HercuTech’s core competency is supplying innovative quality construction components, products, and systems produced in a controlled factory environment. These high performance elements provide a building envelope that is energy efficient, cost competitive, and with durability that will far outlast today’s conventional building methods.
HercuWall® construction is flexible and adaptable, placing few restrictions on architects and their designs. If a structure can be built with wood or concrete block, it can be built with HercuWall®. HercuWall® structures look the same as any others on the street but far outperform conventional building protocols.
HercuWall® is designed to provide architects, engineers, and builders with a superior alternative to concrete block and wood frame construction. HercuWall® speeds up the building process with substantially less job site labor by combining many steps into one system.
HercuWall® is a low-cost, high quality product that gives builders and developers a demonstrable marketing advantage over their competitors. Easy to adopt, HercuWall® is a builder's “Green Alternative” and answers all of the competitive chatter with a superior system. Large production builders and commercial contractors are committed to HercuWall® because of the many advantages noted.
HercuWall® has undergone years of engineering and testing by independent third party engineering firms and test labs. HercuWall® has been approved for use in High Velocity Hurricane Zone areas by Dade County (Florida) Product Approval. (NOA No. 12-0607.03. Expiration Date: November 8, 2017). Dade County HVHZ (High Velocity Hurricane Zone) acceptance is generally considered the most rigorous of all product approvals in the building materials realm. The approval is a prerequisite to entering the Florida market and is the basis for product compliance in Texas, North Carolina, and South Carolina as well as other U.S. coastal regions. Every Caribbean country (island) has either adopted the Dade County Code or based their local codes on it, relying heavily on the Dade County product approvals. This approval provides credibility in all markets whether or not in a hurricane prone area.
HercuWall® is an essential component in green construction that contributes to high energy efficiency ratings and contributes favorably to excellent LEED® scores. HercuWall® is specified in lieu of using wood frame or concrete block in new construction for the purpose of gaining the benefits of the strength, durability, and security of reinforced concrete, speed and ease of installation, the desire to incorporate green construction, and ongoing lower cost of utilities.
HercuWall® consists of a series or “kit” of panels which are manufactured utilizing expanded polystyrene (EPS) foam, a standard building and insulation material. HercuWall® panels are manufactured to match the height of the wall being constructed. Each HercuWall® foam panel contains voids which are filled with concrete on-site. The voids determine the final shape of the concrete within the walls. The unique reinforcing system called ShearStrip™ Technology acts as the primary structural reinforcing component of the wall system. The shape of the concrete within the form is not a solid continuous concrete wall but a wall that has a continuous bond beam at the top, a continuous base beam at the bottom, and vertical concrete “studs” regularly spaced connecting the top and bottom beams. After the concrete is placed and cures within the wall, the forms stay in place as high-performance insulation, a mounting surface for exterior and interior finishes, and as a weather resistive barrier. HercuWall® is both a weather resistant barrier (WRB) and a waterproof drainage plane.
HercuWall® panels are custom manufactured to match the architectural design and structural requirements of a specific building project. HercuWall® will accommodate straight walls, curved walls, corners, and window and door openings of all sizes. Multiple custom made panels are required to construct the walls for a given project. All of the panels for a specific project arrive at the job site as a kit, pre-cut to size on computer controlled equipment and numbered so that each component can be identified and positioned properly. No site modification of the forms is required.
ShearStrip™ Technology eliminates all of the vertical rebar reinforcing that is required in other reinforced concrete construction, thereby reducing costs, eliminating labor, and dramatically speeding up the installation process.
HercuWall® Engineered for Efficiency™
HercuWall® Applications - Guidelines*
|Project Type||Description||Suggested Product||Wall Height|
|Residential||Single Family Home – 1 or 2 Story||Series 7||12’/Floor|
|Residential||Single Family Home – Hurricane Zone||Series 9||Up to 20’|
|Residential||Single Family Home – Seismic Zone||Series 7 or 9||12’/Floor|
|Residential||Multi-Family Apartments||Series 7 or 9||12’/Floor|
|Commercial||Retail or Strip Shopping Centers||Series 9 - Tall Wall||Up to 30’|
|Commercial||Schools, Offices, Medical||Series 9||12’/Floor|
|Warehouse||Industrial/Warehouse/Flex||Series 9 - Tall Wall||Up to 30’|
*This table is a guideline; specific specifications and product determination will be made upon review of
plans and discussions with designers and specifiers on each particular project.
