PROJECT NAME: PROJECT NO: CELCORE PRODUCT DATA SHEET 1 Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874 ® CELCORE ® FOAM CONCENTRATE AND CELCORE ® CELLULAR CONCRETE PRODUCT DATA SHEET 1. PRODUCT NAME Celcore Foam Concentrate for Concrete & Celcore Cellular Concrete 2. MANUFACTURER CELCORE INCORPORATED 775 US Hwy 70 West Black Mountain, N.C. 28711 (704) 669-4875 (704) 669-4874 Fax 3. PRODUCT DESCRIPTION Basic Use: Celcore Foam Concentrate is mixed with water and generated into a preformed foam for addition to cement/water slurry mixtures to create a closed cell cellular concrete of a specific density. Typical air dry densities are in the range of 28 - 39 pcf. Oven dry densities are in the range of 24 - 36 pcf. Typical uses for Celcore Cellular Concrete are poured-in-place insulating applications and geotechnical fills. Celcore Cellular Insulating Concrete is a key component of a Celcore Cellular Insulating Roof Deck System. Celcore Cellular Insulating Concrete may be used in conjunction with expanded polystyrene board to produce a thermally efficient, fire rated, Underwriter's Laboratories Approved, Factory Mutual Approved, South Florida Approved insulation assembly. Celcore Cellular Concrete can be poured over some existing roof membranes in reroofing applications, galvanized steel deck form, precast concrete, or poured-in-place structural concrete. Celcore monolithic insulating concrete roof deck fills placed over metal deck form can be designed into structures as shear diaphragms. These composite systems provide good resistance to shear forces which may result from wind or seismic activity. Shear diaphragms provide bracing to the structures they cover acting to transfer and distribute an acting load force through-out the structure. Composition and Materials: Celcore Foam Concentrate contains no synthetic surfactants. It is comprised of natural saponified rosins and is protein stabilized. Celcore Foam Concentrate is non-corrosive, non-hazardous and readily biodegradable. It is packaged in (5) gallon [18.93 L] pails and displays the UL and FMRC mark on the product label.
Transcript
PROJECT NAME: PROJECT NO:
CELCORE PRODUCT DATA SHEET
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
CELCORE® FOAM CONCENTRATEAND
CELCORE® CELLULAR CONCRETEPRODUCT DATA SHEET
1. PRODUCT NAME
Celcore Foam Concentrate for Concrete & Celcore Cellular Concrete
Basic Use: Celcore Foam Concentrate is mixed with water and generated into a preformed foam foraddition to cement/water slurry mixtures to create a closed cell cellular concrete of a specificdensity. Typical air dry densities are in the range of 28 - 39 pcf. Oven dry densities are in the rangeof 24 - 36 pcf. Typical uses for Celcore Cellular Concrete are poured-in-place insulatingapplications and geotechnical fills.
Celcore Cellular Insulating Concrete is a key component of a Celcore Cellular Insulating Roof DeckSystem. Celcore Cellular Insulating Concrete may be used in conjunction with expandedpolystyrene board to produce a thermally efficient, fire rated, Underwriter's Laboratories Approved,Factory Mutual Approved, South Florida Approved insulation assembly.
Celcore Cellular Concrete can be poured over some existing roof membranes in reroofingapplications, galvanized steel deck form, precast concrete, or poured-in-place structural concrete.Celcore monolithic insulating concrete roof deck fills placed over metal deck form can be designedinto structures as shear diaphragms. These composite systems provide good resistance to shearforces which may result from wind or seismic activity. Shear diaphragms provide bracing to thestructures they cover acting to transfer and distribute an acting load force through-out the structure.
Composition and Materials: Celcore Foam Concentrate contains no synthetic surfactants. It iscomprised of natural saponified rosins and is protein stabilized. Celcore Foam Concentrate isnon-corrosive, non-hazardous and readily biodegradable. It is packaged in (5) gallon [18.93 L]pails and displays the UL and FMRC mark on the product label.
PROJECT NAME: PROJECT NO:
CELCORE PRODUCT DATA SHEET
2Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Applicable Standards: The following ASTM procedures are used to determine variousproperties of Celcore Foam and Celcore Cellular Concrete.
ASTM C-796 “Testing Foaming Agents for Use in Producing Cellular Concrete UsingPreformed Foam”
ASTM C-513 “Test Method for Obtaining and Testing Specimens of Hardened LightweightInsulating Concrete for Compressive Strength”
ASTM C-495 “Test for Compressive Strength of Lightweight Insulating Concrete” modifiedonly in the method of molding the test specimen, size of the mold and initialcuring. ( A copy of the suggested modifications is available upon request.)
