it comes to building a foundation for a home or structure. The corrosion resistance decreases the wear and tear of the foundation, leading to fewer cracks, leaks, and repairs. The durability of the panels, perhaps the hallmark trait, increases the panels ability to withstand wear and tear, daily pressure, and common damages. Concrete, on the other hand, needs additional support in maintaining its durability, when that is its sole purpose. In fact, FRP is stronger and more durable than steel. The strength-to-weight ratio is 10x that of steel alloy, and 2-3x that of reinforced steel.
FRPs have an exceptionally high strength-to-weight ratio compared to alternative materials such as concrete. In fact, when a study was done on the soil load resistance of our panels compared to concrete, it showed that our panels were more than 2x stronger!
3rd Party Testing: Soil Load Resistance
The third party testing done demonstrates the durability of the panels, the flexibility, and the extremely high strength-to-weight ratio. To prove the strength of the panels, we conducted an experiment to put them to the test. We cut sections of the panel and had them elevated off the ground. And then a flatbed truck weighing close to 10,000 LBS was placed on top of the panel sections.
We Placed a Flatbed Truck On Top of Our Panels
As you can see, the panel holds up extremely well and the deflection is minimal. This demonstrates the incredible strength of the panels, and their ability to withstand lateral soil bearing pressure.
Additionally, FRPs are much easier to transport, maneuver, and install. This means they can be shipped just about anywhere, on a flatbed truck, and installed with ease. This reduces the transportation costs, labor costs to install, and significantly reduces the time needed to install leading to a much more efficient construction process.
FRPs are also a long lasting material that does not corrode, deteriorate, or decompose overtime. Love it or hate it, FRPs are a fancy, high quality and performance plastic. And plastics do not decompose. Concrete, on the other hand, can start breaking down in as few as 50 years and needs continual maintenance and care to retain it’s durability. Even steel, which is what rebar is made of, corrodes and breaks down. That is why FRP rebar is growing in popularity especially in states where there is a lot of rain and water, like Florida. This simple demonstration shows the stark difference between FRP and steel.
FRP Rebar vs. Steel Rebar
In just 52 hours steel is corroding and the water is already murky from the deterioration of the steel. This is what happens to foundations once water creates cracks in the concrete. The steel corrodes, leading to a severely diminished foundation that is not as strong or dependable, that needs to be reinforced. This can be extremely costly to fix and repair.
Overall, FRPs have become a beloved building material in many industries due to their reliability, durability, strength, corrosion resistance, and longevity. The demand is growing as organizations such as the Florida Department of Transportation, adopt them for a wide variety of applications.
A Concrete FREE Foundation System
We use a fully ICC and NTA certified composite foundation system which includes both the foundation panels and foundation footings. There is NO CONCRETE involved in the foundation system. There are times when concrete footings are used in conjunction with our foundation panels, and we sometimes use a non-structural concrete slab called flowable fill for the bracing on the bottom before backfilling (see the FAQ). But with our composite panels and footings, the foundation construction process is devoid of concrete.
The old way of pouring concrete footings and walls is extremely time-consuming, labor intensive, prone to mistakes, and creates a lot of waste. It’s a building practice that has not changed in over 100 years. The new way is to build with a completely turnkey foundation system that integrates waterproofing, insulation, framing, the sill plates, and window/door cutouts into a single clean step.
Because There is No Concrete, WE ELIMINATE:
- Forms; having to set up and break down the forms before and after pouring concrete.
- Rebar; no bulky rebar on-site, no having to place rebar, fix rebar that is not placed properly, and no rebar inspections!
- Anchor Bolts; no need to install them in the concrete walls. Never risk constructing a foundation and forgetting to install them (we’ve talked to clients who have made this frustrating mistake).
- Curing; no more waiting for concrete to cure. Cuts out days (even weeks!) from the building cycle.
- Call Backs; gone are crack callbacks, leak callbacks, blowout fixes, and warranty claims. This saves a builder between $1,000-$2,000 per callback.
- Cracks and Spalling; no more cracks/spalling from understrength concrete, under-designed concrete, over-watering, improper curing, inadequate cold weather/hot weather precautions, cracks from shrinkage, cracks from freezing and the footings not extending below the frost line, moisture in the soil adhering to the foundation wall and lifting it. Deterioration from salt.
- Leaks; gone are form tie hole leaks, leaks from cracks.
- Concrete Trucks; no more waiting on trucks, trucks damaging the property, and concrete washouts damaging the property.
- Deliveries to the Job Site; reduce wasted time and unnecessary travel.
- Site Storage and Site Access Needed; the composite foundation system is delivered on a single flatbed truck and installed with a crane, or boom/truck combination. The job site will be clean – no forms, or bulky rebar laying around. And now hard-to-access job sites can be reached.
- Hiring Concrete Companies and Outsourcing the Foundation Construction; because the foundation is prefabricated, we can train and certify teams of installers. The system is straightforward, simple, and very easy to learn to install.
