ICC-ES Legacy Report ER-5885 Reissued March 2004 www.icc-es.org (800) 423-6587 (562) 699-0543 A Subsidiary of the International Code Council Legacy report on the 1997 Uniform Building Code, the 2000 International Building Code and the 2000 International Residential Code DIVISION: 03 CONCRETE Section: 03540 Cementitious Underlayment LEVELROCK BRAND 2500, 3500, 4500 AND RH FLOOR UNDERLAYMENT PRODUCTS USG CORPORATION 125 SOUTH FRANKLIN STREET CHICAGO, ILLINOIS 60606-4678 1.0 SUBJECT LEVELROCK Brand 2500, 3500, 4500 and RH Floor Underlayment Products. 2.0 DESCRIPTION 2.1 General: LEVELROCK Brand 2500, 3500, 4500, and RH Floor Underlayments are gypsum cement underlayments used for sound insulation and fire-resistance of floor/ceiling assemblies in accordance with Appendix Chapter 12 and Chapter 7, respectively, of the 1997 Uniform Building Code (UBC); Section 1206 and Chapter 7, respectively, of the 2000 International Building Code (IBC); and Appendix K and Section R321, respectively, of the 2000 International Residential Code (IRC), for use over precast concrete plank, plywood subfloors and poured concrete in new construction, and over concrete and wood floors in existing structures. The underlayments are also used as leveling agents. Floor coverings, such as ceramic tile, vinyl tile, carpeting, and wood, are applied over the underlayment. 2.2 Materials: 2.2.1 LEVELROCK Brand Underlayments: The gypsum cement floor underlayment has a dry density (aggregated) of 115 to 125 pounds per cubic foot (1842 to 2002 kg/m 3 ). LEVELROCK Brand 2500 Floor Underlayment is applied at a minimum 3 / 4 -inch (19.1 mm) thickness over plywood substrates in wood-framed construction. LEVELROCK Brand 2500 Floor Underlayment is formulated to achieve a compressive strength from 2,000 psi to 3,000 psi (13.8 to 20.7 MPa). Mix proportions are 80 pounds (36.3 kg) of LEVELROCK Brand 2500 (one bag), 1.9 cubic feet (0.054 m 3 ) of sand, and 4.5 to 5.0 gallons (17.0 to 18.9 L) of potable water. Shelf life of the bagged material is six months when the material is stored in dry conditions. LEVELROCK Brand 3500 Floor Underlayment is applied at thicknesses up to 1 inch (25.4 mm) over wood and concrete subfloors. LEVELROCK Brand 3500 is formulated to achieve a compressive strength from 3,000 psi to 4,000 psi (20.7 to 27.6 MPa). Mix proportions are 80 pounds (36.3 kg) of LEVELROCK Brand 3500 (one bag), 1.6 cubic feet (0.045 m 3 ) of sand, and 4.0 to 4.5 gallons (15.1 to 17.0 L) of potable water. Shelf life of the bagged material is six months when the material is stored in dry conditions. LEVELROCK Brand 4500 Floor Underlayment is applied over concrete slabs, prefabricated-stressed concrete or concrete planks to a maximum thickness of 3 inches (76 mm). The underlayment is formulated to achieve a compressive strength from 4,000 psi to 5,000 psi (27.6 to 34.5 MPa). Mix proportions are 80 pounds (36.3 kg) of LEVELROCK Brand 4500 (one bag), 1.6 cubic feet (0.045 m 3 ) of sand, and 4.0 to 4.5 gallons (15.1 to 17.0 L) of potable water. Shelf life of the bagged material is four months when stored in dry conditions. LEVELROCK Brand RH (Radiant Heat) Floor Underlayment is specifically formulated for electric and hot water radiant heat floor installations. LEVELROCK Brand RH Floor Underlayment is formulated to achieve a compressive strength from 2,000 to 3,000 psi (13.8 to 20.7 MPa). The underlayment is applied at thicknesses of 3 / 4 inch (19.1 mm), minimum, to 3 inches (76 mm), maximum. Mix proportions are 80 pounds (36.3 kg) of LEVELROCK Brand RH (one bag), 1.6 cubic feet (0.045 m 3 ) of sand, and 4.5 to 5.0 gallons (17.0 to 18.9 L) of potable water. Shelf life of the bagged material is six months when the material is stored in dry conditions. 2.2.2 Sand: Sand must be clean and contain no more than 1.5 percent water-soluble impurities and no more than 1.0 percent of clay and other contaminants. Sampling, testing and grading must be in accordance with ASTM C 144. 2.2.3 Substrates: Plywood and OSB substrates must be a minimum of 23 / 32 inch thick (18.3 mm), with tongue- and groove-edges, must comply with UBC Standard 23-2 or 23-3 (UBC) or PS-1 or PS-2 (IBC and IRC), respectively, as applicable, and must comply with UBC Tables 23-II-E-1 and 23-II-E-2 or IBC Tables 2304.7(3) and 2304.7(4). Concrete substrates must comply with Chapter 19 of the UBC or IBC. Maximum permitted deflection of substrates under total load is L/360, where L is the distance between support joists or beams. 2.2.4 Primer: LEVELROCK Brand Ready Mix PRIMER is applied to wood and concrete substrates before application of the underlayment. The primer is applied, ICC-ES Evaluation Reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, LLC, express or implied, as to any finding or other matter in this report, or as to any product covered by the report. Copyright 2014 Page 1 of 4 1000