ASTM C-518 “Test Method for Steady - State Heat Flux Measurement and ThermalTransmission Properties by Means of the Heat Flow Meter Apparatus”
References:
ACI 523.lR "Guide for Cast-in-Place Cellular Concrete"
4. TECHNICAL DATA for CELCORE CELLULAR INSULATING CONCRETE
Physical Properties:
Wet (cast) Density 36 to 49 pcf [578-787 kg/m3]
Air Dry Density 28 to 39 pcf [417- 626 kg/m3]
Compressive Strength 175 psi min. avg. [1.19 MPa]
Drying Shrinkage 0.20 - 0.40 %
Coefficient of Thermal Expansion 5.0 to 7.0 x 10-6 per ºF
Thermal Resistance R=2.22 per in. thick (avg. 18ºF to 190ºF)
Preformed Foam Density 3.5 to 4.5 pcf [ 57-72 g/L]
Theoretical compressive strength = 200 psi (1.36 MPa)w/c ratio = 0.36 using type I portland cement
Estimated oven dry density = 24-26 lbs/ft³ (401 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
PROJECT NAME: PROJECT NO:
CELCORE PRODUCT DATA SHEET
3Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
Theoretical compressive strength = 225 psi ( 1.72 MPa)w/c ratio = 0.36 using type I portland cement
Estimated oven dry density = 26-28 lbs/ft³ (434 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
Theoretical compressive strength = 275 psi ( 1.87 MPa)w/c ratio = 0.36 using type I portland cement
Estimated oven dry density = 28-30 lbs/ft³ (466 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
Theoretical compressive strength = 300 psi ( 2.04 MPa)w/c ratio = .36 using type I portland cement
Estimated oven dry density = 30-32 lbs/ft³ (498 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
Theoretical compressive strength = 350 (+) psi ( 2.38 MPa)w/c ratio = .36 using type I portland cement
Estimated oven dry density = 32-35 lbs/ft³ (538 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
PROJECT NAME: PROJECT NO:
CELCORE PRODUCT DATA SHEET
4Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
Theoretical compressive strength = 450 (+) psi ( 3.06 MPa)w/c ratio = .36 using type I portland cement
Estimated oven dry density = 34-37 lbs/ft³ (570 kg/m³)Note: As with all concrete mix designs, actual test should be conducted using the available component materials to verify all predicted theoreticalphysical properties.
“U” Factor and loading tables over metal deck:26 Gage metal deck 15/16”
4 8.93 .040 .040 9.74 .039 .039 10.03 .039 .039All of the above values on this page include proper allowances for WINTER and SUMMER conditions and the BUR.
“U” Factor is based on 36 lbs/ft³ wet (cast) density Celcore Cellular Insulating Concrete.
PROJECT NAME: PROJECT NO:
CELCORE PRODUCT DATA SHEET
5Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
“U” Factor and loading tables over structural concrete:Structural Concrete SubstrateThickness 5 ½” Density 142 pcf
4 7.33 .040 .040All of the above values on this page include proper allowances for WINTER and SUMMER conditions and the BUR.
“U” Factor is based on 36 lbs/ft³ wet (cast) density Celcore Cellular Insulating Concrete
5. AVAILABILITY
Celcore Foam Concentrate is supplied to applicators licensed by Celcore Incorporated. CelcoreCellular Concrete is jobsite produced by these licensed applicators as a service to theconstruction industry. Unauthorized use of the Celcore product is strictly prohibited. CelcoreFoam Concentrate may not be resold or distributed outside of the Celcore Approved ApplicatorGroup or without first receiving written authorization from Celcore Incorporated.
Footnote: This revised Celcore Product Data Sheet (12/97) supersedes all previous subject documents. This documentmay be reproduced locally by Approved Celcore Applicators. This information is intended for use byCelcore Approved Applicators along with Specification and Design Professionals considering use of theCelcore Product.
Celcore® Material Safety Data Sheet
FOAM CONCENTRATE MSDS1
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Foam Concentrate for Concrete
Section IManufacturer Emergency Telephone Number
Celcore Inc.Address Telephone Number for Information
775 US Hwy 70 West (704) 669-4875Date Prepared
Black Mountain, NC 28711 August 27, 1997
Section IIHazardous Ingredients/Identity Information
Chemical Name OSHA PEL ACGIH TLV Other LimitsHydrolyzed protein N/A
Section IIIPhysical/Chemical Characteristics
Boiling Point N/AVapor Pressure (mm Hg) N/AVapor Density N/ASpecific Gravity 1.08Melting Point N/AEvaporation Rate N/ASolubility in Water GoodAppearance and Odor: Light Brown, scent of pine
Section IVFire and Explosion Hazard Data
Flash Point N/AFlammable Limits N/A
Extinguishing Media: N/ASpecial Fire Fighting Procedures: N/AUnusual Fire and Explosion Hazards: N/A
Section VReactivity Data
UnstableStability
Stable XConditions to avoid: Do not mix with petroleum oils.
May OccurHazardousPolymerization Will Not Occur X
Conditions to avoid: None
Section VIHealth Hazard Data
No known adverse effects from inhalation oringestion. Continuous handling without gloves maycause dryness of skin. This material is not a knowncarcinogen and is not regulated by OSHA. Noknown medical conditions aggravated by exposure.
May cause eye irritation. If splashed in eyes, irrigatewith water immediately. See physician.
Section VIIPrecautions for Safe Handling and Use
In Case of Spill: Dike spill with inert material such assand. Recover spilled material and place incommon container. It may be disposed of ascommon waste.
Waste Disposal: Disposal should be in accordancewith local, state and federal regulation. Non-Hazardous
Handling/Storage Precautions: Store product out ofdirect sunlight.
