ECO FAB STRUCTURES Inc.
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The Polycore Foundation Floor System eliminates traditional poured concrete floors by using an insulated system of factory made sections that are easily delivered to and assembled on site. Using minimal tools, no large equipment, and no special skilled trades a typical sized residential foundation floor (1200 - 1500 square feet) can be set in place by three workers in as short a time as one single working day. With an energy efficiency of R16+, it significant energy savings over traditional concrete floors at a lower price point.
A Simple Concept
Once your footing is in place, a packed sand base level with your footings is all that is needed to install you Polycore Foundation floor system. This eliminates the need to poor a concrete slab, scheduling of concrete trucks and multiple skilled trades typically required to complete your foundation floor. The Polycore Foundation Floor system provides an insulated foundation floor (R16+) easily setup by two or three workers. Strength is ensured by industrial grade steel studs, EPS (expanded polystyrene) insulation provides optimum energy efficiency. Once the floor system is in, place 3/4" tongue and groove plywood is glued and screwed into the steel studs creating a solid foundation floor. Manufacturing efficiency and the simplicity of components keep costs lower than traditional concrete slabs.
The Design Basics
Polycore Canada uses industry accepted 2 1/2" galvanized structural steel studs, encased in 4" builder quality type I EPS (expanded polystyrene) rigid insulation provided in standard size sections. In combination, these components provide the strength and properties that easily replace a traditional concrete foundation floor for all residential applications. Each Polycore Floor System is mapped out and designed for easy installation. Modifications can be made to accommodate "In Floor Heating" if needed, although the R16+ insulated floor often replaces the need for "In Floor Heating."
The Advantages
Advantages in pricing, construction scheduling, installation, finishing labor cost, and short-term availability are just a few of the ways this floor system significantly saves costs through the entire foundation floor process. For the homeowner, the advantages continue with increased R-value energy savings, and benefits the product provides in maximizing many other modern efficiencies such as geothermal energy systems. Combined with the consumer benefits of over-all lower project costs, the foundation floor system is a must have for any residential building.
The Established Projects
Polycore Foundations Floor Systems are the fastest growing product line of Polycore Canada. Since the release of the product in 2007 more than 50% of the foundation series sold to small and large builders in Alberta were completed with a Polycore Floor System.
The Future
The Polycore Foundation Floor system offers a faster, better, and noticeably less expensive option that will grow to a major percentage of new home builds as consumers demand an affordable method to combat high energy prices and escalating build costs of new homes in all market areas. Designed and installed for a lifetime of efficiency and structure, Polycore Foundation Floor Systems are the new future of today's building industry.
Brochure (Pdf)
Brochure (Pdf)
*NOTE: This page is still being developed. Please check back later for the completed page*
The Polycore Foundation System will eliminate the need for a concrete foundation. The wall panels are fully structural, insulated system of factory made sections that are easily delivered to and assembled on site. Using minimal tools, no large equipment, and no special skilled trades a typical sized residential foundation (1200 - 1500 square feet) can be set in place by three workers in as short a time as one single working day. With an energy efficiency of R32+, it provides the single most significant energy savings that the Polycore system can bring to any residential project.
A Simple Concept
Once your footing is in place, you no longer need concrete or forms; eliminating the scheduling of multiple skilled trades typically required to complete your foundation. Polycore provides an insulated foundation easily setup by two or three workers, engineered and tested to perform well above your project requirements. Strength is ensured by industrial grade steel studs, EPS (expanded polystyrene) insulation provides optimum energy efficiency. The components merge in a simple and effective design that exceeds the needs of your residential foundation. Manufacturing efficiency and the simplicity of components keep costs competitive or lower than traditional concrete systems.
The Design Basics
Polycore Canada uses industry accepted G-90 grade 6" galvanized steel studs, sized to the specific building Engineering requirements, encased in builder quality type I EPS (expanded polystyrene) fire retardant rigid insulation. In combination, these components provide the strength and properties that easily replace a traditional concrete foundation for full size residences, walkout designs, and even modular home situations that have to accept placement of pre-built houses winched or lifted directly onto the system. With below grade exterior protected by a vinyl peel and stick membrane, your waterproofing is easy and provides better than standard protection.
