1.2 DEFINITIONS, REFERENCES, AND OVERALL STANDARDS Follow 07500

Transcription

1 07503 ROOF ASSEMBLY LIGHTWEIGHT INSULATING CONCRETE SPECIFIER: All roof-related items above or outside the structural roof deck, including such work as blocking, insulation, membrane, sheet metal, hatches, vents, and curbs are components of the Roof Assembly. The entire Roof Assembly carries a special warranty by the roof membrane producer, as specified in the lead Roof Assembly section, 07500, and Note that no wood blocking is permitted. Use only galvanized steel SRB as specified in CSI 2004 MasterFormat number: Optional keynotes to Drawings follow each major product title, for A/Es using National CAD Standard. PART 1 GENERAL 1.1 RELATED REQUIREMENTS A. Coordinate Roof Assembly roof insulation work with work before and after. See especially: 1. The lead section (roof membrane) for the entire Roof Assembly Wood-free galvanized steel roof blocking (SRB) Other Roof Assembly components such as roofing, sheet metal, hatches, vents, portals, and equipment curbs Div 07, DEFINITIONS, REFERENCES, AND OVERALL STANDARDS Follow QUALITY ASSURANCE B. Design Intent. The shown styrene and lightweight (LW) concrete roof insulation assembly is intended to achieve an average R-value of at least The styrene board in the subassembly may be omitted within 1 ft of roof drains as long as the LW concrete component forms a proper sump for positive drainage. 2. If there is any reason to believe that this insulating value will not be achieved using products and thicknesses specified in the Construction Documents, notify A/E and the Board in writing before preparing submittals, with a brief explanation why. C. Installer s Qualifications. Each installer of a shown part of the Roof Assembly shall: 1. Have 5 years of successful experience in the installation of that roof component. 2. Be currently listed in the MDCPS Pre-Qualified Roofing Contractor List. 3. Be currently licensed or certified by the producer of that part of the Roof Assembly. D. Insurer Certification. Assist Board in preparing roof insulation acceptance certification as needed for the fire and extended coverage insurance of the Roof Assembly. E. Pre-Installation Meeting. At least 6 weeks before installation of Roof Assembly, the Contractor shall conduct a meeting at the worksite with installers of each part of the Roof Assembly, affected installers of other work, A/E, AHJs, and Board representatives. 1.4 SUBMITTALS Follow F. Special Warranties. Before making any other submittals, and at least 10 weeks before pre-installation meeting, submit and obtain approval of draft of (or form for) each specified Special Warranty. project number RA Lightweight Insulating Concrete

2 G. Product Data. Description of each product, including standards met, and the following: 1. Miami-Dade Product Notice of Approval (NOA) number and expiration date. 2. Minimum thickness of concrete at thinnest point over styrene, as stated in NOA. 3. Thermal resistance values from ASTM C177 or C518 tests. 4. FMA Wind Resistance Classification. 5. Producer s installation instructions. H. Shop Drawings. Roof plan showing slopes, roof penetrations, thickness of styrene, LW concrete insulation, and details for proper installation. 1. Show openings such as hatches, vents, equipment curbs, portals, as well as crickets. 2. Show negative pressures on each part of the roof (no less than those shown in the Construction Documents) along with modifications to producer s roofing design, such as fastener numbers & patterns, as needed to withstand negative pressures, calculated by a Florida registered professional engineer following TAS Show details of interface between deck, steel blocking, and LW concrete insulation. I. Samples. Styrene insulation board in thickness to be used, 8 x 8 in. J. Certification, before installation. Affidavit, from LW concrete producer, approving installer. 1.5 SPECIAL WARRANTIES Follow 01790, K. By Membrane Producer. Provide a 20 year Special Warranty from the roof membrane producer covering correction of defects in the roof insulation component of the Roof Assembly. L. By LW Concrete Insulation Producer and Installer. Provide a 10 year Special Warranty in which the LW roof insulation producer / installer agrees to correct defective roof insulation work. 1. See for the full requirements of this Special Warranty that shall be included in this LWIC Special Warranty (that will accompany the Roof Assembly Special Warranty). 2. At time of project closeout, submit this signed Special Warranty to the roof membrane producer, for transmittal to Contractor, A/E, and Board. PART 2 PRODUCTS Follow STYRENE INSULATION BOARD [07230-lwic-s] M. Description. Expanded polystyrene boards, free of chlorinated fluorocarbons, with bonding / venting slots. Mark bundles with FM label and name of producer. 1. Thickness: As needed to bring the total R-value of LW concrete + styrene board to the specified R-value of the styrene + LW concrete subassembly. 2. Bond slot area in each 2x4 or 4x4 ft board: At least 3% of board area. 3. R-value of unslotted foamed styrene, at 110 F: At least 3.0 / in. of thickness. 4. Density: lb/ft Water absorption, by total immersion: 4.0% maximum, by volume. N. Standard. ASTM C578, Type I. O. Product / Producer. 1. Holey Board, by Apache project number RA Lightweight Insulating Concrete