Other Precautions: None
Section VIIIControl Measures
Respiratory Measures: N/AVentilation: N/AProtective Gloves: Recommended with prolonged
handling.Eye Protection: RecommendedOther Protective Clothing or Equipment: NoneWork/Hygenic Practices: Normal hygenic practices
Celcore® Material Safety Data Sheet
PVA MSDS1
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
PVA Curing Compound
Section IManufacturer Emergency Telephone Number
Celcore Inc. (800) 441-3637Address Telephone Number for Information
775 US Hwy 70 West (704) 669-4875Date Prepared
Black Mountain, NC 28711 August 27, 1997
Section IIHazardous Ingredients/Identity Information
Chemical Name OSHA PEL ACGIH TLV Other LimitsPolyvinyl Alcohol N/A
Section IIIPhysical/Chemical Characteristics
Boiling Point 212 °FVapor Pressure (mm Hg) N/AVapor Density N/ASpecific Gravity 1.06Melting Point N/AEvaporation Rate N/ASolubility in Water Good above 190 ºFAppearance and Odor: Cloudy Liquid, generally
odorless
Section IVFire and Explosion Hazard Data
Flash Point N/AFlammable Limits N/A
Extinguishing Media: N/ASpecial Fire Fighting Procedures: N/AUnusual Fire and Explosion Hazards: N/A
Section VReactivity Data
UnstableStability
Stable XConditions to avoid: Freezing
May OccurHazardousPolymerization Will Not Occur X
Conditions to avoid: None
Section VIHealth Hazard Data
No known adverse effects from inhalation or contactwith skin. Do not ingest, product has mild toxicity.This material is not a known carcinogen and is notregulated by OSHA. No known medical conditionsaggravated by exposure.
May cause eye irritation. If splashed in eyes, irrigatewith water immediately. See physician. Wash fromskin with soap and water.
Section VIIPrecautions for Safe Handling and Use
In Case of Spill: Dike spill with inert material such assand. Recover spilled material and place incommon container.
Waste Disposal: Disposal should be in accordancewith local, state and federal regulation. Non-Hazardous
Handling/Storage Precautions: Keep from freezing.Other Precautions: None
Section VIIIControl Measures
Respiratory Measures: N/AVentilation: N/AProtective Gloves: YesEye Protection: YesOther Protective Clothing or Equipment: NoneWork/Hygenic Practices: Normal hygenic practices
Celcore® Material Safety Data Sheet
THIN PATCH MSDS1
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Thin Patch Admixture
Section IManufacturer Emergency Telephone Number
Celcore Inc. (800) 523-9374Address Telephone Number for Information
775 US Hwy 70 West (704) 669-4875Date Prepared
Black Mountain, NC 28711 August 27, 1997
Section IIHazardous Ingredients/Identity Information
Chemical Name OSHA PEL ACGIH TLV Other LimitsVinyl Ester RP-226 N/A
Section IIIPhysical/Chemical Characteristics
Boiling Point N/AVapor Pressure (mm Hg) < 1Vapor Density N/ASpecific Gravity 1.1Melting Point No dataEvaporation Rate N/ASolubility in Water InsolubleAppearance and Odor: White, free flowing powder,
no odor
Section IVFire and Explosion Hazard Data
Flash Point N/AFlammable Limits N/A
Extinguishing Media: Extinguish fires with spray ormulti purpose dry chemical.
Special Fire Fighting Procedures: Will burn andsupport combustion. Self-contained breathingapparatus should be used when fighting fires.
Unusual Fire and Explosion Hazards: Dust in highconcentration can form explosive mixture withair.
Section VReactivity Data
UnstableStability
Stable XConditions to avoid: Temperatures above 150 °C
May OccurHazardousPolymerization Will Not Occur X
Conditions to avoid: NoneSection VI
Health Hazard DataNo known adverse effects from inhalation, exposureto skin, or ingestion. This material is not a knowncarcinogen and is not regulated by OSHA. Noknown medical conditions aggravated by exposure.
May cause eye irritation. If dust enters eyes, irrigatewith water.
Section VIIPrecautions for Safe Handling and Use
In Case of Spill: Product should be shoveled intofiber drums for eventual use or disposal.
Waste Disposal: Dispose of in a landfill inaccordance with local, state, and Federalregulation.
Handling/Storage Precautions: Store product in acool dry place to avoid caking.
Other Precautions: None
Section VIIIControl Measures
Respiratory Measures: Treat as a “nuisance dust”.Ventilation: Local exhaust should be provided to
control airborne dust levels.Protective Gloves: RecommendedEye Protection: RecommendedOther Protective Clothing or Equipment: NoneWork/Hygenic Practices: Normal hygenic practices
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035221
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
SECTION 03522
CELLULAR INSULATING CONCRETEROOF DECK
PART 1: GENERAL
1.01 SECTION INCLUDES:
Note to Specifier: List below generic types of products, work or requirements specified in thisSection. Do not include procedure, process, or preparatory work. Do not "scope" the Section or implya trade responsibility.
A. Cellular lightweight insulating concrete roof deck.
Note to Specifier: Include insulation board, metal decking and reinforcing mesh if specified in Part 2:Products.
B. [Insulation Board.]
C. [Metal Decking.]
D. [Reinforcing Mesh.]
1.02 RELATED SECTIONS:
Note to Specifier: List Sections with specific requirements pertaining to this work. References mayinclude a system interface with other systems.
A. Section 0300 - Cast-in-place Concrete: Structural roof deck.
Note to Specifier: Delete the following Section when metal decking is specified as part of thisSection.
B. Section 05300 - Metal Decking: Steel roof deck and accessories.
C. Section 06100 - Rough Carpentry: Wood blocking, curbs.
Note to Specifier: Delete the following Section when insulation is specified as part of this Section.
D. Section 07220 - Roof and deck insulation.
Note to Specifier: Coordinate the Section Number for the following with the roofing specificationused on each project.
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035222
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
E. Section 07500 - Membrane Roofing.
F. Section 07600 - Flashing and Sheet Metal.
1.03 REFERENCES:
Note to Specifier: Include reference standards that are to be indicated within the text of this Section.Edit the following as required for the particular project.
A. AMERICAN SOCIETY FOR TESTING MATERIALS (ASTM).
Note to Specifier: Include 1.03.A.1 if corrugated steel form units are used as a substrate for roofassembly.