ER-5885 Most Widely Accepted and Trusted Page 2 of 4 without dilution, by spraying, rolling or with a broom at a maximum coverage of 400 square feet per gallon (9.8 m 2 /L). 2.3 Application: The materials are mixed at the jobsite and are pumped into place by applicators approved by USG Corporation. Substrates must be clean, dry, and free of mud, grease, oil or other contaminants that affect the bond. All grouting must be done at least 30 days before application of the underlayment. Wood substrates must be primed before underlayment application. Concrete substrates must cure a minimum of 28 days before application of primer or underlayment. Conduits and pipes embedded in the LEVELROCK must have a minimum cover of 3 / 4 inch (19.1 mm) in accordance with Section 1906.3 of the UBC and Section 1906 of the IBC. 2.4 Sound Control: 2.4.1 Assembly 1: The assembly consists of 1-inch-thick (25.4 mm) LEVELROCK Brand 2500, 3500, 4500 or RH Underlayment poured over Enkasonic 9110 acoustical mat (ER-4778), with duct tape applied along the seams of the mat. The mat is loose laid over 23 / 32 -inch-thick (18.3 mm), APA-rated Sturdifloor plywood attached to 18-inch-deep, open web, parallel chord 2-by-4 lumber trusses using 2-inch-long (51 mm) galvanized steel screws spaced at 12 inches (305 mm) on center. The trusses are spaced a maximum of 24 inches (610 mm) on center. The joist cavities contain a layer of 3 1 / 2 -inch-thick (89 mm), unfaced R-11 fiberglass insulation attached to the underside of the floor deck with steel clips. Resilient channels, spaced at 16 inches (406 mm) on center, are attached to the bottom chord of the trusses using 1.25-inch-long (31.7 mm) Type W screws, one screw per truss and channel intersection. Minimum 5 / 8 -inch-thick (15.9 mm) USG SHEETROCK Brand Firecode C gypsum panels are attached perpendicular to the resilient channels using 1-inch-long (25.4 mm), Type S bugle head drywall screws spaced at 12 inches (305 mm) on center. End joints of gypsum panels must be supported by resilient channels. Joints in the gypsum panels must be taped and treated with joint Screw heads must be covered with joint The assembly as described has a sound transmission class (STC) rating of 50 or greater. When 0.07-inch-thick (2 mm) Armstrong Caspian sheet vinyl; 24-ounce-persquare-yard (813.7 g/m 2 ) carpeting and 7 / 16 -inch-thick (11.1 mm), 6 psf (29.3 kg/m 2 ) foam pad; or 5 / 16 -inch-thick (7.9 mm) ceramic tile, is applied over the underlayment, the impact insulation class (IIC) rating of the assembly is 50 or greater. See Figure 1. 2.4.2 Assembly 2: The assembly consists of 1-inch-thick (25.4 mm) LEVELROCK Brand 2500, 3500, 4500 or RH Underlayment poured over 0.4-inch-thick (10.2 mm) Enkasonic 9110 acoustical mat with duct tape applied along the seams of the mat. The mat is loose laid over 23 / 32 -inch-thick (18.3 mm) APA-rated Sturdifloor plywood attached to 9 1 / 2 -inch-deep (241 mm), wood I-joists, using 2-inch-long (51 mm) galvanized steel screws spaced at 12 inches (305 mm) on center. The I-joists are spaced a maximum of 24 inches (610 mm) on center. The joist cavities contain a layer of 3 1 / 2 -inch-thick (89 mm), unfaced R-11 fiberglass insulation attached to the underside of the floor deck with steel clips. Resilient channels, spaced at 16 inches (406 mm) on center, are attached to the bottom chord of the I-joists using 1.25-inch-long (31.7 mm), Type W screws, one screw per truss and channel intersection. Minimum 5 / 8 -inch-thick (15.9 mm) USG SHEETROCK Brand Fire-code C gypsum panels are attached perpendicular to the resilient channels using 1-inch-long (25.4 mm), Type S bugle head drywall screws spaced at 12 inches (305 mm) on center. Joints in the gypsum board must be taped and treated with joint Screw heads must be covered with joint The assembly as described has a sound transmission class (STC) rating of 50 or greater. When 0.07-inch-thick (2 mm) Armstrong Caspian sheet vinyl; 24 ounce per square yard (813.7 g/m 2 ) carpeting and 7 / 16 -inch-thick (11.1 mm), 6 psf (29.3 kg/m 2 ) foam pad; or 8 mm thick PERGO laminate flooring over PERGO SOUNDBLOC foam, is applied over the underlayment, the impact insulation class (IIC) rating of the assembly is 50 or greater. See Figure 2. 