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 an absolute pain to fix. Not only does it cost delays, but there can be expensive fixes that need to be made. With 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, and pressure treated lumber can be supplied upon request.

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.

Each panel is 9′ high and 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, and serve multiple purposes.

First is the framing for the interior wall. If you are building a basement, the old way of framing 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. 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.

Additionally, 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. Since they are extremely strong and have an exceptionally high strength-to-weight ratio, we also use them for beam pockets and to support I-Beams for basemenrs. As you can see in the images below, the studs are holding up the I-beams.

This detail is something the structural engineer will design. Included in our fabrication process are the beam pockets.

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 for basements.

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 entirely. 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, turning the insulation into a breeding ground for mold. And as we know, mold leads to costly repairs and remediation.

As you can see in the picture above the insulation is encapsulated in the panel between two sides of impervious fiberglass. The insulation is 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. This 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 a 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.

Totally Encapsulated Insulation Reduces The Ability for Mold to Accumulate and Cause Damage to the Interior of a Home. Also Increased Energy Efficiency Leads to Money Saved on Utility Bills

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.

The Foundation is Cut to the Exact Dimensions and Specifications in a Controlled Environment, Leading to Maximized Efficiency, Accuracy, and Fewer Mistakes. Which Saves Time and Money.

The beautiful thing about prefab construction is the ease of delivery and installation. Because our panels are lightweight, made from an extremely high strength-to-weight FRP, they are extremely easy to pick up and install.

The old way of constructing a foundation is extremely laborious and time consuming. You need to deliver all the rebar, forms, and materials to the job site. Construct the footing forms, lay the rebar, get an inspection. Pour the concrete, which depends on the weather and or factors. Then get the footings inspected. If passed, then construct the wall forms, set the rebar, get an inspection. Pour the concrete, which again is dependent on the weather. Get the walls inspected, and if passed, move on to the next step in the construction process. And this is a very simplified version. There is room for error in setting the rebar, the concrete truck getting delayed, the inspector failing and inspection, and so on.

The NEW way to build foundations is to fabricate the entire foundation in a quality controlled environment, ship the whole foundation on a single flatbed truck (2 deliveries if it’s big), and install it the same day with a crane or telehandler and small crew of 4-5 workers. You can see how easy it is to deliver the foundation on a flatbed truck and then install it with a crane and just 4 workers from this video:

A Full Foundation Can Be Delivered and Installed in Just 1 day with a Small Crew of 4-5 Workers and a Crane. This Leads to an Optimized Construction Process and Maximized Efficiency. Build Foundations 10x EASIER!

Our system is completely ICC and NTA certified. Both the panels and footings are certified and up to code, and they have prescriptive engineering that any structural engineer can easily understand and use to design a foundation for a project.

There is no rebar, forms, or concrete, and waterproofing is included with the installation. So we eliminate the rebar inspections, footing and wall inspections, and the damp proofing inspection. 4 inspections gone!

Failing an inspection is a huge setback and an extremely painful process to remedy. Let’s say that 1/10 inspections fail, this would result in 1/3 houses failing an inspection which results in lost time, delays, increased labor and material costs to fix the mistake, and then having to get the inspector back out to re-inspect the foundation. Failing an inspection enormous opportunity cost.

We bypass the inspection from the city with a structural letter of compliance from the EOR (this is recommended method). The cost is a few hundred dollars extra, but is well worth the investment. If something does need to be corrected, only a few days will be added to the construction timeline as mistakes are extremely easy to fix with our modular system.

Another topic that comes up a lot is how we address expansive soils. There are a lot of expansive soils on the Front Range of Colorado and traditionally a deep foundation system such as concrete piers, piles, and caissons extending to the bedrock below would be needed to account for bad soils. The cost for this goes through the roof, especially with the current high prices of concrete.

With our system, because the panels and footings have prescriptive engineering, the engineer can avoid using a deep foundation system altogether by over-excavating and refilling with compacted, native or non-native soil. This avoids the need to use costly piles, piers, and caissons.

In summary, the benefits of using an ICC and NTA certified composite foundation system include:

• Bypass the foundation inspections; only a structural letter of compliance from the EOR is needed to pass the foundation inspection.
• No More FAILING INSPECTIONS; save time, delays, costly fixes and repairs. Decrease material and labor costs, stress, and the fear of going over budget.
  • Approximately 1/10 inspections fail, which is 1/3 homes. Never fail a foundation inspection again.
• Prescriptive Engineering; Structural engineers can easily understand, design, and stamp plans using the prescriptive engineering from the testing and certification of the panels.
• Avoid Costly Deep Foundation Systems; a deep foundation system can be avoided by over-excavating and refilling the hole with native or non-native soils. This saves everyone time and money.

Bypass All The Foundation Inspections with A Fully Tested and Certified Composite Foundation System. 

In construction, we are at the whims of mother nature and whatever obstacles she throws at us. Colorado is home to a volatile weather environment where it can be sunny and warm one minute, and raining and cold the next. Unfortunately for concrete, this presents a lot of problems.

Concrete needs to be poured when the conditions are just right. The ideal temperature is between 50-60 degrees and anything above or below will need additional equipment. If it is too cold, under 42 degrees F, then additional expenses are incurred for keeping the concrete warm – blankets, heaters, extra additives, and water. Problems can easily arise within the concrete as it sets in cold weather such as the water inside the concrete freezing, expanding, and cracking concrete. If that happens then the newly poured concrete needs to be demolished and re-poured. Ouch. It also takes much longer for concrete to cure, adding days and weeks to the construction timeline.