The Advantages
Advantages in pricing, construction scheduling, installation, finishing labor cost, and short-term availability are just a few of the ways this series significantly saves costs through the entire foundation process. For the homeowner, the advantages continue with increased R-value energy savings, easier sheeting and interior finishing, and benefits the product provides in maximizing many other modern efficiencies, such as in floor heating and geothermal energy systems. Combined with the consumer benefits of over-all lower project costs, the foundation series is a must have for any residential building product.
The Established Projects
Polycore foundations continue to be the most significant component in our product line, accounting for half of all projects produced in our Edmonton facility. The scope of foundation projects includes major builders, modular home manufacturers, and a great number of private and small builder projects across western Canada including a local heritage house restoration. The heritage project saw a 75 ton structure moved off of its existing footings onto a Polycore foundation in order to provide a full basement for the house offering with the optimum insulation value that only Polycore could provide.
The Future
Concrete and trade shortages in active building markets, coupled with the demand for housing replacements from natural disasters such as hurricanes and earthquakes are taking toll on traditional supplies and timelines of other systems. The Polycore FB series foundations offer a faster, better, and often noticeably less expensive option that will grow to a major percentage of new home builds as consumers demand an affordable method to combat high energy prices and escalating build costs of new homes in all market areas. Designed and installed for a lifetime of efficiency and structure, Polycore foundation systems are the new future of today's building industry
Brochure (Pdf)
Brochure (Pdf)
*NOTE: This page is still being developed. Please check back later for the completed page*
Product Availability
As of January 2015, Eco Fab Structures no longer markets our above grade residential main and second floor wall systems to private "One Of" residential builders. Eco Fab Structures does continue to offer this product to both small and large home building companies who may purchase the system for use in projects for their own individual customers. Individual owners that may wish to use the Polycore Wall System for their home should have their builder contact Eco Fab Structures directly for information on using the system and becoming a Recognized Builder of Polycore systems.
Product Overview
The Polycore Residential Wall systems provide an R32+ insulated structural above grade wall. The wall sections are precision cut light weight EPS and steel sections that are easily delivered to and assembled on site, using minimal tools and trades to build almost any style of residential structure in a fast and cost effective manner. With thermal and insulation properties that are significantly better than other building systems, Polycore Residential Walls offer faster and less expensive buildings that give the end user better quality and more energy efficient structures.
A Simple Concept
Polycore uses a combination of two common and long established building products to create simple and manageable building sections that are used to quickly erect complete buildings. EPS insulation, (expanded polystyrene or Styrofoam) and galvanized roll formed steel studs are merged in a simple but effective design that meets the strength needs of residential buildings, while retaining manufacturing simplicity that keeps its cost extremely competitive.
The Design Basics
Our most adaptable line provides a complete wall structure for single or two story residences that is suitable for almost any typical home design. Using a 8" thick EPS integrated with 3-5/8" structural steel galvanized studs (the gauge chosen by basic engineering), Polycore converts almost any residential design into basic manufactured sections that create each wall. Every section is easily managed by basic site labor with no lifting machinery, and all designs are numbered for simple installation. Our steel framing can be pre-shaped for windows, and our EPS foam has built in channels for electrical. A short production process gets components to each building site in a quick and efficient manner to reduce build times and site costs.
The Advantages
Polycore Residential Walls offer significant savings to both builders and owners. Though material costs may be 10-15% higher for the Polycore system as compared to traditional stick built homes, a significant labor savings on the construction results in markedly reduced costs for the completed project. Advantages continue through increased R-value energy savings, easier sheeting and finishing procedures, and the ease at which small structure changes and upgrades can be made in the construction process.
The Established Projects
As of late 2008, Polycore has completed hundreds of projects which included basic wall systems including small contractor builds, privately built residences, and spec homes by larger builders. A most notable aspect of the system is that over 50% of projects to date were bought and entirely built by private individuals without the involvement of a contract builder. The ease of Polycore use coupled with the high cost and the current shortage of skilled framers and builders, provides a significant opportunity that leads Polycore to become the cornerstone of sales to the fast paced residential building market.
The Future
Polycore offers the modern homebuyer an alternative to high costs and low efficiency. The small builder has a chance to compete in the large housing market, and the large builder the chance to provide a better product to their customers while still maintaining the volumes and profits that larger corporations require. With a focus on efficiency and quality at every stage of the game, Polycore Wall Systems are the future of the Residential Building Industry.
Brochure (Pdf)
Brochure (Pdf)