1. ASTM A525 - Steel Sheet Zinc Coated (Galvanized) by Hot Dip Process.
2. ASTM C150 - Portland Cement
3. ASTM C495 - Compressive Strength of Lightweight Insulating Concrete.
4. ASTM C796 - Foaming Agents For Use in Producing Cellular Concrete UsingPreformed Foam.
5. ASTM C869 - Foaming Agents Used in Making Preformed Foam for CellularConcrete.
B. FACTORY MUTUAL (FM):
1. Roof Assembly Classifications.
Note to Specifier: Select the applicable code based upon the location of the project.
C. [South Florida Building Code (SFBC), {Broward} {Dade} County Edition.]
D. [Southern Standard Building Code, {Palm Beach} County Edition.]
E. Steel Deck Institute (SDI):
1. Diaphragm Design Manual. Second Editions, 1987.
F. Underwriters Laboratories (UL):
1. Fire Resistance Classifications.
1.04 PHYSICAL PROPERTIES:
Note to Specifier: Select the appropriate values below.
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035223
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
C. Wet Density at Point of Placement: [36] [ ] pcf +/- 5. [576] [ ] kg/m3 +/- 2.25 kg/m3.
D. Thermal Conductivity ("k" Value): [.45 at 25 pcf.] [at ____pcf.]. [.45 at 400 kg/m3][at_____kg/m3].
1.05 SUBMITTALS:
Note to Specifier: List data to be furnished by contractor prior to construction such as shop drawings,product data, samples, design data, manufacturer's instructions, and manufacturer's certificates thatproducts meet or exceed this specification.
A. Submit [shop drawings] [and] [product data] under provisions of Section [01300.][01340.]
B. Indicate roof plan, layout of roof-mounted equipment, slopes and adjoining surfaces.
C. Submit product data for cellular concrete, insulation board [.] [,] and metal deck.]
D. Submit design data under provisions of Section 01340.
Note to Specifier: Delete Paragraph 1.05.E. when project is outside area of South Florida BuildingCode.
E. Submit manufacturer's current Metropolitan Dade County Product Approval indicatingproduct's acceptance for use in accordance with Section 203 and 204 of the SFBC. Noticeof product approval to indicate, as a minimum, the date of expiration of the approval andthe specific conditions governing the approval.
F. Submit test reports under the provisions of Section [01400.] [01405.]
G. Submit test reports indicating that cellular insulating concrete physical properties forcompressive strength and density meet specification requirements.
H. Submit manufacturer's certificate; under provisions of Section [01400] [01405] thatproducts meet or exceed [specified requirements.] [ ________.]
Note to Specifier: When manufacturer's instructions for specific installation requirements are utilized,ensure that statements in Part 3: Execution agree with those instructions.
I. Submit manufacturer's installation instructions under provisions of Section [01300.][01340.]
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035224
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
1.06 QUALIFICATIONS:
A. Foam concentrate: The foam concentrate used to produce the cellular lightweightinsulating concrete must have a trouble free history of at least five years with acceptabledocumentation of UL, FM and SFBC Approvals.
B. Applicator: Company specializing in application of cellular lightweight insulatingconcrete [with minimum { } years {documented} experience and approved by themanufacturer.]
1.07 REGULATORY REQUIREMENTS:
A. Conform to [applicable] [South Florida Building] code for roof assembly fire hazardrequirements.
B. Fire Resistance Classification: UL Classified [Floor-] [Roof-] Topping Mixture FireResistance Classification Design Nos. [ ____ ] in accordance with UL Fire ResistanceIndex.
Note to Specifier: For metal roof deck applications, identify whether the FM classification is to beI-60, I-90, I-120, I-150 or I-180.
C. Roof Assembly Classification: FM Class [I-60] [I-90] [I-120] [I-150] [I-180]construction, in accordance with FM Construction Bulletin 1-28.
D. Provide certification of inspection confirming approval of [by] [authority havejurisdiction].
1.08 DELIVERY, STORAGE AND HANDLING:
A. Deliver products to site under provisions of Section [01600.] [01620.]
B. Deliver products in manufacturer's original undamaged containers or acceptable bulkhandling.
C. Store and protect products under provisions of Section [01600.] [01620.]
D. Store packaged products off ground in manner to protect them from elements, especiallymoisture damage.
E. Remove products from site that show indication of moisture damage, caking, or othersigns of deterioration and replace with undamaged materials.
1.09 ENVIRONMENTAL REQUIREMENTS:
A. Avoid installation of cellular lightweight insulating concrete when outside temperatureswill be below 40ºF. [4.5 C].
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035225
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
B. When it is anticipated that outside temperatures will be below 40ºF [4.5 C] 24 hours afterplacing concrete, heat mixing water to maximum of 120ºF. [49 C].
PART 2: PRODUCTS
2.01 MATERIALS:
A. Insulating Concrete:
1. Foaming Agent: Celcore Foam Concentrate for Concrete produced by CelcoreIncorporated, 775 US Highway 70 West, Black Mountain, NC 28711 (704)669-4875.
2. Portland Cement: ASTM C150, type I unless otherwise approved.
3. Water: Clean, fresh, and free from injurious quantities of acid, alkali, salt, oil,organic matter, or other impurities.
4. Admixtures: Do not use admixtures without the approval of the insulating concretemanufacturer; use approved admixtures in strict accordance with manufacturer'srecommendations.
Note to Specifier: Coordinate inclusion of the following with Paragraphs 1.01 and 1.02. Includeinsulation board if required for project.
