SECTION 03342 LIGHTWEIGHT INSULATING CONCRETE PART 1 GENERAL 1.01 SUMMARY A. Related Sections: 1. 03300 - Cast-In-Place Concrete. 2. 05310 - Steel Deck. 3. 07511 - Multi-Ply Mineral Surfaced Built-Up Roofing 4. 07525 - SBS Modified Bitumen Mineral Surfaced Roofing. 5. 07530 - Fully Adhered Thermoplastic Sheet roofing. 6. 07600 - Flashing and Sheet Metal. 7. 15421 - Drains, Floor Sinks, and Cleanouts. 1.02 REFERENCES AND CODES A. Florida Building Code (FBC) including FBC Test Protocols TAS 117 and TAS 105. B. Miami-Dade County Product Control. C. American Society for Testing and Materials (ASTM): 1. A653/A-96 Specification for Steel Sheet, Zinc-Coated (Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by the Hot-Dip process. 2. C138-92 Test Method for Unit Weight, Yield, and Air Content (Gravimetric) of Concrete. 3. C150-96 Specification for Portland Cement. 4. C177-85(93) Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Guarded-Hot- Plate Apparatus. 5. C332-87(91) Specification for Lightweight Aggregates for Insulating Concrete. 6. C495-91a Test Method for Compressive Strength of Lightweight Insulating Concrete. 7. C513-89(95) Test Method for Obtaining and Testing Specimens of Hardened Lightweight Insulating Concrete for Compressive Strength. 8. C518-91 Test Method for Steady-State Heat Flux Measurements and Thermal Transmission Properties by Means of the Heat Flow Meter Apparatus. Project No. SPECIFICATION GUIDELINES 03342-1
9. C578-95 Specification for Rigid, Cellular Polystyrene Thermal Insulation. 10. C869-91 Specification for Foaming Agents Used in Making Preformed Foam for Cellular Concrete. D. Factory Mutual (FM). E. Steel Deck Institute Design Manual, latest edition. F. Underwriters Laboratories (UL) for Class A fire resistance. 1.03 SUBMITTALS A. Product Data: Submit for each product required and application instructions. B. Current Factory Mutual and Miami-Dade County product approvals. C. Shop Drawings: Provide roof plan showing roof slopes, thickness of insulation, roof penetrations, and specific details required for project installation. D. Submit samples of insulation board. E. Quality control submittals: 1. Laboratory results for Thermal Resistance Values based on ASTM C177 or C518. ****** ***** **** *** ** * ** *** **** ***** ****** NOTE TO SPECIFIER: Insert required FM wind uplift classification, in the following paragraph 2, as determined by ASCE 7-98 using a wind speed of 146 mph, exposure category "C", and with a wind importance factor for educational buildings of 1.15. ****** ***** **** *** ** * ** *** **** ***** ****** 2. Test reports showing compliance with FM 1 - Wind Resistance Classification. 3. Current affidavit from insulating concrete manufacturer approving applicator before installation. 4. UL listing. 1.04 QUALITY ASSURANCE A. Comply with the Florida Building Code (FBC). B. Insulating cellular concrete shall be applied by a manufacturer's certified applicator. Project No. SPECIFICATION GUIDELINES 03342-2
C. Any excess water on the lightweight concrete shall be removed before roof installation by vacuuming, evaporation, or other method complying with membrane manufacturers requirements. D. Applicator shall maintain a job log for submittal to A/E. The job log shall contain cast density recordings taken at a minimum interval of 1 hour. 1. Cast densities shall be measured with a calibrated scale measuring from 1 to 50 pounds in increments of 1/4 pound and be accurately calibrated to 1/16 pound. 2. The measuring bucket shall be 5 quarts or larger. 3. Measurements shall be taken according to ASTM C138. E. A "Walkability Inspection" by the A/E and the Board shall determine the lightweight insulating concrete installation as a satisfactory substrate. 