HydroLOCK's System is a manufactured, seamless approach to foundation construction that is impermeable to water and radon and has integral insulation. Foundations often can be installed in half a day, so well scheduled jobs can benefit from at least a three-day time savings over formed and poured concrete walls.
What makes these walls unique is the six-inch, 14 gauge, cold formed steel structural members that comprise the interior of a sandwiched high density polyethylene (HDPE) and extruded polystyrene skin (XPS). The steel "studs" provide axial support to the walls and have punched uniform openings to accept wiring and plumbing allowing for an easily-finished basement on the interior.
Like precast concrete walls, the HydroLOCK System is manufactured in a controlled factory setting. Built to the builder's blueprint specifications, window and door openings, brick ledges, and beam pockets are integrated into the wall design during manufacture. Wall height can be customized allowing the system to be used for frost walls, crawlspace walls, as well as, in-ground and walkout basement walls. Walls are typically fabricated in lengths that represent the depth of the house -- 28 feet to 32 feet, but actual manufactured lengths are limited only by shipping constraints. Walls are secured to a custom polymer track with an integral interior and exterior perimeter drainage system that is fastened to a concrete footing sized for soil type and house design. Polyethylene fusion welding completes the foundation wall intersections, fastener heads, and the wall and footing connection providing a redundant barrier to liquids and gasses.
After installation, the foundation walls are permanently braced with the floor system and the basement slab. The walls can be backfilled as soon as the first deck and slab are securely in place. Filling the basement's over-excavated area early in the home construction process allows safe access to the home by the trades.
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HydroLOCK's sandwiched skin design includes 2 of extruded polystyrene foam with a thermal resistance of R-10. The design complies with energy efficiency requirements for basements and crawlspaces in many U.S. climates and allows for adding extra insulation in cold climates.
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The walls are fabricated in a controlled factory environment. The process minimizes variation due to imprecise fit, workmanship, or weather while streamlining the installation process by shaving days from the foundation schedule of poured concrete or block foundation walls. Fusion welding makes a seamless barrier to water intrusion at junctions and intersections.
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Where the product is available, the manufacturer reviews architectural plans and creates a foundation plan for builder review and approval. Walls are then manufactured to specification, shipped, and installed into a HydroTrac on concrete footings provided by the builder. Foundation walls are secured in the track, braced with the first floor deck and basement slab, then backfilled. Frost and crawl walls can be installed in the Hydrotrac on top of a trenched footing, braced with the floor deck, then backfilled.
Currently, product distribution is limited to an area within a 300 mile radius around Warren, OH. Builders in the Cincinnati, Columbus, Akron, OH, as well as, Philadelphia and Pittsburgh, PA markets are able to order a HydroLOCK System now. Distribution plans are underway for franchisees and licensees to offer the system nationwide.
HydroLOCK foundations can be installed at prices similar to those of precast concrete foundation walls - $65 to $75 per lineal foot of 8-foot wall, dependent on the complexity of the design. The cost is competitive with a block foundation and slightly higher than the cost of an 8-inch formed concrete foundation in metropolitan markets.
HydroLOCK foundations include 2 inches of XPS foam that provide R-10 thermal resistance.
HydroLOCK is not covered prescriptively in the International Residential Codes (IRC). Local building department construction pre-approval of the system will be required. Hydrolock Systems provides documentation that includes an engineer’s seal on the foundation drawing as required.
The walls meet prescriptive energy codes (IECC 2003) for basement walls as far north as Zone 14, or geographical areas with 6,500 heating degree days (HDD) or less. Crawlspace foundations are compliant through Zone 10 or areas with less than 4,000 HDD. As with traditional basement wall construction, additional insulation may be installed on the inside of the walls to meet all States' energy code requirements.
None at this time.
The walls are installed on top of a level footing installed by others by a trained crew and crane provided by the manufacturer. The walls fit in a proprietary track that contains an integrated footing drain. Wall junctions are fusion welded to preserve the continuity of the exterior surface.
Experienced carpenters have mounted the learning curves associated with both wall manufacture and installation very capably, so it is possible that framing contractors will vertically integrate their operations to include foundations in high-volume new home markets.
The manufacturer offers a transferable 20-year warranty on the foundation walls.
HydroLOCK foundations offer an alternative to labor-intensive traditional concrete or masonry foundations. The continuous external material of the wall is impervious to liquid and enhanced by a 2-inch thickness of XPS. Factory fabrication enhances the system's quality and allows delivery and site installation for an average-sized home (2,400 square foot 2-story) to take place in one day or less.
The system's cost is slightly greater than traditional masonry foundation alternatives. However, the system includes features that add value which are not included in typical cost comparisons. For example, the cost of insulating and stud-framing the interior area in preparation for a finished basement is included with the HydroLOCK system and some precast concrete walls, but not accounted for in typical cost comparisons.
Availability is limited. Special code approval is required.
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