B. Insulation Board: Foam plastic (polystyrene), with a minimum of (1) pcf [16 kg/m3]density; fabricate board with (8) 2-1/2 inch +/- 1/2 inch [6.35 cm +/- 1.27 cm] diameterholes to provide a positive keying action; Factory Mutual (FM) and UL approved.
Note to Specifier: Coordinate inclusion of the following with Paragraphs 1.01 and 1.02. Include metaldecking if appropriate for project. Specify gage and size as recommended by deck manufacturer tosupport required live and dead loads and to comply with applicable Building Code Approvals.
Note to Specifier: Include the following when required for fire or insurance ratings.
2.02 MIXES:
A. Mix materials in accordance with recommendations of manufacturer to yield the specifiedphysical properties.
B. Mix and pump cellular lightweight insulating concrete into place using a mixing plantapproved by the manufacturer. Thoroughly blend all materials before discharging themixer.
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035226
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
C. Maintain a wet density of 36 pcf +/- 5 pcf [576 kg/m3 +/- 2.25 kg/m3] at place of deposit.
D. Maintain a consistency suitable to provide a plastic mix capable of being screeded to asmooth finish.
PART 3: EXECUTION
3.01 EXAMINATION:
Note to Specifier: Include Paragraph 3.01.A. below if installed over structural concrete.
A. Verify that top surface of structural concrete scheduled to receive insulating concrete isfree of any materials or coverings that may prevent bond.
Note to Specifier: Include Paragraph 3.01.A. below if installed over metal deck.
A. Examine surfaces for inadequate anchorage, foreign material, moisture, and unevennesswhich would prevent proper application of insulating concrete.
B. Beginning of installation means applicator accepts existing [surface] [substrate]conditions.
3.02 PREPARATION:
A. Cover roof deck penetrations, drains, etc. before installing insulating concrete.
B. Clean [surfaces] [substrate] of deleterious material and water.
C. Set screeds to assure insulating concrete is applied to the required depth.
D. Protect elements surrounding the work of this Section from damage or disfiguration.
3.03 INSTALLATION:
Note to Specifier: Include Paragraph 3.03.A. if metal deck is used for substrate.
A. Install metal deck in accordance with Plans, Specifications, and/or applicable codes.
Note to Specifier: Include Paragraphs 3.03.B., C. and D. where insulation board is used. Whereinsulation board is not used, include Paragraph 3.03.E.
B. Place cellular concrete slurry to a minimum thickness of 1/8 inch [.32 cm] over top ofcorrugations or substrate.
C. The insulation board shall be placed in such a manner as to cause full contact of the boardsurface with the plastic cellular concrete. Cellular concrete shall enter into the keying
PROJECT NAME: PROJECT NO:
CSI FORMATTED SPECIFICATION 035227
Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
holes of the board. The insulation board shall be placed in a brick-like pattern of staggeredjoints butted tightly together.
D. Place cellular concrete on top of the insulation board to a minimum thickness of two (2)inches [5.08 cm].
E. Place cellular concrete to minimum thickness of two (2) inches [5.08 cm] over top ofcorrugations or substrate.
Note to Specifier: Include Paragraph 3.03.F. where wire fabric is used.
F. Wire Fabric:
1. Install with minimum end lay of six (6) inches [15.24 cm] with sides lappedminimum two (2) inches [5.08 cm], or tied.
2. Cut to fit at walls, curbs and openings in the roof decking.
3. Do not run fabric through expansion joints.
3.04 FIELD QUALITY CONTROL:
A. Field [inspection] [and] [testing] will be performed under the provisions of Section[01400.] [01410.]
B. Test insulating concrete in accordance with ASTM C495 as modified below:
1. Test specimens to be cylinders six (6) inches [15.24 cm] in diameter and twelve(12) inches [30.48 cm] in length.
2. During molding, place the concrete in two (2) approximately equal layers. Raiseand drop the cylinders approximately one (1) inch [2.5 cm] three (3) times on ahard surface after placing each layer. Do not rod the concrete.
3. Keep concrete in molds for a minimum of seven (7) days.
3.05 PROTECTION:
A. Apply a curing membrane [ Celcore PVA Curing Compound] [ ] over deck surface assoon as the deck will support foot traffic for protection against excessive evaporation ordry out. This PVA membrane shall be an integral part of the deck system. Prevent excessroof traffic for 24 hours.
-END OF SECTION-
PROJECT NAME: PROJECT NO:
CELCORE RETROFIT SPECIFICATION
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
CELCORE® CELLULAR INSULATING CONCRETESPECIFICATION FOR RETROFIT PLACEMENT OVER
EXISTING ROOF MEMBRANES
PART 1: SCOPE
1.1 An Approved Celcore Applicator shall furnish all labor, materials and supervision for theinstallation of the complete cellular insulating concrete roof deck to be placed over the existingroofing surface.
1.2 The cellular concrete roof deck shall be placed as noted on the project shop drawings and asdetailed in the project specifications.
PART 2: GENERAL
2.1 A professional analysis shall be obtained, conducted by a registered Architect and/or Engineer,for determination of items 2.2.1, 2.1.2 and 2.1.3.
2.2.1 Adequacy of the structural deck to support the loads to be imposed by the roofing system. TheCellular Concrete Applicator shall supply the Architect and/or Engineer with both the cast anddry weights of the new insulation system in [lbs./sq.ft.] [kg/sq.m] as it is proposed to beinstalled.
2.1.2 Condition of the existing structural deck system and/or the state of deterioration of the originalconstruction.
2.1.3 Adequacy of the existing roof system to meet the design pressure requirement of the specifieduplift resistance value.