1. If the installation fails the inspection, additional testing shall be required by the A/E to confirm fastener spacing or provide data for the roof system manufacturer to calculate a new fastener pattern. a. Fastener testing shall be required. b. Any areas where fasteners will not hold a minimum of 40 pounds after 5 days of cure shall be removed and recast. F. If continued noncompliance is observed and the roof deck and associated roof system cannot be corrected based on additional testing and attachment calculations, the nonconforming lightweight shall be removed and recast. G. If a denser fastener pattern is required for elevated pressure zones, a Florida registered professional engineer shall recalculate perimeter and corner spacing according to FBC Test Protocols TAS 117. H. Field withdrawal resistance testing of lightweight concrete fasteners shall be conducted according to FBC Test Protocols TAS 105. 1. The average withdrawal resistance values obtained in field testing shall be within 10 percent of the values listed in the Roof Assemblies Limitations. 2. If the values are not achieved, a Florida registered professional engineer can recalculate the fastener density following the procedures outlined in FBC Test Project No. SPECIFICATION GUIDELINES 03342-3
Protocols TAS 117. I. Roofing Contractor shall consult with roofing system manufacturer for compatibility with all surface coatings or treatments. J. Direct-adhered single ply systems shall be installed in strict compliance with manufacturer's specifications and the Miami-Dade County Product Control Notice of Acceptance. K. Installation of this decking component and diaphragm load requirements shall be in strict compliance with application requirements set forth in Chapters 19 and 22 of the Florida Building Code (FBC). L. All coatings or surface preparation materials applied to the lightweight concrete shall be listed as an approved interface material with the roof membrane manufacturer. M. Topping applied over insulation boards and any decking/substrate that allows deflection under normal traffic shall be installed within 4 hours of board installation. 1. If installation is interrupted due to inclement weather or other situations beyond the control of the contractor, the installed insulation board shall be inspected to confirm adhesion to the substrate. 2. Over solid substrates, topping installation shall not be delayed over 24 hours. N. Roof Membrane Application: Contractor shall coordinate commencement of roofing over the lightweight insulating concrete after satisfactorily passing Florida Building Code TAS 105 fastener pullout test. O. Conduct pre-roofing conference before the installation of the roof insulation with A/E and representatives from manufacturer of insulating concrete, roofing membrane materials, and all other related trades in attendance. At the meeting date determined, by mutual agreement, between parties concerned. P. Oven-Dry Density: Determine according to Section 7 of Test for Compressive Strength of Lightweight Insulating Concrete, ASTM C495. Q. Compressive Strength: Determine compressive strength according to requirements of ASTM C495. Project No. SPECIFICATION GUIDELINES 03342-4
1.05 DELIVERY AND STORAGE A. Deliver material in manufacturer's original undamaged packages or acceptable bulk containers. B. Store packaged material to protect them from the elements or physical damage. C. Do not use cement that shows indications of moisture damage, caking, or other signs of deterioration. 1.06 WARRANTY A. Warrant to the Board that for 10 years from the date of the completion of the lightweight insulating concrete that: 1. The roof insulation system shall remain in a reroofable condition should the roof membrane require replacement. 2. The actual resistance to heat flow through the roof insulation system shall be at least 80 percent of design thermal resistance. 3. The roof insulation will remain in place even if the roof membrane sustains wind damage. PART 2 PRODUCTS 2.01 MANUFACTURERS A. Insulating Concrete: 1. Concrecel by Concrecel International. 2. Cellular Hybrid by Elastizell. 3. NVS (Non-Vented Substrate) by Siplast. 4. Zonocel by Siplast. 5. Insulcel by Siplast. 2.02 MATERIALS A. Insulating Concrete Physical Properties: 1. Portland cement and pregenerated foam with water: a. Wet density at point of placement: 42-50 pcf. b. Minimum oven dry density: 32-40 pcf. c. Minimum compressive strength: 300 psi. 2. Portland cement and vermiculite concrete with water(1:3.5): Project No. SPECIFICATION GUIDELINES 03342-5