- Inspections; say goodbye to the footing rebar inspection, footing final inspection, wall rebar inspection, wall final inspection, and damp proofing inspection. We eliminate 5 inspections!
A Completely Waterproof Foundation GUARANTEED
Bottom View of the Panel
As previously mentioned, our panels are made from a Fiberglass composite material, similar to the material boats hulls are made from. Compare the image above and below and see that they have the exact same composition.
This means the panels are completely impervious to moisture, providing an airtight barrier that cannot be penetrated. Extra measures are taken to waterproof the seams where the panels connect (panel-to-panel), and the panels connect to the footing (panel-to-footing). Where the panels connect, a Henry Blueskin® Vapor Barrier Membrane is used. Where the panel connects to the footings, a Henry Aqua-Bloc® emulsified asphalt membrane is used. These products are applied directly after the installation of the foundation and ensure a completely waterproof foundation.
Contrary to Popular Belief, Concrete is Porous.
Which means it has spaces and holes through which air and liquid can pass through. When concrete cures, tiny pores develop. Water is one of the main ingredients used to make concrete, and any water that does not interact with cement during the curing process also created pores. Cement paste is so porous, that 96% of the pores are actually connected.
In addition, cement, the main ingredient used to make concrete, contains calcium, which is soluble in water. Because of the concentration of calcium in concrete, the pores in concrete get gradually larger in the presence of water. Water destroys porous concrete overtime, leading to cracks in the walls, which leads to water leaks and damage, radon seeping through the cracks, and gas seeping through the cracks. This leads to expensive fixes that need to be done.
“44% of New Homes Have Leaky, Wet Basements”
A survey conducted by Fine Homebuilding of 33,000 new homeowners revealed 44% of the new homes had moisture problems. Of all the homes that have moisture problems in the US, which is approximately 60%, it is estimated that 38% of those homes have mold and fungus growth. Mold and fungus can be extremely dangerous and detrimental to one’s health. They are harmful pathogens that release spores into the air, which can make people very sick.
Mold and fungus can trigger allergic reactions, asthma attacks, and cause serious problems for people with compromised immune systems. In addition to the health risk is the financial burden of remediating mold and fungus growth. If it is not taken care of immediately, the cost to remove skyrockets. It can cost up to $5,000 to remove. And if it’s black mold, it can increase the cost by six-fold, or $30,000. Now that’s an expensive problem that could have been avoided altogether by using a waterproof foundation system.
95% of all Foundations are Damp Proofed
Another reason so many have moisture problems is because when the foundations were constructed, they were damp proofed, and not waterproofed. What’s the difference? Damp proofing refers to keeping soil moisture out of the foundation, it is intended to prevent the flow of water vapor in the soil. It is not intended to prevent water leakage through cracks and holes in the wall. Waterproofing, on the other hand, protects the foundation completely from soil moisture and liquid water. Waterproofing is much more robust.
Let’s be honest, the reason most foundations don’t get waterproofed is because it’s not required by code, and it’s more expensive.
But there’s major problems with damp proofing, such as:
- Damp Proofing does not completely seal cracks or form tie holes;
- Poor and negligent backfilling can damage the thin damp proofing material;
- Hydrostatic pressure will not be stopped, leading to water seeping through;
Because the majority of foundations are damp proofed, and not waterproofed, inevitably moisture will seep through the foundation cracks. And once the seal has been broken the floodgates to mold, fungus, mildew, and rot are opened.
These harmful substances can lead to a myriad of other problems, even including damage to the rest of the home. As a matter of fact, wet basements can cause severe problems in the rest of the house including the attic. Mold can very easily travel upwards and disperse throughout the rest of the house, leading to the accumulation of mold upstairs and in the attic. Mold and fungus can also enter the heating and cooling system, and the spores can then get circulated throughout the rest of the home. They can then find new, damp places to call home and grow/expand.
In addition, the floor above can rot, and pose a risk of collapsing. Mold causes structural integrity issues which can also be very expensive to fix.
Now, for the first time ever, a completely waterproof foundation system exists that is impervious to water and moisture. Not only will your basement stay dry, but you will prevent serious problems from every occurring. And an important thing to note is that the fully waterproof solution we provide IS INCLUDED WITH THE INSTALLATION OF THE FOUNDATION. This means that as a the builder you save an extra day or two of time on the project, and there is not an additional expense for waterproofing materials. So now it is both economical to waterproof the foundation and it saves time. And time is money.
And if that wasn’t good enough, we include a guarantee for our foundations and waterproofing. Each foundation we install includes a 15-year warranty backing up the waterproofing and ensuring a completely dry foundation. No more having to worry about leaky, wet, moldy, and fungus infested foundations and homes!
Sill Plates Are Pre-Attached
The new way of building foundations includes a double top plate which we pre-attach the sill plates. This may seem like a trivial detail, but it is not. The sill plates assure that the foundation is square and level, a HUGE problem that occurs with concrete on a regular basis. And an unlevel and out of square foundation can be a pain to fix. Not only does it cost delays, but there can be expensive fixes that need to be made. Wit our system you never have to worry about the foundation being out of square or unlevel again.