2.2 The surfaces on which the cellular concrete is to be placed shall be clean of foreign debris,loose gravel, free of standing water and blisters in the roof membrane.
2.3 Blisters in the existing roof shall be cut or shaved and then repaired to a watertight condition.This work shall be accomplished by the roofing contractor and performed prior to thebeginning of the cellular concrete placement. It shall be the responsibility of the Prime and/orroofing contractor to maintain the building in a watertight condition during the period ofconstruction.
2.4 The Cellular Concrete Applicator shall visually inspect and approve the surface condition ofthe existing membrane prior to beginning placement of the cellular concrete. Areas ofunsoundness or requiring additional preparation shall be brought to the attention of the Primeand/or roofing contractor for correction prior to placement.
2.5 All expansion joints, bulkheads, wood nailers, edge forms, angles and other framing, or otherwork normally within the scope accomplished by other trades, shall be furnished by others.
PROJECT NAME: PROJECT NO:
CELCORE RETROFIT SPECIFICATION
2Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
2.6 The Cellular Concrete Applicator shall demonstrate that all Approvals, as required for theproject, are current with the respective agencies.
PART 3: MATERIALS
3.1 Cellular Insulating Concrete
3.1.1 Foaming Agent; Celcore Foam Concentrate for Concrete shall be manufactured and strictlycontrolled by Celcore Incorporated, 775 US Highway 70 West, Black Mountain, NC 28711(704) 669-4875. The concentrate shall have clear identification on each container and shallbear the UL and FM marks on the labels.
3.1.2 Portland cement, Type I meeting ASTM C150 shall be used unless otherwise approved.
3.1.3 Water for mixing and curing shall be clean, fresh and free from injurious quantities of acid,alkali, salt, oil, organic matter or other impurities. Installations during cold weather mayrequire the use of heated water.
3.1.4 Admixtures; No admixture shall be used without the approval of Celcore Incorporated, thearchitect and/or the engineer. Approved admixtures shall be used in strict accordance with themanufacturer's recommendations.
3.2 Insulation board, Foam Plastic (polystyrene)
3.2.1 The insulation board used in Celcore Cellular Concrete roof deck systems shall be a product ofexpanded polystyrene produced in accordance with ASTM C578, Type I, having a nominaldensity of 1 pcf [16 kg/m3]. The boards shall be fabricated in a 2 ft. by 4 ft. [.61m by 1.22 m]configuration at specified thicknesses with (8) 2-1/2 in. (+/- 1/2 in.) [6.35 cm (+/- 1.27 cm)]diameter holes to provide a positive keying action. The insulation boards shall be FM and ULapproved.
3.3 Curing Compound
3.3.1 Celcore PVA Curing Compound (CCC) is produced by Celcore Incorporated. Drums of CCCshall be clearly marked and identifiable by labeling.
3.4 Reinforcing Mesh (wire fabric)
3.4.1 When required, wire fabric shall be equal to Keydeck, Type 2160-2-1619.
PART 4: APPLICATION
4.1 Cellular Concrete Physical Properties
4.1.1 The mix proportions shall be designed by Celcore Incorporated to yield the proper physicalproperties. [i.e. compressive strength, density, and thermal conductivity]
PROJECT NAME: PROJECT NO:
CELCORE RETROFIT SPECIFICATION
3Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
4.2 Mixing and Placing
4.2.1 Celcore Cellular Concrete shall be produced and pumped into place using an approved batchplant. All mixture ingredients shall be thoroughly and homogeneously blended before beingdischarged from the mixer.
4.2.2 A cast (wet) density of 36 pcf (+/- 5 pcf) [576 kg/m3 (+/- 2.27 kg/m3)] shall be maintained atthe point of placement.
4.2.3 The consistency of the mix shall be such to provide a flowable mix that can be screeded to asmooth finish.
4.2.4 The cellular concrete shall have a minimum thickness of 2 inches [ 5.08 cm] over allsubstrates. When composite fills are required, a minimum 2 in. [5.08 cm] topping is requiredover the polystyrene insulation board.
4.2.5 When ambient temperatures are predicted to be above 40 F [4.4 C] for the first (24) hours afterplacement of the cellular concrete, normal placing procedures shall be followed.
4.2.6 Cold weather placement (35 F [1.7 C] and falling) of cellular concrete should be avoided dueto the possibility of the concrete freezing prior to final set. If cold weather installations arerequired, special considerations must be met. Contact Celcore Incorporated for guidance.
4.3 Insulation board and Cellular Concrete Placement
4.3.1 Prior to placement of the insulation boards, the substrate shall be filled with a slurry coat ofcellular concrete to minimum thickness of 1/8 in. [.3175 cm]. Where the installation is over anexisting membrane with embedded gravel, the surface fill shall be a minimum of 1/8 in. [.3175cm] thickness over the top of the embedded gravel.
4.3.2 The insulation board shall be placed immediately into the plastic cellular concrete slurry coat.
4.3.3 The insulation boards shall be placed in such a manner as to cause full contact of the boardsurface with the plastic cellular concrete. Cellular concrete shall enter into the keying holes ofthe board. The insulation boards shall be placed in a brick-like pattern of staggered joints. Alljoints shall be butted tightly together.
4.3.4 Polystyrene boards, particularly in thickness of 2 inches [5.08 cm] or more, have a tendency tofloat if the cellular concrete topping is applied prior to the adequate bonding of the polystyreneboards to the slurry coat. It shall be the responsibility of the cellular concrete applicator toinstall the system in an approved manner, ensuring proper thickness of the topping layer ofcellular concrete.