2.4.3 Assembly 3: The assembly consists of 3 / 4 -inchthick (19 mm) LEVELROCK Brand 2500, 3500, 4500, or RH Underlayment poured over a 3 / 8 -inch-thick (9.5 mm) USG Levelrock Brand Sound Reduction Board. The board is loosely laid over 23 / 32 -inch-thick (18.3 mm), APA-rated, tongue-and-groove Sturdifloor OSB attached to 9½-inchdeep (241 mm) wood I-joists, using 2-inch-long (51 mm) galvanized steel screws spaced at 12 inches (305 mm) on center. The I-joists are spaced a maximum of 24 inches (610 mm) on center. The joist cavities contain a layer of 3 1 / 2 -inch-thick (89 mm), unfaced, R-11, fiberglass insulation attached to the underside of the floor deck with steel clips. Resilient channels, spaced at 16 inches (406 mm) on center, are attached to the bottom chord of the I-joists using 1 1 / 4 -inch-long (31.7 mm), Type W screws, one screw per joist and channel intersection. Two layers of 1 / 2 -inch-thick (12.7 mm) USG SHEETROCK Brand Firecode C gypsum panels are attached perpendicular to resilient channels using 1-inch-long (25.4 mm), Type S bugle head drywall screws for the base layer, and 1 5 / 8 -inch-long (41.2 mm), Type S bugle head drywall screws for the face layer. Screw spacing for both layers is 12 inches (305 mm) on center in the field of the panels and 8 inches on center (203 mm) at the butt joints. Joints on the face layer must be taped and treated with joint compound; screw heads must be covered with joint The assembly as described above with floor covering of 5 / 16 -inch-thick (8 mm) Pergo Original wood laminate flooring over a 0.05-inch-thick (1.3 mm) Pergo SoundBlock foam; 0.0625-inch-thick (1.6 mm) sheet vinyl flooring; or ceramic tiles, nominally 3 / 16 inch (4.75 mm) thick, adhered to a 0.03-inch (0.76 mm) crack isolation sheet, provides a sound transmission class (STC) rating of 50 or greater and an impact insulation class (IIC) rating of 50 or greater. See Figure 3. 2.4.4 Assembly 4: The assembly consists of 1-inch-thick (25.4 mm) LEVELROCK Brand 2500, 3500, 4500, or RH Underlayment poured over a 1 / 4 -inch-thick (6.5 mm) USG LEVELROCK Brand SRM-25 Sound Reduction Mat. The mat is laid directly over but not attached to 23 / 32 -inch-thick, APA-rated, tongue-and-groove Sturdifloor OSB attached to 9 1 / 2 -inch-deep (241 mm) I-joists, using 1 1 / 2 -inch-long (38 mm) galvanized steel screws spaced at 12 inches (305 mm) on center. The I-joists are spaced a maximum of 24 inches (610 mm) on center. The joist cavities contain a layer of 3 1 / 2 -inch-thick (89 mm), unfaced, R-11 fiberglass insulation attached to the underside of the floor deck with steel clips. Resilient channels, spaced at 16 inches (406 mm) on center, are attached to the bottom chord of the I-joists using 1 1 / 4 -inch-long (31.7 mm), Type W screws, one screw per joist and channel intersection. Two layers of 1 / 2 -inch-thick (12.7 mm) USG SHEETROCK BRAND FIRECODE C gypsum panels are attached perpendicular to resilient channels using 1-inch-long (25.4 mm), Type S bugle head drywall screws for the base layer, and
ER-5885 Most Widely Accepted and Trusted Page 3 of 4 1 5 / 8 -inch-long (41.2 mm), Type S bugle head drywall screws for the face layer. Screw spacing for both layers is 12 inches (305 mm) on center in the field of the panels and 8 inches on center (203 mm) at the butt joints. Joints on the face layer must be taped and treated with joint compound; screw heads must be covered with joint The assembly as described above with floor covering of 5 / 16 -inch-thick (8 mm) Pergo Original wood laminate flooring over a 0.05-inch-thick (1.3 mm) Pergo SoundBlock foam; 0.0625-inch-thick (1.6 mm) sheet vinyl flooring; or ceramic tiles, nominally 3 / 16 inch (4.75 mm) thick, provides a sound transmission class (STC) rating of 50 or greater and an impact insulation class (IIC) rating of 50 or greater. See Figure 4. 