2" Thermal Serts

  • SKU:  00TS200

BuildBlock ThermalSert Insulation Insert

BuildBlock ThermalSert are insulation inserts for BuildBlock and BuildLock Knockdown ICF forms. ThermalSert inserts are placed inside the BuildBlock or BuildLock Knockdown ICF forms between each course against the inner edge of the block outside wall side. Each 1-inch of foam insert adds 4.2 R-Value increasing the overall r-value of the wall. The insert is placed toward the outside of the block to insulate against the greatest difference in temperature.

ThermalSert Logo

ThermalSert is available in two styles one for BuildBlock ICF forms and another style for BuildLock Knockdown ICF forms. The BuildLock Knockdown web is slightly larger and the TermalSert KD is designed to accommodate the larger web size.

These inserts may be used with any core size form, though reducing the concrete core width too much may create a wall outside the prescriptive code and BuildBlock product engineering. Project specific engineering may be required if you exceed these design specifications.

ThermalSert KD Logo

When specifying your ICF block size, keep in mind that adding the additional insulation will decrease the concrete core size by the same amount of your insulation insert. You can increase the block core size to compensate. For example if your project requires an 8-inch finished wall, and you are using a 2-inch ThermalSert insert you would need to utilize a 10-inch BuildLock Knockdown ICF to maintain an 8-inch concrete core.

Using the insert inside the wall is much easier than adding additional insulation on the outside of the wall and maintains full access to the attachment points and block markings.
ThermalSert and ThermalSert KD are available at multiple locations across North America.

General Specifications

SPECIFICATION Imperial Metric
Expanded Polystyrene density 1.5 lbs./cu.ft. 24.02769 kg/m3
Average thickness of EPS 2½” per panel (5” total) 12.7cm (6.35cm per panel)
Material R-value R-22 Foam Value R-22 Foam Value
Performance R-value
(concrete, form R-value, air infiltration reduction, and thermal mass)
R-30 to R-52 R-30 to R-52
U 0.33 to U 0.02
Actual R-value per inch of EPS Foam 4.2/inch  
Thermal Mass (form & concrete) 4” Core: 47.5 lbs./ft2
6” Core: 72 lbs/ft2
8” Core: 96 lbs/ft2
10” Core: 119 lbs/ft2
12” Core: 143 lbs/ ft2
4” Core: 231.9 kg/m2
6” Core: 351.5 kg/m2
8” Core: 468.7 kg/m2
10” Core: 581.0 kg/m2
12” Core: 698.2 kg/m2
K-Factor .24/inch  
Water absorption - 3% (ASMC272) - 3% (ASMC272)
Water vapor 0.56 perms per 2½” Panel 0.84 metric perms per 2½” Panel
Sound class 52 with ½” sheet rock on inside 52 with ½” sheet rock on inside
Fire wall 3 Hour Fire Rating on BB-600 Wall (Loading 5,000 lb. per lineal feet throughout test.)
(Post test loading 12,000 lbs. per lineal foot with no additional depletion.)
3 Hour Fire Rating on BB-600 Wall (Loading 7440.6 kg/m throughout test.)
(Post test loading 17857.9 kg/m with no additional depletion.)
Concrete compressive strength Recommended 3000 psi minimum Recommended 20 MPa minimum
Recommended concrete pouring temperature* 15°F to 120°F* (-9°C to 49°C)*
*Properly handled, specially formulated concrete can be poured at temperatures as low as -15ºF (-26ºC). Consult your ready mix company. Important: At temperatures below freezing, you must cover all exposed concrete with insulating material.

ASTM Standards Product Testing

BuildBlock ICFs are evaluated to ensure they meet or exceed a variety of industry standards tests. Visit http://buildblock.com/technical-support/product-testing/ for more information.

Properties ASTM TEST RANGE REQUIRED TEST VALUE
Density ASTM D1622 1.5lb/ft³ 1.69lb/ft²
Thermal Resistance ASTM C177 4.0F.ft².h/Btu/in 4.08F.ft².h/Btu/in
Compressive Strength ASTM D1621 15.0 psi 23.1 psi
Flexural Strength ASTM C203 40.0 psi 50.4 psi
Flame Spread ASTM E84 25 Maximum >25
Smoke Developed ASTM E84 450 Maximum >450
Fire Wall Rating ASTM E119   3hr
R-Value ASTM C518 R-22 R-22
STC Rating ASTM E413 STC 50 STC 50
Vapor Permanence ASTM E96 3.5 perms/inch Maximum 2.04 perms/inch