4.3.5 A minimum of 2 inches [5.08 cm] of cellular concrete shall be placed over the substrate, or incomposite fills, over the insulation board and screeded to grade. The finished surface shall beof adequate texture to receive the roofing membrane.
PROJECT NAME: PROJECT NO:
CELCORE RETROFIT SPECIFICATION
4Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
4.4 Curing
4.4.1 Celcore PVA Curing Compound (CCC) shall be applied over the cellular concrete decksurface as early as is practical once the deck has developed strength sufficient to support foottraffic without damage. The preferred method of application shall be by spraying. Preventexcess roof traffic during the first (24) hours after the cellular concrete placement.
4.5 Quality Control
4.5.1 The cellular concrete applicator shall be familiar with substrate preparation, experienced andequipped for this type of work with a minimum of (5) years experience in placing cellularconcrete.
4.5.2 Approval Requirements:
4.5.2.1 Approved by Underwriters Laboratories.
4.5.2.1 Approved by Factory Mutual Research to include reroofing Approvals.
4.5.2.3 When applicable, Metropolitan Dade County product approval for re-roof applications.
4.6 Testing
4.6.1 Celcore cellular insulating concrete shall be tested in accordance with ASTM C495 modifiedas follows:
4.6.1.1 Test specimens shall be cylinders 6 in. [15.25 cm] in diameter and 12 in. [30.48 cm] in length.
4.6.1.2 In molding the specimens, the cellular concrete shall be poured into the molds in (2)approximately equal layers. The cylinders shall be raised and dropped approximately 1 in.[2.54 cm] (3) times on a hard surface after pouring each layer into the mold. The cellularconcrete specimens shall not be rodded.
4.6.1.3 After molding the specimens, do not seal the molds. Store the specimens, for the initial setperiod, on a level surface in a place where they will not be disturbed for a least (16) hours.
4.6.1.4 The cellular concrete specimens shall not be removed from the molds prior to (7) days of age.
PART 5: REFERENCES
5.1 American Society For Testing Materials (ASTM)
5.5.1 ASTM C 150 Portland Cement
5.1.2 ASTM C 495 Compressive Strength of Lightweight Insulating Concrete
5.1.3 ASTM C 578 Polystyrene Thermal Insulation
PROJECT NAME: PROJECT NO:
CELCORE RETROFIT SPECIFICATION
5Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
5.1.4 ASTM C 518 Thermal Transmission Properties by Means of Heat Flow Apparatus
5.1.5 ASTM C 796 Foaming Agent for use in Producing Cellular Concrete Using Preformed Foam
5.1.6 ASTM C 869 Foaming Agents used in Making Preformed Foam for Cellular concrete
5.2 American Concrete Institute (ACI)
5.2.1 ACI Committee Report 523.1R Guide for Cast-in-Place Cellular Concrete
5.3 Factory Mutual Research Corporation (FMRC)
5.3.1 Roof Cover and Roof Deck Assembly Classifications (4454)
5.4 Underwriters Laboratories (UL)
5.4.1 Fire Resistance Classifications
- END OF SECTION -
PROJECT NAME: PROJECT NO:
CELCORE PVA SPECIFICATION
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
CELCORE® PVA CURING COMPOUNDSPECIFICATION FOR CURING
CELCORE CELLULAR INSULATING CONCRETE
PART 1: SCOPE
1.1 An Approved Celcore Applicator shall furnish all labor, materials and equipment required toproperly apply Celcore PVA Curing Compound (CCC).
1.2 The CCC film shall become an integral part of the deck system.
PART 2: GENERAL
2.1 The CCC shall be applied as early as is practical after the deck topping has been placed andonce the cellular concrete has developed strength sufficient to support foot traffic withoutdamage.
2.2 The deck surface shall be clean and free of debris. The preferred method of deck preparationshall be by sweeping or blowing.
2.3 Any roof deck repair work or scraping should be accomplished in advance of the curingapplication if possible. The aforementioned work however, must not cause long delays to thecuring application. During weather conditions favorable to rapid drying, curing is mosteffective when applied within 24 hours after placement.
2.4 Excess traffic on the deck shall be limited during the first 24 hours after deck toppingplacement and also limited after applying the CCC until the film has dried. (typically within30 minutes after application)
2.5 In cold weather placements of cellular concrete where concrete set times are slowed andprolonged by low ambient temperatures, curing applications maybe delayed or may not berequired.
PART 3: MATERIALS
3.1 Celcore PVA Curing Compound (CCC) is produced by Celcore Incorporated, 775 US Hwy70 West, Black Mountain, NC 28711 (704) 669-4875. CCC is shipped as a liquid concentratein 55 gallon [208 L] drums. Drums of CCC shall be marked and clearly identifiable bylabeling.
3.2 Drums of CCC shall be stored where protected from freezing and kept sealed during storageto prevent skinning of the air exposed surface.
3.3 CCC is produced by thermally processing certain grades of Polyvinyl Alcohol (PVA) whichare designed to form water resistant films. Water soluble PVAs or PVA emulsions producedby others are not approved.
PROJECT NAME: PROJECT NO:
CELCORE PVA SPECIFICATION
2Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
3.4 Water for diluting the CCC concentrate shall be clean, fresh and free of injurious quantitiesof acid, alkali, salt, oil, organic matter or other impurities.
PART 4: DILUTION
4.1 CCC shall typically be mixed with water at a rate of one part CCC to one part water. Higherconcentrations up to 3 parts CCC to 1 part water are approved when deck protection isdesired.