2.5 One-hour Fire-resistive Construction: The assembly consists of 3 / 4 -inch-thick (19.1 mm) LEVELROCK Brand 2500, 3500, 4500 or RH Underlayment poured over minimum 1 / 2 -inch-thick (12.7 mm) plywood attached to nominal 2-by-10 wood joists spaced a maximum of 16 inches (610 mm) on center using 8d sinker nails spaced at 10 inches (254 mm) on center. The plywood is oriented perpendicular to the joists and must be staggered a minimum of 32 inches (813 mm). Three-inch-wide-by- 1 / 2 -inch-deep (76 mm by 12.7 mm), No. 22 gage furring channels are attached perpendicular to the joists, spaced a maximum of 24 inches (610 mm) on center, using 1 1 / 4 -inch-long (31.7 mm) 0.150-inchdiameter-shank (3.8 mm), self-drilling, self-tapping screws, one screw per joist/channel intersection. Minimum 1 / 2 -inchthick (12.7 mm) USG SHEETROCK Brand Firecode C gypsum boards are attached perpendicular to the resilient channels using 1-inch-long (25.4 mm) Type S bugle head drywall screws spaced at 12 inches (305 mm) on center. End joints in the gypsum board must be staggered a minimum of 48 inches (1219 mm) between adjacent rows. Joints in the gypsum board must be taped and treated with joint Screw heads must be covered with joint 2.6 Identification: LEVELROCK Brand floor underlayments are identified by the USG Corporation name and address, the product name, the date code and the evaluation report number (ER-5885). 3.0 EVIDENCE SUBMITTED Reports of tests in accordance with UBC Standard 7-1; reports of density and compressive strength tests; soundinsulation tests in accordance with ASTM Standards E 90-97, E 413-73 (1980) and E 492-90 (1996); product information; and a quality control manual. 4.0 FINDINGS That the LEVELROCK Brand 2500, 3500, 4500, and RH Floor Underlayments described in this report comply with the 1997 Uniform Building Code, the 2000 International Building Code and the 2000 International Residential Code, provided the installation is in accordance with this report and the manufacturer s installation instructions, and the installation is done by applicators approved by USG Corporation. This report is subject to re-examination in one year. FIGURE 1 SOUND CONTROL ASSEMBLY 1 FIGURE 2 SOUND CONTROL ASSEMBLY 2
ER-5885 Most Widely Accepted and Trusted Page 4 of 4 FIGURE 3 SOUND CONTROL ASSEMBLY 3 FIGURE 4 SOUND CONTROL ASSEMBLY 4
ICC-ES Legacy Report ER-5885 Supplement Issued June 2001 www.icc-es.org (800) 423-6587 (562) 699-0543 A Subsidiary of the International Code Council Filing Category: FIRE-RESISTIVE CONSTRUCTION Other Fire-resistive Construction LEVELROCK BRAND 2500, 3500, 4500 AND RH FLOOR UNDERLAYMENT PRODUCTS USG CORPORATION 125 SOUTH FRANKLIN STREET CHICAGO, ILLINOIS 60606-4678 1.0 SUBJECT LEVELROCK Brand 2500, 3500, 4500 and RH Floor Underlayment Products. (Issued October 1, 2001.) Reduce minimum floor underlayment thickness in Section 2.5 of the report from 1 inch (25.1 mm) to 3 / 4 inch (19.1 mm). 2.0 DESCRIPTION 2.1 General: No change. 2.2 Materials: No change. 2.3 Application: No change. 2.4 Sound Control: No change. 2.5 One-hour Fire-resistive Construction: Revise the first sentence as follows: The assembly consists of 3 / 4 -inch-thick (19.1 mm) LEVELROCK Brand 2500, 3500, 4500 or RH Underlayment poured over minimum 1 / 2 -inch-thick (12.7 mm) plywood attached to nominal 2-by-10 wood joists spaced a maximum of 16 inches (610 mm) on center using 8d sinker nails spaced at 10 inches (254 mm) on center. 2.6 Identification: No change. 3.0 EVIDENCE SUBMITTED No change. 4.0 FINDINGS That the changes noted herein comply with the 1997 Uniform Building Code, provided the installation is in accordance with this report and the manufacturer s installation instructions, and the installation is done by applicators approved by USG Corporation. Unless specifically noted in this evaluation report supplement, the master report remains valid and unchanged. This report expires concurrently with the master report dated June 2001. ICC-ES Evaluation Reports are not to be construed as representing aesthetics or any other attributes not specifically addressed, nor are they to be construed as an endorsement of the subject of the report or a recommendation for its use. There is no warranty by ICC Evaluation Service, LLC, express or implied, as to any finding or other matter in this report, or as to any product covered by the report. Copyright 2014 Page 1 of 1 1000