Standard Specification for Rigid, Cellular Polystyrene Thermal Insulation

Specification Reference: ASTM C 578-92 Type I Type VIII Type II Type IX
Property   Units ASTM Test        
Density, minimum   (pcf) D 303 or D 1622 0.90 1.15 1.35 1.80
Density Ranger   (pcf) C 177 or C 518 0.90-1.14 1.15-1.34 1.35-1.79 1.80-2.20
Thermal Conductivity           
K Factor                              

at 25 F
at 40 F
at 75 F

BTU/(hr.)
(sq.ft.)(F/in.)
  0.23
0.24
0.26
.22
.235
.255
.21
.22
.24
.20
.21
.23
Thermal Resistance at 25 F
at 40 F
at 75 F
at 1 inch thickness   4.35
4.17
3.85
4.54
4.25
3.92
4.76
4.55
4.17
5.00
4.76
4.35
Strength Properties
Compressive 10% Deformation
Flexural
Tensile
Shear
Shear Modulus
Modulus of Elasticity
  psi
psi
psi
psi
psi
psi
D 1621
C 203
D 1623
D 723
_____
_____
10-14
25-30
16-20
18-22
280-320
180-220
13-18
30-38
17-21
23-25
370-410
250-310
15-21
40-50
18-22
26-38
460-500
320-360
25-33
50-75
23-27
33-27
600-640
460-500
Moisture Resistance
WVT
Absorption (vol.)
Capillarity
  perm. in
%
––––
  2.0-5.0
less than 4.0
none
1.5-3.5
less than 3.0
none
1.0-3.5
less than 3.0
none
0.6-2.0
less than 3.0
none
Coefficient of Thermal Expansion   in./(in.)(F) D696 0.000035 0.000035 0.000035 0.000035
Maximum Service Temperature
Long-term Exposure
Intermittent Exposure
      167
180
167
180
167
180
167
180
Oxygen Index   % D 2863 24.0 24.0 24.0 24.0

Please use the BuildBlock ICF installation resources mentioned below to build the safest and most successful ICF projects possible. More information can be found on our mail website at http://buildblock.com. Please also visit our Youtube Channel at https://youtube.com/buildblock for product videos, installation videos, project tours, howto videos and more.

Installation Brochures & Quick Start Guides

BuildBlock Product Installation Manuals

The table below provides a link to the BuildBlock Product Installation Manual. The manual is freely downloadable and a hard copy is available for purchase here in the store. Please read this manual to fully understand how to properly install BuildBlock ICFs. If you have any questions, more information can be found on our website at http://buildblock.com/technical-support or by contacting your sales representative or our technical department at 866-222-2575. Our goal is for you to build successful ICF projects that will last for generations. Our motto is Build it once, Build it for life.

Section Content Revised Download
Section 1 BuildBlock Installation & Technical Manual 10/2015 (8 MB)
  BuildBlock Installation & Technical Manual (High Resolution) 10/2015 (71 MB)
Section 2 GlobalBlock Installation & Technical Manual 9/2015 (13 MB)
Section 3 BuildDeck Roof & Floor Decking System Design, Engineering, and Installation Manual 1/2011 (5 MB)
Section 4 BuildBlock Hardwall Installation Manual 12/2015 (11 MB)
Section 5 ThermalSert & ThermalSert KD Manual 7/2014 (4 MB)
Section 6 BuildBrace ICF Bracing & Alignment System Manual 8/2015 (7 MB)
Section 7 BuildBuck ICF Window & Door Bucking Product & Installation Manual 12/2015 (7 MB)
Section 8 BuildShield Termite & Firestop Protection Product & Installation Manual 12/2015 (4 MB)
Section 9 BuildBlock ICF Products & Safe Room Engineering Manual 4/2016   (14 MB)
Section 10 BuildBlock CAD Details 10/2015 (17 MB)
Section 11A Prescriptive Method for Insulating Concrete Forms in Residential Construction, Second Edition 1/2002 (2 MB)
Section 11B Prescriptive Method for Insulating Concrete Forms in Residential Construction, Second Edition Appendix 1/2002   (2 MB)
Section 12 Prescriptive Method for Connecting Structural Insulated Panel Roofs to Concrete Wall Systems 5/2008 (519 kB)
Section 13 BuildBlock 03 11 19 CSI Specifications 10/2015 (55 kB)
(30 kB)
(52 kB)
(80 kB)
Section 14 BuildBlock Code Approvals & Product Testing  7/2015 (5 MB)
Section 15  White Papers and Industry Research (Click here to visit download page)
New research and whitepapers are added to this section regularly.
10/2015  
These files create the most current version of the BuildBlock Technical & Installation Manual Binder.

BuildBlock Installation & Howto Videos