elastizell of st. louis solving engineered fill, flooring & roofing problems for over 40 years
TRANSCRIPT
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Elastizell of St. Louis
Solving Engineered Fill, Flooring & Roofing problems
for over 40 years.
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Types of Lightweight Concrete We’ll Discuss
Gypsum Concrete Gypsum Based
Density – 120 pcf
Strength Varies from 1000 – 8000 PSI
Cellular Concrete Portland Cement Based
Varies in Density- 20 to 120 pcf
Strength Varies from 1000 – 3000 PSI
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Characteristics of Cellular Concrete
Strong & lightweight
Batched on site
Easy to apply
Has many densities
Designed density does not vary
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Uses for Cellular Concrete
Engineered Fills Flooring Roof Decks
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Differences of Cellular Concrete
Engineered FillsStrength Varies from 40 to 1000 psiDensity Varies from 20 to 70 pcf
Roof DecksMinimum Strength 160 psiDensity Varies from 36 to 50 pcf
Flooring Strength 1000 to 3000 psi Density is 100 - 125 pcf
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Advantages of Cellular Concrete
Cost Savings
Faster Installation
Load Balancing to Increase
Elevations
No Compaction Required
Flowability Characteristics
Low Density - as low as 20 pcf
Maintain Traffic During
Construction
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Engineered Fill
Roadways
Bridges
Voids
Tunnels
Retaining Walls
Soil Stabilization
Plaza Fills
Before After
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St. Louis Arch Project
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Bridge Approach Fills
Poor soils usually exist at
bridges
Compaction is not necessary
Replace longer bridge with
roadway
Reduce maintenance and life
cycle costs
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Roadway Fills
Cellular Concrete is excellent for widening roadways with shoulders that have never been preloaded
Load balancing removes existing heavy soil and replaces it with much lighter Cellular Concrete
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Void Fills
Because Cellular Concrete flows, it completely fills voids.
Basements
Tanks
Sinkholes
Pipeline abandonment
Fills around pipes,
Annular space fills of one pipe within another.
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Swimming Pool Void Fill
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Insulating Roof Deck Systems Slope to drain eliminates ponding Lightweight High R value Low cost Superior to insulation board
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Roof Deck Problems & Solutions
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Advantages Over Other Roof Insulation Systems
A solid base for roofing systems
Reduced dead weight
Slope to drain capability
Fire, seismic & wind uplift ratings
Does not require slotted steel decks
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More Advantages of Cellular Concrete Roof Decks
•No Ridges
•Maintains R value
•Not damaged by water
•No need to remove old membrane
•Several membranes can be placed
• Cost
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LIGHT WEIGHT CONCRETE FLOORS
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What are Lightweight Concrete Floor Toppings?
Gypsum Concrete Gypsum Based Density – 120 pcf Varies in Strength – 1000 – 8000 PSI
Cellular Concrete Portland Cement Based Varies in Density- 100 to 125 pcf Varies in Strength – 1000 – 3000 PSI
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GYPSUM CONCRETE
FLOORS
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What is Gypsum?
Hydrated Calcium Sulfate
CaSO4 2H2O
NaturalChemicalSynthetic
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Gypsum Concrete Flooring
Specially formulated gypsum concrete plaster
Chemically sets (does not “cure”)
Does not shrink
1000-8000 compressive strengths
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Gypsum Concrete Floors
Pumped
Poured
Feather edge
Up to 3”
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CELLULAR CONCRETE
FLOORS
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Cellular Concrete Floors Portland Cement Based
Calcium Silicate Hydrated
Ca SiO3
Natural Chemical
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Cellular Concrete Floors
Portland cement based
Resists abrasive damage
Not damaged by water –
below grade
Steel trowel finish
1000-3000 compressive
strengths
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Lightweight Concrete Floor Toppings
Trade ready next
morning
Excellent substrates
Economical
Lightweight
Fire resistant
Sound rated
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Perform density/slump test
Take test cylinder/cube sample
on job site
Quality Controls & Tests
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New & Rehab Lightweight Concrete Applications Multifamily
Apartments Condos Hotels
Senior Living
Commercial Office Building Hospitals
Residential Custom Homes Radiant Heating
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Solutions for Rehab Projects
Out of Level Substrates
Load Limited Structures
Sound Mat Option
Plaza Decks
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Decorative Surfaces
Gypsum Concrete Stain the surface
Seal the surface
Cellular Concrete Integral Color
Stain the surface
Seal the surface
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The Construction Trend….Lighter Weight Materials
Thinner Floors Gypsum Light Weight Concrete
Light Weight Decking
Light Weight Joists
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Sound Control Issues
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Airborne and Structure Borne Noise
Airborne = STC Structure Borne = IIC (Impact Noise)
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Sound Measurement and People’s Reaction
• STC Sound Transmission Class
• If the STC = 35 clearly hear conversation
• If the STC = 45 conversation is muddled
• If the STC = 55 won’t hear conversation; can still hear loud sounds such as raised voices, bass music or television
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Sound Measurement and People’s Reaction
• IIC Impact Insulation Class
• If the IIC = 40 then 30 % of people will be happy
• If the IIC = 50 then 50 % of people will be happy
• If the IIC = 60 then 70 % of people will be happy
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• Intensity, or loudness
• Generally expressed in dB’s
• dB’s = a range of sound from very quiet to very loud
• dB, dBA, dBC, others
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Range of Sounds
Whisper – 20 dB
Kitten Meow – 40 dB
Soft Music – 60 dB
Restaurant Conversation– 80 dB
Traffic Noise – 100 dB
Jet Aircraft – 120 dB
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Hard Finished Flooring Trends
Tile and Vinyl Tile
Hardwood and Laminate Floors
Concrete
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Is Sound Control an Amenity ? Yes !
Poll of Residents - # 1 Preference Peace and Quiet
Biggest Problem – Vertical Sound Transmission Floor to Floor
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Building Codes
• ICBO, BOCA, and SBCCI = IBC Code
• St. Louis City and County are moving to IBC Code
• Code Requires minimum performance IIC and STC for Floors of 50
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Other Sound Improvements
ImprovementIIC STC
Resilient Channels RSIC vs. RC-1 5 to 7 1 to 2
Insulation Mineral Fiber vs. FG 1 to 3 1 to 2 Thickness 3” to 6” 1 to 2 0 to 1
Ceiling Drywall 1 to 2 Layers 4 to 5 1 to 2
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Typical IIC Values
Rehab Concrete 6 to 8 inches No Sound Mat FIIC 33 to 37 With Sound Mat – FIIC 58 to 68
Rehab Heavy Timber Floors No Sound Mat FIIC 30 to 35 With Sound Mat – FIIC 45 to 50
Mass/Weight Does not Improve IIC
Mass Improves STC
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Sound Control Summary
Impact noise is harder to control
Sound mat controls impact noise
Mass does NOT control Impact noise
Meeting code doesn’t mean meeting client expectations
Sound mats are The Best Choice
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Lightweight Concrete Summary
Floor Fills Fire Rating Sound Attenuation Rehab
Roof Decks Permanent Slope to Drain
Engineered Fills Geotechnical Solutions Low Cost Alternative Design Assistance