Extruded polystyrene foam insulation laminates for pour-in-place concrete walls

An improved method for forming a composite wall comprising a thermal insulation board disposed between concrete layers, the method comprising:

• setting into place spaced-apart rigid forms to define a thickness for the composite wall and circumscribe a cavity;
• setting into place a thermal insulation foam panel, the panel having opposed, spaced-apart and generally parallel primary surfaces, the foam board being placed within the cavity and between the forms so as to define two subcavities, each subcavity being defined by a form and a proximate primary surface of the thermal insulation foam panel;
• and
• filling the subcavities with concrete and thereafter curing the concrete which fills the cavities to form the concrete layers of the composite wall;
• wherein the improvement comprises adhering, a thermoplastic facer film to each of the primary surfaces of the foam panel to form a foam board, each thermoplastic facer having a thickness of from 0.35 mils (10 micrometers) to 10 mils (250 micrometers), an ultimate elongation of less than 200% in both machine and transverse directions, a yield strength of at least 7,000 pounds per square inch (48,400 kPa) in both machine and transverse directions, and a 1 percent secant modulus of at least 200,000 pounds per square inch (1,380 megapascals), adhesion between the facer films and the foam panel being sufficient to provide a peel strength of at least 100 grams per inch (39.4 gm/cm).