3 2. Insulperm, by Siplast 3. Equal product in quality and performance as reviewed and approved by the A/E, the Board and its Roofing Dept. SPECIFIER: In editing the following articles: Use cellular concrete over cast-in-place structural concrete roof decks. Use LW aggregate concrete or LW hybrid concrete over vented steel decks. Where both types of structural deck occur in a project, retain all specified mixes. 2.2 LIGHTWEIGHT INSULATING CONCRETE, FOAMED CELLULAR [07230-lwic-c] P. Description. Cement and pre-generated foam, mixed using water. Thickness at thinnest point shall exceed the minimum thickness specified below as needed to achieve the required R-value in the styrene board + LW concrete insulation subassembly. 1. Formulation: As will produce at least 300 lb/in 2 compressive strength and R-value of at least 1.00 / in. of thickness with 300 lb/in 2 mix.. 2. Wet density at point of placement: lb/ft Oven dry density: lb/ft Portland cement; ASTM C150, Type I, II, or III. 5. Foaming agent: Liquid concentrate, labeled as to material and producer; ASTM C Bonding agent: As recommended by LW concrete producer for use on steel decks. 7. Fiber reinforcing (optional with producer): 3/4 in. polyester fibers. 8. Admixtures: Other than a superplasticizer / water reducer (optional with producer), use no admixtures unless authorized in writing from LW concrete producer. 9. Water: Potable, free of sand, alkali, organic matter; maximum CL - content: 250 ppm. 10. Curing compound. Compatible with first ply of roofing membrane and its asphaltic adhesive. Use over cast LW concrete as needed to retard moisture loss during cure. Q. Product / Producer. 1. Celcore, by Celcore, Inc. 2. Concrecel, by Concrecel Intl. 3. Elastizell, by Elastizell Corp. 4. Equal product in quality and performance as reviewed and approved by the A/E, the Board and its Roofing Dept. 2.3 LIGHTWEIGHT INSULATING CONCRETE, WITH LW AGGREGATE [07230-lwic-l] R. Description. Cement and lightweight aggregate, mixed using water. 1. Formulation: As will produce at least 300 lb/in 2 compressive strength and R-value of at least 1.00 / in. of thickness. 2. Wet density at point of placement: lb/ft Oven dry density: lb/ft Portland cement; ASTM C150, Type I, II, or III. 5. Bonding agent: As recommended by LW concrete producer for use on steel decks. 6. Aggregate: Asbestos-free vermiculite, treated to reduce water absorption; ASTM C332, Group I. a. Do not use perlite unless LW perlite concrete installer causes 1 in. expansion material to be applied to all restraining surfaces at perimeter of roof area and at all penetrating items such as hatches, vents, and equipment curbs. 7. Admixtures: Use none unless authorized in writing from LW concrete producer. 8. Water: Potable, free of sand, alkali, organic matter; maximum Cl content: 250 ppm. project number RA Lightweight Insulating Concrete

4 9. Curing compound. Compatible with first ply of roofing membrane and its asphaltic adhesive. Use over cast LW concrete as needed to retard moisture loss during cure. S. Product / Producer. 1. ZIC, by Siplast. 2. Equal product in quality and performance as approved after review by the A/E, the Board and its Roofing Dept. 2.4 LW INSULATING CONCRETE, CELLULAR / LW AGGREGATE HYBRID [07230-lwic-h] T. Description. Cement and lightweight aggregate, mixed using water. 1. Formulation: As will produce 300 to 350 lb/in 2 compressive strength and R-value of at least 0.85 / in. of thickness for 300 lb/in 2 mix and 0.85 / in for 350 lb/in 2 mix.. 2. Wet density at point of placement: lb/ft Oven dry density: lb/ft Portland cement; ASTM C150, Type I, II, or III. 5. Bonding agent: As recommended by LW concrete producer for use on steel decks. 6. Aggregate: Asbestos-free vermiculite, treated to reduce water absorption; ASTM C332, Group I. Do not use perlite. 7. Fiber reinforcing: 3/4 in. polyester fibers. 8. Admixtures: Other than a superplasticizer / water reducer, use no admixtures unless authorized in writing from LW concrete producer. 9. Water: Potable, free of sand, alkali, organic matter; maximum Cl content: 250 ppm. 10. Curing compound. Compatible with first ply of roofing membrane and its asphaltic adhesive. Use over cast LW concrete as needed to retard moisture loss during cure. U. Product / Producer. 1. Cellular Hybrid with Zell-Crete fibers, by Elastizell. 2. Equal product in quality and performance as reviewed and approved by the A/E, the Board and its Roofing Dept. 2.5 ACCESSORIES SPECIFIER: specify reinforcement in LW concrete over steel or fiber decks when needed to comply with the UL fire rated assembly that is required in the Construction Documents. V. Reinforcement in LW Concrete: Galvanized steel welded wire reinforcement, such as 2x2 W0.5 x W0.5, or non-welded longitudinally reinforced twisted hexagonal wire type, such as Keydeck, by Keystone. 1. Where no fire rating is required, alkali-resistant plastic fiber reinforcing may be used in cellular concrete formulations. W. Joint fillers, for use at structural movement joints in roof, and for expansion strip at perimeter of perlite aggregate LW concrete : 1 in. semi-rigid glass fiber; ASTM C612, Type II or IV. X. Curing compound: Aqueous emulsion. project number RA Lightweight Insulating Concrete

