R-Blocks: Build Smart, Live Secure
R-Blocks is the pinnacle of Insulated Concrete Forms (ICF) manufacturing. Our stay-in-place reinforced concrete wall molds are exclusively made with polyurethane foam and precision methods, offering superior construction advantages, lifetime savings, and value. Our products are backed by 30 years of experience in creating the most cost-efficient permanent building solutions for commercial and residential projects.
The R-Blocks Difference
The advantages of polyurethane R-Blocks are immediate and long-term. Compared to EPS foam molds, you get far greater:
Durability
R-Blocks’ solid, reinforced concrete walls are superiorly resilient to seismic activity and can withstand sheer-force winds of 160+ mph. Also, the high-density polyurethane foam is significantly more resistant to water and insects.
Sound abatement
Our stay-in-place polyurethane forms have vastly better sound dampening with a rating above STC 50. You can save time and money by not installing liner panels to reach low sound transmission levels.
Easy installation
R-Blocks' density and rigidity produce straighter walls (no bows or bulging). They also do not require a covering during installation, saving time and money as foundations and walls with R-Blocks can remain exposed during installation.
Precision manufacturing
Our process combines extremely tight molding and exact temperatures to create dense polyurethane foam. By contrast, the density of EPS blocks is far lower because steam is injected into the molds to fuse the EPS beads.
Flame resistance
Polyurethane R-Blocks have the highest fire protection rating (Class A) and a smoke index below 450, which allows their use in all applications, including interior or exterior walls. Excellent flame resistance saves time and money since you don’t need to cover surfaces not seen by the public, such as elevator shafts.
R-value, Rigidity, Ruggedness
R-Blocks meet and exceed all IBC and IRC requirements for building materials. Our polyurethane ICF blocks deliver rapid payoff compared to traditional stick-frame or concrete walls from ICF blocks made with expanded polystyrene (EPS).
R-Blocks' advantages over EPS rapidly accelerate during construction and last long after project completion. Our durable polyurethane ICF molds deliver quantifiable benefits from:
R-value
The insulation value of solid, reinforced concrete walls with R-Blocks is between R-40 and R-50 (with exterior and interior cladding). This is more than 2x the R-Value of finished walls made with EPS forms and 3-4x that of stick-framed insulated walls.
Rigidity
Polyurethane R-Blocks' greater thickness and density make them easier to install than EPS blocks. Minimum bracing lets you pour walls higher, straighter, and seamlessly without the risks of blowouts associated with EPS molds.
Ruggedness
R-Blocks are built to last and are significantly more resistant to water, fire, bugs, and other environmental conditions. Our high-grade plastic inserts will not split or crack when attaching interior drywall or exterior materials.
Every detail sets R-Blocks apart.
Our process is highly refined based on over 30 years of expertise in polyurethane ICF manufacturing.
Thickness
Our stay-in-place molds place 2.5 inches of dense polyurethane foam on the interior and exterior of solid, reinforced concrete walls to give you the highest R-value.
Width options
We offer 6 and 8-inch mold widths to build foundation walls to complete exterior and interior structures.
Flame resistance
Unlike EPS, polyurethane foam does not melt when exposed to temperatures over 200 degrees.
Rigidity
Polyurethane is approximately 7x higher in compressive strength than EPS. This prevents blowouts when pouring concrete.
More robust inserts
Our molds use rigid plastic inserts to place rebars before pouring concrete. The inserts have superior pull strength to attach interior drywall or exterior products such as stucco, brick, stone, or foundation plaster.
Thickness
Our stay-in-place molds place 2.5 inches of dense polyurethane foam on the interior and exterior of solid, reinforced concrete walls to give you the highest R-value.
Width options
We offer 6 and 8-inch mold widths to build foundation walls to complete exterior and interior structures.
Flame resistance
Unlike EPS, polyurethane foam does not melt when exposed to temperatures over 200 degrees.
Rigidity
Polyurethane is approximately 7x higher in compressive strength than EPS. This prevents blowouts when pouring concrete.
More robust inserts
Our molds use rigid plastic inserts to place rebars before pouring concrete. The inserts have superior pull strength to attach interior drywall or exterior products such as stucco, brick, stone, or foundation plaster.
Trusted by Industry Professionals
"Over the 23 years I have been practicing as a structural engineer, I have designed many structures using ICF forms. R-Blocks and its polyurethane foam mold have the highest R-value, fire resistance, and longevity. I recommend it for any commercial or residential project, knowing that it’s the best product on the market ."
"As a contractor, R-Blocks' benefits include happier customers, straighter walls, and getting jobs done faster. This has been a great product ."
Discover how BTM Concrete in Heber City, Utah gets superior results with R-Blocks
ICF Solutions
R-Blocks is the ideal ICF solution for all commercial and residential construction projects. It meets all requirements for stay-in-place forms in IRC 608.4 and delivers lifetime advantages from solid, reinforced, insulated concrete walls.
Whether you choose R-Blocks for foundation walls or a complete structure, you will save significant time and money during construction and have superior results.
R-Blocks' cost is competitive with that of EPS foam molds. Yet, It offers much higher value from building faster, straighter, stronger, and more durable walls with significantly higher R-value and sound dampening, among other benefits.
For example, most EPS blocks are poured at intervals of no more than 4 feet during installation. R-Blocks can be poured 10+ feet at a time. Besides saving significant labor and material costs, the higher and seamless pours eliminate “cold joints” in concrete walls, virtually eliminating the probability of holes and leaks.
R-Blocks need far less bracing and setup time due to the superior foam density and rigidity supporting higher concrete pours. The benefits continue long after construction. Polyurethane molds do not break down over time, as EPS molds do, ensuring lifetime value.
Residential Solutions
Polyurethane ICF blocks offer unparalleled residential construction advantages for concrete foundations, basements, and full-length exterior walls. You will save hundreds, and perhaps thousands, on heating and air conditioning costs every year. You will also get the most durable, watertight, and resistant walls to flame and pests.
R-Blocks works closely with you and your engineering firm, architect, and builders to consult, design, and provide training for your custom ICF solution.
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Commercial Solutions
A custom R-Blocks solution for public and commercial building projects will save many hours, reduce construction costs, and provide a lifetime of value.
When choosing R-Blocks, engineering and architecture firms, contractors, and property owners gain a competitive advantage. For example, you can separate units with a solid, reinforced concrete wall made with R-Blocks when building luxury townhomes. This solution provides unparalleled sound dampening, insulation, and flame resistance compared to EPS molds or stick-framed walls, which require liner panels and have much lower R-values.
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Resources
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Partners
R-Blocks has close partnerships with engineering, installation, and logistics experts to fully support your residential and commercial building projects from design to completion.
Partner references and contact information are available upon request for
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