Technology
At the core of every Onsite ICF project is our cutting-edge foam-block technology, designed to deliver unparalleled performance across all building types—whether residential, educational, or commercial. These blocks combine energy efficiency, structural durability, and environmental sustainability, making them the ideal solution for projects of any size or scope. Our versatile system allows us to meet your needs without compromising on quality, speed, or cost-effectiveness.
The Block
The block is the central element to Onsite ICF. They are molded out of rigid polyurethane foam and mass-produced onsite using a simple but elegant Reaction Injection Molding (RIM) method.
Choose between 100mm, 150mm, and 200mm sizes, one meter long.
Blocks are lightweight – 200mm are ~1kg and 100mm ~275grams each
Blocks fit together like Legos
Rigid foam is structurally solid, flame retardant, and does not absorb moisture
Fabrication
The Onsite RIM™ system fabricates the blocks.
Foam injection machine. This portable, cart-mounted unit pumps, heats, then mixes the polyurethane under high pressure for injection into the mold. The pump system ensures proper ratio of the two chemicals, maintains high flow rate and creates a uniform mix that creates most efficient fill in the mold. The results are consistent and dependable across a reasonable range of environmental conditions. This cart weighs approximately 150kg.
Mold: The mold receives the chemical injection and conforms it to the block shape while it reacts and becomes rigid foam. The finished block is extracted from the mold after sufficient cure time. The extraction process is simple and the mold quickly ready for the next injection. This portable mold is designed for operation and maintenance in remote areas. Patents applied for.
Production
A crew of three can keep six molds operating simultaneously with one pump system. With a typical cycle time of 12 minutes per block, the run rate on six molds can reach 30 blocks per hour.
A basic house of 60 square meters would require approximately 300 blocks. Production time on this is estimated to be 10-12 hours. Total chemical required is estimated at 300kg/265 liters.
Air & Electric are required for operation. Commercially sized portable generator and air compressor are suitable. See specification sheet for details.
Cordless Impact Drivers (2) are highly recommended for mold operation.
The Chemicals
Polyurethane is a two-part chemical reaction system. It uses a ‘Part A’ which is a standard isocyanate and ‘Part B’ resin. Approved formulations of these chemicals are available and in stock at Onsite ICF. Optionally you may contact us to certify other sources/formulas. These are typically supplied in drums conforming to local standard sizes such as 200 liters, 55 gallons, 44 gallons, etc. The chemicals weigh approximately 9 pounds per gallon or 1kg per liter.
Mobile Factory
The RIM System is available as a trailer configuration to be hauled to jobsites. Complete with the pump system, generator, compressor, multiple molds and drums of polyurethane this portable factory makes blocks where you need them!