5 PART 3 EXECUTION Follow EXAMINATION AND PREPARATION Y. Check and prepare substrates that are to receive LW insulating concrete. 1. Concrete finish. The texture of the roof structure s concrete finish shall be suitable for properly bonding and preventing LW concrete lift-off. Structural roof concrete finish shall be sufficient to interact with LW concrete roof fill to meet the minimum wind uplift resistance figures as noted in the Roof Wind Pressure diagrams on the Drawings and shall follow the NOA requirements for proper application of the roof membrane. 2. Concrete condition: Dry and free of shrinkage cracks, laitance, bond-breaking substances, and loose material. Surfaces shall be free of pits, honeycomb, ridges and roughness that could interfere with bonding of: a. Slurry coat applied to receive styrene boards over normalweight CIP concrete; b. The 2 in. nominal LW concrete (without styrene) that is first applied over normalweight CIP concrete before installing roof membrane. 3. Steel deck condition. Dry, clean, and free of oily and bond-breaking substances that could interfere with the bonding of: a. LW concrete fill in flutes of ribbed steel deck followed by slurry coat to receive styrene boards; b. The 2 in. nominal LW concrete (without styrene) that is first applied over flat steel deck before installing roof membrane. c. In addition, this LW concrete deck component and its diaphragm load capacity shall have been designed and installed to follow FBC, Chapters 19 and Bonding and Composite Action with Structural Decks. a. At steel roof decks, ribbed or flat, check the full and proper installation of any shear connectors required by the Construction Documents. b. Check ribbed steel roof deck for embossed lugs in the flute walls that are specified to be provided for composite action between deck and LW concrete fill. c. Report incomplete or improper installation of connectors and lugs. d. Provide adhesive to bring wind uplift resistance levels up to the requirments of the LWIC s NOA where mechanical bonding is inadequate or missing. 5. Expansion Joints. Provide expansion joints in LWIC: a. Above expansion joints, changes of direction of steel framing or decking and changes in type of structural deck occur. b. Where building wings occur in new construction or are added to existing construction. c. Above boundaries between air conditioned and non-conditioned spaces. d. Where differential movement between walls and deck may occur. 6. Nailers and blocking: Clean, oil-free galvanized steel only. Use no wood or aluminum. Z. Prepare and bring substrates to the above-specified conditions before Installing slurry coat, styrene insulation, and LW insulating concrete. AA. Installation of other work on or passing through roof deck shall be complete and tested. Steel blocking shall be in place, as well as framing for openings, hatches, curbs, supports, roof drains and other penetrations. 3.2 INSTALLATION OF LIGHTWEIGHT CONCRETE ROOF INSULATION BB. Delivery and Storage. project number RA Lightweight Insulating Concrete