Professional Installation Details
HercuWall® installation is uncomplicated and the learning curve is very short. HercuWall® arrives at the job site as a kit of numbered panels consisting of straight wall panels, corner panels, window panels and door panels. Each component is manufactured exactly to match the specifications of the project. Metal base track sections and prefabricated corner sections eliminate all miter cuts. Metal inner and outer top cap sections and fastening screws complete the kit. Field drawings are furnished in advance to the builder and a copy is delivered with the kit depicting the overall dimensions and HercuWall® panel positions.
HercuWall® panels are lightweight but durable and each component has been engineered for easy handling by one or two workers. A 4’ x 9’ wall panel weighs less than 50 pounds. No cranes are required and no costly tools are needed. No job site alteration or modification is required. No scrap is generated, only the reusable wall and window bracing is removed from the job site.
HercuWall® sequence of construction starts with the installation of the Base Track, then the setting up of the HercuWall® Wall Panels and finally Placing Concrete. If the site is properly prepared and slab or stem walls are within dimensional tolerance and HercuWall® installation guidelines are adhered to, the installation process will be trouble free.
The Base Track establishes the position of the HercuWall® panels and must be laid out to match the building plans and the field drawings furnished by HercuTech. Typically corners are placed first and straight sections fill in between the corners. A bead of HercuWall® approved sealant is applied to the edge of the slab prior to setting the track in place. The seal provides an added moisture and insect barrier between the track bottom and the concrete. The track is then pinned or nailed to the slab to prevent movement. Typically the architectural details call for the track to overhang the slab by 1” providing clearance for a drip edge and a shadow line.
Wall Panels are sequentially numbered. Starting with corner panel number “001,” stand the panel in its correct position as indicated on the field drawings. The bottom of the panels slide into the bottom track. Continue with panels “002,” “003,” and so forth. Tongue and groove joints between each of the panels ensure proper alignment. As several panels of the wall are set in place, inner and outer top caps are set into position. Ensure that the position of the end joints between the inner top cap ends and the outer top cap ends are offset a minimum of 24” facilitating a straighter alignment of the panels. Brace the wall sections to the inside floor as shown on the field drawings. Plumbing (straightening) the wall should be done in long sections not on a panel by panel basis; rely on the top caps to assist. After the HercuWall® panels are positioned in the track, they are fastened through the base track to each ShearStrip™ with the screws furnished in the kit. Top caps are also to be secured to each ShearStrip® at the top of the wall with screws. Two horizontal #4 steel reinforcing bars (rebar) are placed within the bond beam. Factory installed nylon rebar hooks designed to hold the rebar, are positioned within the bond beam cavity. No wire ties are required. Be extra aware that with high wind conditions, more bracing will be required.
Placing Concrete is trouble free if HercuWall™ guidlines are closely adhered to. Concrete must be ordered to specification and use of a proper grout pump will provide succesful results time after time. Remember “slower is faster” in this instance. Start placing concrete away from a corner section and work through the corner. The operator at the discharge end should keep the hose moving so that three or four columns are progressively being filled. Fill ports are supplied below window openings. Avoid overfilling in under window areas. Walls can be filled to the top in one lift. A second worker should follow the hose operator and trowel the surface of the concrete. Top caps function as a screed edge for this purpose. A third worker on the ground assisting with the pump hose and handling filling the windows will round out the crew. Concrete can be placed in 200 linear feet of 9’ tall wall by the aforementioned method in approximately one hour. Blowouts caused by concrete pressure when suggested procedures are followed, are almost non-existent. Should a blowout take place, it is normally one column or a few shovels full of concrete. Repairs are quick and do not slow down the process. Our engineers or field staff will assist in sourcing concrete suppliers and recomending pumping equipment.