If it is raining outside, the concrete can get damaged and lose strength and structural integrity. The cement mix can get washed out, making the surface a weaker consistency and also reducing it’s strength. This is not ideal for the foundation of a new home.

If the weather is too hot and dry, and there is a lot of direct sunlight like the conditions of Colorado summers, the concrete surface can easily crack and there can be additional shrinkage. Concrete will set much quicker than normal, and the workability will diminish. In warm weather water will usually be added to the mix, which causes the concrete to lose it’s strength and durability.

These are all problems that can be avoided with our foundation system that is independent of the weather. Since the panels are prefabricated, we just need a foundation hole that is excavated, clean, and dry. We can install foundations in the winter, up in the cold mountains. We can install foundations in the hot summer heat with no humidity. The weather does not affect the installation, unless there is a downpour of rain.

The benefits of using a weather independent foundation system, include:

• Decrease Delays; bad weather, hot and cold weather is no longer a factor. Experience no significant delays due to the weather ever again.
• Increase Predictability; construction schedules can now accurately predict their timelines and stay on schedule.
• Year Round Building Cycle; increase the building cycle to a year round schedule. Build in the winter when it’s cold and snowy. Build in the summer when it’s extremely hot and dry.

Eliminate Weather as a Factor for Installing a Foundation and Build Year Round. No More Delays, Setbacks, and Pouring Concrete in Bad Conditions.

Significantly Increase Efficiency and Predictability of Construction Timelines.

Most concrete foundations do not come with a warranty, and if they do, they are extremely limited. If problems arise during the construction of the foundation it becomes extremely stressful, especially for the builder, who may not be any recourse for a bad job done. If problems arise after the house is complete, the homeowner may have no recourse for a failing foundation. Plus the cost to fix a bad foundation can skyrocket into the 10’s of thousands of dollars, fast. This should be alarming since a study by Fine Homebuilding discovered that 44% of new homes had wet and leaky foundations.

With our system, there is a 15-year warranty included for each foundation installed. We guarantee a foundation without structural defects that is completely waterproof. Since the product itself has a warranty, there is very little to dispute about the installation or problems that arise from the foundation. Concrete, on the other hand, is considered a service where the installation and final product have a lot more that is up for interpretation. With our system, everything is cut and dry, ensuring the builder and homeowner a durable and waterproof foundation.

For builders, we ELIMINATE:

• Any concerns about cracking, spalling, leaking, insufficient reinforcing, or barrier failure between the foundation and the top plates.
• Callbacks of any kind.
• Arguing with concrete contractors about the work done, fixes and repairs to the poured foundation.
• The stress of pouring concrete.

To date, we have had 0 warranty callbacks for any of the composite foundations we have installed.

For homeowners, the benefits include:

• A GUARANTEED waterproof foundation. No more worrying about leaks, mold, rot, fungus, and expensive future repairs.
• A GUARANTEED structurally sound foundation.

Each Foundation Installed Comes with a 15-Year Warranty – 15 years More Than Concrete. A Completely Waterproof and Structurally Sound Foundation GUARANTEED.

Concrete is also the 2nd most consumed product on the planet (right after water) with 4 billion tonnes of CO2 polluted annually. Concrete production has increased 300% in the last 40 years, with the demand growing every day. The cement sector is the 3rd largest consumer of energy and the 2nd largest emitter of CO2.

CO2 is a potent greenhouse gas that has many adverse effects on the planet and harms the species that live on it, including us. It magnifies these catastrophes;

• The thawing of glaciers;
• The flooding of islands and coastal cities;
• The increase in intensity of hurricanes;
• The desertification of fertile areas;
• The adverse impact on agriculture and livestock.

These catastrophes will lead to food shortages from reduced agricultural outputs, and a rise in infectious diseases such as malaria, cholera, and dengue. Extreme heat which will cause cardiovascular and respiratory problems (source).

There are several key factors to look at when analyzing the harmful effects of concrete. First is the extraction of all the raw materials that go into making concrete, which is laborious and intensive. The second is all the energy, fossil fuels, and pollution created by the equipment needed to extract the materials, process, refine, mix them, transport them, and then install concrete. The third way is all the harmful secondary and tertiary effects on the environment such as the depletion of the earth’s topsoil, the acidification of the oceans, and the eutrophication of our lakes and streams.

These are a few of the harmful effects of concrete production:

• the extraction of raw materials from our environment;
• the production process of cement and concrete leading to 4 billion tonnes of CO2 emitted, ~8% of the global production of CO2 emissions;
• the emissions from traveling and delivering raw materials and concrete;
• the catastrophic chain reaction from concrete production leading to Earth’s topsoil being damaged, the acidification of the oceans, the eutrophication of lakes and streams, poor air quality, acid rain, smog, and the increase in wildfires.

These are all things we want to reduce.

The good news is our foundation system is 10X more environmentally friendly than concrete.

Take a look at this graph below comparing the negative effects of concrete vs. our fiberglass foundation system.

The Negative Environmental Impact of Concrete is 10X More Than That of Our Composite Foundation System. Reduce Carbon Emissions, Waste, and Pollution.