6 1. Deliver products in producer s sealed packages or tight bulk containers. 2. Store products to protect them from weather and physical damage. 3. Do not use cement that is damaged by moisture, dirt or caking. CC. Installing Insulation Board. 1. Lay out I in. joint fillers over movement joints in substrate. Coat top surface with 10 to 30 mils of water-based acrylic sealant to keep LW concrete from entering joint filler. a. If LW concrete contains perlite aggregate, install 1 in. of joint filler at all restraining surfaces at perimeter of roof area and at all penetrating items such as hatches, vents, and equipment curbs. 2. Cover steel deck or CIP normalweight concrete substrate with a 1/8 to 1/4 in. slurry coat of LW concrete. 3. Install insulation board within 20 minutes of placing the slurry coat so that slurry and board are in full contact. Never lay boards without full bed of slurry beneath. 4. Lay insulation board in brick pattern (lateral joints staggered) with joints butted snugly. Remove loose boards and immediately re-grout. DD. Installing Lightweight Concrete Fill over Insulation Board. 1. Install LW concrete the same day that the styrene insulation has been set in place. 2. Joints. Install joint filler over movement joints in structural deck. Support and seal. 3. Placing. Place LW concrete fill over insulation board while fill in the insulation board cores is still plastic. Screed to an even surface to receive the roofing membrane. 4. Cover. Provide full 2 in. of LW concrete over styrene insulation board, measuring the depth from topmost edges of styrene. 5. Drainage. Increase thickness of LW concrete as needed to obtain roof drainage slope of at least 1/4in./ft, or greater slope as shown or implied by Construction Documents. 6. Crickets: In sumps between roof drains, between roof drains and parapets, and at high side of curbs, construct crickets uniformly sloped to drain 1/4 in./ft or more. 7. Curing: Apply curing agent to retain moisture for proper cure. Observe other proper curing instructions of the LW concrete provider. EE. Installing Lightweight Concrete Fill Directly over Impervious Structural Decks. 1. No roof membrane shall be placed directly over unvented steel deck or CIP concrete unless the following venting mechanisms are provided: a. Place at least 2 in. of LW insulating concrete fill with bonding agent to achieve roof assembly uplift resistance figure before installing the mechanically fastened venting base sheet and the rest of the roof membrane assembly; b. Unless waived by the A/E because of low moisture test readings in the substrate and fill, provide vents in the roof membrane as specified in that section (07522) in. is only the minimum thickness of this fill. Install LW concrete above the steel or concrete deck to whatever thickness is needed to provide at least 1/4 in. slope from high point to the point of discharge. a. Fill flutes in ribbed steel deck at same time the 2 in. fill is placed above it. 3. Place joint material in this LWIC fill, over expansion and other movement joints, as well as at perimeters of perlite LW concrete fill. 4. Finish this fill to match other LW concrete that is receiving roof membrane assembly. SPECIFIER: The following paragraph should be omitted unless LW concrete is being placed over a resilient material such as Tectum. FF. Installing Fill Over Deflecting Substrate project number RA Lightweight Insulating Concrete

7 1. A deflecting substrate is one that allows more than 1/8 in. deflection in 4 ft under normal traffic: In this condition, install LW concrete within 4 hours of setting insulation. 2. Plan early installation of insulation each day to ensure both a 4 hour slurry cure and sufficient time to place LW concrete in one uninterrupted operation. 3. If installation is interrupted due to wet weather or other situations beyond human control, inspect installed insulation board to confirm adhesion to the substrate. GG. Curing: Apply curing compound by roller or spray to partly seal surface of the LWIC against rapid moisture loss while curing. 3.3 FIELD QUALITY CONTROL HH. Check density each hour at point of placement, following ASTM C Keep a log for submittal to A/E. Record measured density each 60 minutes or less. 2. Measure cast densities with a scale ranging from 1 to 75 lb in increments of 1/4 lb. Calibrate scale to1/16 lb accuracy. Use a 0.2 ft 3 (1.3 gal) or larger measuring bucket. II. Testing Oven Dry Density and Compressive Strength. Make a set of 4 standard cylinders for each 75yd 3 or fraction thereof. Test cylinders following ASTM C495. JJ. Walkability Inspection and Withdrawal Testing by Contractor. 1. Jointly walk the roof with A/E and Board representative to determine if the LW concrete is sufficiently cured, indentation-free, sloped, smooth and dry for application of roof membrane. 2. Test at least 5 fastener withdrawals, following FBC TAS 105, to empirically establish average uplift resistance. 3. In any areas where fasteners, upon testing, will not hold at least 40 pounds after 5 days of cure, remove LW concrete and recast. 4. The average empirical uplift resistance values x the number of fasteners / ft 3 shall achieve the resistances to various negative wind pressures specified for the Roof Assembly, as stated in the roof wind pressure diagrams on the Drawings.. 5. If resistances are not achieved, a Florida registered professional engineer retained by Contractor shall recalculate the number of needed fasteners following FBC TAS Perform additional testing and calculations as needed to determine how uplift resistance can be achieved by improving quality of LW concrete, type, number, pattern and spacing of fasteners, using galvanized steel fastening plates with expansion bolts into structure, or other remedies. 7. If a deficiency in uplift resistance continues and the LW insulating concrete roof deck and/or its fastening scheme cannot be corrected after further testing and calculations, remove the defective LW concrete and fasteners, then recast and refasten. KK. Drainage Test: If there are any areas that appear to slope less than 1/4in./ ft, flood and observe drainage in those areas to ensure that there is full gravity flow toward didcharge points without ponding. Remove and recast LW concrete as needed to achieve proper drainage 3.4 PROTECTION LL. Do not expose LW concrete to weather more than 7 days. Cover with weighted opaque plastic film if exposure will be longer. MM. Prevent traffic on LW concrete until it is dry and does not indent from footwear traffic. project number RA Lightweight Insulating Concrete

8 NN. Do not use LW insulating concrete as a temporary working surface without installing a sturdy protection course. /// project number RA Lightweight Insulating Concrete