Also, pre-attaching the sill plates saves time, labor, and materials. No longer do the sill plates need to be installed in the field. We include the double top plates with all of our foundations (we do charge a small extra fee for pressure treated lumber).
With the sill plates pre-attached, we eliminate:
- The need to fix a foundation for being out of square or level.
- A day of labor, materials, and time.
Composite Studs Are Pre-Attached
Each panel comes with composite studs already attached, 16″ O.C. Because these studs are made from the same composite material as the panels, they are incredibly strong and robust. They serve multiple purposes.
First is the framing for the interior wall. The old way of framing a basement can be very challenging. The wall needs to be square and level or else the walls will need to be furred out. The walls can easily be unlevel due to improper backfilling. Then someone on-site would need to install the framing, which means additional expenses for the framer, materials, and time are added to the construction process.
The new way of building ELIMINATES the need for a framer altogether, and having to deal with unlevel walls. Each panel is 9′ high and includes a 2×4 composite stud 16″ O.C. that is also 9′ high. Now there is no framer needed, additional expenses for the materials, and no time lost in having to frame a basement. Plus no more headaches with unlevel walls.
In addition, the studs are structural component of the panel. They add support for the soil load resistance, and increase the width of the panels, increasing the compressive strength. And since they are extremely strong, we also use them for beam pockets and to support I-Beams. As you can see in the images below, the studs are holding up the I-beams.
As illustrated in the pictures, the composite studs are holding up I-Beams. This detail is something the structural engineer will design. We include the beam pockets in our fabrication process.
With our system, the foundation comes framed, with beam pockets, completely square and level.
This eliminates:
- Having to frame a foundation on-site with poor conditions. Reducing labor, materials, and time wasted;
- Having to construct beam pockets.
A Highly Efficient Insulated Foundation Panel
Bottom View of the Panel
Each panel contains closed-cell R-16.5 insulation that is continuous and rigid. The old way of having to insulate the foundation on-site, with blanket batt or roll insulation is over. This time-consuming step is now eliminated from the construction process. This saves a day of work, about $2,000 in material costs (depending on the size of the foundation it can be more or less), and the possibility of the insulation getting wet.
One thing that is overlooked by many builders is the fact that concrete contains a lot of moisture, and it can take a year for that moisture to evaporate. This results in moisture getting trapped in the insulation, creating mold over time. And as we know, mold leads to costly repairs and remediation.
As you can see in the picture the insulation is encapsulated in the panel between two sides of impervious fiberglass. The insulation is essentially in an airtight chamber. This prevents any moisture from percolating into the insulation, becoming moldy, losing effectiveness, and causing problems to the rest of the house or structure.
Now, there are different zones here in Colorado which determine the R-value of insulation needed to be up to code. The R-16.5 insulation contained in our panels meets the standards in most jurisdictions. Additional insulation is needed in the colder climates, like the mountains, which we can easily insulate and get the R-value up to 30 by filling the stud cavities with Batt insulation.
Here are the benefits of our insulated panels:
- Basements can account for 20% of a home’s total heat loss. This can be reduced with our highly energy-efficient foundation panels.
- No longer is insulation needed to be installed on-site. This reduces a day of work and materials for an estimated total savings of $2,680.
- The insulation is encapsulated in the airtight panels which removes the risk of moisture and mold feasting and growing in the insulation. Which reduces costly fixes needed to repair and replace insulation, and remediate mold.
- Additional insulation can be added to the stud cavities to easily get the R-value up to 30.
- Because the insulation is very efficient, a basement can now be used as a climate controlled storage unit. Antiques, vinyl records, DVD’s, instruments, etc. can now be stored in a controlled environment without needing to spend $1000’s per year on a storage unit.
- This also reduces energy bills. Less energy is consumed by the homeowner because the efficiently insulated walls reduce the heat needed to warm a basement in the winter, and cold air needed to cool a basement in the summer.
The Panels are Fabricated in A Quality Controlled Environment
Prefab construction is on the rise, and for good reason. There are many benefits such as:
- Significantly increased efficiency;
- High levels of precision and quality;
- Cuts are made the exact dimensions and specifications called out on the plans;
- Maximized accuracy and fewer mistakes;
- Reduced labor needed (during a time of labor shortages);
- Less waste;
- Safer working conditions;
This all translates into a much more streamlined construction process for foundations. Since we fabricate the panels in our fabrication plant to the exact dimensions in the foundation plans, we assure accuracy and quality foundations. In fact, before installing a foundation, we do a mock-up install at our factories site, making sure everything lines up perfectly.
The old way of building foundations on site presents many problems. For one, the weather is an unknown variable. Here in Colorado it can be sunny and warm one minute, and snowing the next. Unpredictable weather makes it tough to pour concrete. Secondly, mistakes are easy to make. With a concrete foundation, there are tons of possible mistakes that can be made, and these will continue to happen. Nobody is perfect. But mistakes can be avoided altogether by using a foundation system that is prefabricated to the exact dimensions ahead of time, where quality is our number one priority.
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