a. Wet density at point of placement: 60-68 pcf. b. Minimum oven dry density: 35 pcf. c. Minimum compressive strength: 300 psi. B. Insulation Board: One pound density expanded polystyrene board with 25 to 35 bonding and venting slots. Deliver each bundle of 2 foot by 4 foot boards to the job site with clear identification as to the manufacturer and shall carry the FM approval label on each bundle. C. Portland Cement shall comply with ASTM C150, Type I, II, or III. D. Water: Potable, clean, maximum chloride level of 250 ppm, and free from deleterious amount of acid, alkali, and organic material. E. Foaming agent: Liquid concentrate shall be manufactured and be delivered to the job site with clear identification as to manufacturer and type of material according to ASTM C869. F. Admixtures shall not be used unless specifically recommended by the manufacturer. ****** ***** **** *** ** * ** *** **** ***** ****** NOTES TO SPECIFIER: Reinforcing mesh may be required in some fire rated assemblies. ****** ***** **** *** ** * ** *** **** ***** ****** G. Mesh Reinforcement: Keydeck style 2160-2-1619 galvanized mesh or equal. PART 3 EXECUTION 3.01 EXAMINATION A. Surfaces to receive insulating concrete shall be sound, free of loose material, and free from defects affecting application. B. Installation of other work passing through fill or concealed shall be complete and accepted before starting the work. C. The applicator shall be responsible for inspection and approval of the substrate as suitable for roof insulation. D. Installation of curbs, equipment supports, roof drains, Project No. SPECIFICATION GUIDELINES 03342-6
framing for openings, and wood nailers shall be in place before application of material. E. Poured Surface Finish: 1. Surface shall be bonded firmly and free from loose materials. 2. Screeded finish of surface shall be free from extreme roughness capable of interfering with proper bonding of roofing membrane and free from shrinkage and cracks. 3. Surface Dryness: Exposed surface shall look and feel substantially dry, and shall have a uniformly gray cement color. 3.02 INSTALLATION A. Slurry: Cover substrate with a 1/8" slurry coat of the lightweight insulating fill. B. Insulation Board: 1. Place insulation board in the 1/8" slurry coat. 2. Insulation board placement shall be made within 30 minutes of slurry coat placement. 3. Place insulation board in a manner that provides full contact of slurry to board. 4. Lay insulation board in brick paver pattern with joints staggered and side and end joints butted snugly. 5. Under no circumstances shall insulation board be laid dry on substrate. 6. Remove loose boards and immediately re-grout. C. Lightweight Insulating Fill: 1. Within 24 hours of insulation board placement, place a minimum of 2 inches of lightweight insulating fill over the insulation board and screed to an even surface to receive the roofing membrane. 2. Increase thickness as required at 1/4" per foot slope to obtain roof drainage slopes as indicated on Drawings. 3. Roof Crickets: At roof low points between roof drains, between roof drains and parapets and at high side of fan curbs, provide insulation concrete crickets uniformly sloped not less than 1/2" per foot. D. Installed system shall achieve a minimum average R-value of Project No. SPECIFICATION GUIDELINES 03342-7
20. 3.03 QUALITY CONTROL A. Check the cast density according to ASTM C869 hourly at the point of placement. B. Testing: Make set of 4 standard cylinders of each day's mix and text according to ASTM C495. When more than 75 cubic yards of concrete are poured in 1 day, make a set of specimens of each 75 yards. C. Drainage Test: After initial set, provide hose test to assure proper drainage slopes with no ponding. 3.04 PROTECTION A. Do not expose insulating concrete to prolonged exposure to the elements more than 7 days. B. Do not use as a temporary working surface without adequate surface protection, nor allow it to function as a temporary dry in. C. Prevent traffic on roof deck until applicator allows such traffic. END OF SECTION Project No. SPECIFICATION GUIDELINES 03342-8