Ideally, the design of the structure to be built would take into account the 9.6 inch dimensions of the cells of the block. Exterior dimensions would be figured to allow full or complete cells to be used eliminating the need for a splice seam in the middle of the wall.
Foundation footing design needs to be determined by an Architect/Engineer to meet the needs of each individual structure. Infinity Structures recommends as a general rule of thumb for residential application that an 18 inch wide x 12 inch deep steel reinforced concrete footing be used. Additionally, it is important to embed a ¼ inch eyebolt every four feet around the footing inside and out to be used later to tie the hold-down bracket to. Once the foundation footing is placed and set up, layout for the Infinity wall can begin.
Using a chalk line lay out the center lines of walls to be built. Starting at the corners of the structure and working towards the center, mark on the center lines the locations of each vertical rebar to be placed, these locations represent the center of the vertical cores to be reinforced. The first rebar in each corner will be directly at the intersecting centerlines. Each corner should consist of 3 reinforced vertical cores each way, at 0 inches, 9.6 inches and 19.2 inches. Continue towards the center of the wall marking every 19.2 inches (every other core). Do not measure past center of wall, instead start at the other corner and measure towards center. Continue this layout for all Infinity walls to be built.
Using a hammer drill, drill holes 6 inches deep to accept the vertical rebar. 5 foot to 7 foot lengths of reinforcement bar can now be inserted vertically into these holes. The desired length is determined by the need to be able to safely lower the blocks over the rebar. Once the vertical reinforcement bar is pinned into the foundation footing all the way around, the Infinity forms can begin to be placed.
The first step in doing this is to cut the interlocking key system flush to the bottom surface of the form for each of the blocks in the first course. This is done only to the bottom surface of the block (the surface that meets the foundation footing) and only to the blocks that will be used in the first course. Once this is done, the InfinityICF's can be lowered over the reinforcement bar with the surface that just had the keys removed facing the foundation footing. The first course of the Infinity forms will create a seal once the hold down brackets are placed and secured. Starting at the corners and working towards the middle of the wall lower the block over the reinforcement bar all the way around the foundation footing, and align so that the reinforcement bar is in the center of the cores.
Place first horizontal reinforcement bar. Starting at a corner, use a full length of rebar with a 90 degree bend in the middle and lay it in the cavity of the first course block. Now raise the rebar so that it is the same height as the sides of the block and tie to the vertical rebar using the wire. This will be the location of the center of the horizontal core. Repeat this at each corner, then place the straight lengths of rebar in the same way, making sure that all lengths are connected with a minimum of a two foot overlap.
Now place the second course of block, in a 2-3 cell offset staggered bond pattern again starting at the corners and working in towards the center of the wall. Vertical guidelines on the face of the Infinity ICF assist in lining up the key system for easy connection to the previous course. Corners must alternate with each course the direction the block runs in the wall (e.g. even courses, the corner runs to the right and odd courses, the corner runs to the left).
Continue these methods until you have reached your desired pour height; then place the hold down brackets directly over the seams where the top course blocks meet one another. Tie the hold down brackets to the eyebolts previously placed in the foundation footing using the hold down bracket tie line; all the while verifying correct placement and alignment of the InfinityICF's. Ground auger anchors are attached to the hold down brackets for additional lateral stability.
Concrete should be poured starting at the corners and working towards the center of the wall section in 2-4 foot lifts back and forth around the structure with the ability to accomplish a 12 foot single pour.
Window and Door rough openings are built using three lengths of 2x10 lumber for bucks at the top and sides of the opening and by using two lengths of 2x4 lumber for the bottom bucks spaced apart so that correct concrete placement is assured. 1x3's are used to seal the vertical sides of the window and door bucks to the face of the Infinity ICF's. Window and door bucks are anchored by imbedding 1/2 inch x 8 inch J anchor bolts in a countersunk manner through the buck and tied to the corresponding horizontal rebar and into the horizontal cores. Top plate is anchored to the top of the wall using J anchor bolts embedded into the vertical cores while the concrete is still wet. J anchor bolts may be tightened after concrete is set.
Three different block configurations are used - a running block, an end block, and a corner block (right and left-hand corners are accomplished by inverting block).
Our unique interlocking keyway system assures that work stays in place straight and true during the entire building process. This keyway system also provides for complete flexibility by allowing the block to be stacked in any of the following ways:
In-Line - Stacked in a 2-3 cell off set staggered bond method
Perpendicular - used for intersecting walls, pilasters and ledger supports
Inverted - for the purpose of using one corner block configuration for both right and left-hand corners