4.2 CCC concentrate mixes readily with water, accordingly no special mixing is required.
PART 5: APPLICATION
5.1 CCC shall be applied as early as is practical after the deck has developed strength sufficient tosupport foot traffic without damage.
5.2 The preferred method of application is by spraying. Spraying may be accomplished by using apressurized tank, applying the CCC to the deck thru a wand or a garden nozzle.
5.3 Other methods shall include, but not be limited to, brushing or roller applying. Theapplication shall be such as to avoid puddling.
5.4 Coverage shall be at a rate of approximately 200 to 400 sq. ft. per diluted gallon [5 to10 / m2per Liter ]. CCC shall not be applied when raining.
-END OF SECTION-
PROJECT NAME: PROJECT NO:
CELCORE THIN PATCH SPECIFICATION
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
CELCORE® THIN PATCHDATA/SPECIFICATION
PART 1: GENERAL
THINPATCH is a non-hazardous, non-corrosive additive to Portland cement mixes. It was developed to prevent rapiddrying of concrete mixtures used to make repairs or detail cementitious roof decks. Rapid drying can cause powdering,chalking and/or severe cracking of non-modified mixtures. Additionally, THINPATCH is added to ensure adequate bondto the parent surface and to lower the modules of elasticity in high cement factor concrete mixtures. Accordingly, thebrittleness of the repair material is reduced, lessening the possibility of fragmentation which could damage the roofmembrane by puncture. THINPATCH also serves as a plasticizer which will allow mixing water reductions of 10% to15% over corresponding mixes without its use. In situations where THINPATCH is used to cap or repair roofingsubstrates, its use should be communicated to the roof membrane manufacturer. Although THINPATCH has been testedby several roofing manufactures for BOND and UPLIFT resistance, there may be special conditions that the roofmembrane manufacturer may want to confirm by test or verbally with CELCORE Inc.
PART 2: MATERIALS:
THINPATCH is produced by CELCORE, Inc., of Black Mountain, North Carolina. Containers of THINPATCH shall beclearly identifiable by labeling. The admixture is a free flowing, redispersible powder which shall be kept in dry storageto avoid caking.
PORTLAND CEMENT used may be of various brands, however, the Types must be identified as either I, II, or III, andlabeled as meeting the requirements of ASTM C-150.
WATER for mixing shall be lean, fresh, and free from injurious quantities of acid, alkali, salt, oil, organic matter or otherimpurities. Installation in cold weather may require the use of heated water.
AGGREGATES, if utilized, may be conventional concrete aggregates (limited however to fines) meeting therequirements of ASTM C-33, perlite lightweight aggregate meeting the requirements of ASTM C-322, Group 1, orpreformed foam for cellular concrete, meeting the requirements of ASTM C-796. The use of vermiculite aggregate is notapproved.
PART 3: MIXES:
Where minimum thickness of 1/8 in. [.32 cm] or less are required for surface smoothing, THINPATCH modified neatcement slurry mixtures are recommended. These THINPATCH modified cement paste mixtures may be applied bytroweling, squeegee, or other method resulting in the desired smoothness of the finished surface. The THINPATCHmixture for this type of application shall be formulated as follows:
Cement: 94 lbs [42.64 kg] 1 sack
Water: 56 lbs [25.4 kg] 6.7 gal [22.36 L]
THINPATCH: 3 lbs [1.36 kg]
After mixing the above ingredients thoroughly, allow the mixture to stand idle for about 10 minutes to allow adequatewetting of the cement, then re-mix to assure uniform dispersion. Begin application of the mixture immediately.
Where repair thickness greater than 1/8 in. [.32 cm] but less than 3/4 in. [1.09 cm] are required, an aggregate filler isrecommended. For nailable decks use perlite concrete aggregate. For non-nailable decks use concrete or masonry fineaggregates. Depending on strengths required, mixes of 1 part cement to 2 parts or 3 parts aggregate may be used.THINPATCH additive shall be used at the rate of 3 lbs [1.36 kg] per bag of cement. Aggregate gradations shall be chosento fit the thickness of the fill required. Water content shall be sufficiently high to allow an easy flow for placing.
PROJECT NAME: PROJECT NO:
CELCORE THIN PATCH SPECIFICATION
2Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Where thicknesses greater than 3/4 in [1.09 cm] are required cellular or perlite concrete is recommended. Perlite mixesshall not have a cement factor of less than 1 part cement to 6 parts perlite with 6 lbs [ 2.72 kg] of THINPATCH per cubicyard. Cellular concrete mixes shall be designed to 40 lbs/ft3 [64 kgs/m3] cast density. Water content shall be sufficientlyhigh to allow an easy flow for placing.
PART 4: PREPARATION:
Before the application of the selected THINPATCH mixture, the surface must be thoroughly cleaned of loose debris. Thepreferred method of deck preparation shall be by sweeping, vacuuming or blowing. Deck surfaces may be moistened toreceive thin applications particularly in hot weather. A covering of standing water shall not be permitted however. Anyportion of the existing deck determined to be unbonded to the structural substrate or otherwise unsound shall be pointedout to the architect/contractor/owner for proper corrective action.
PART 5: PLACING:
The crew installing the THINPATCH mix must be of sufficient size to handle the volume of the batches. Placement timefor any size batch should not exceed one hour. in no case shall batches be retempered with water after the placingoperation has commenced. Materials which have exceeded the time limitation or have lost desired workability shall not beused in the application.
With the exception of applications having thickness of less than 1/8 in. [.32 cm], screeds should be set when capping toprovide a uniform and true surface.
CELCORE PRODUCT APPROVALS
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Celcore Product Approvals
FACTORY MUTUAL SYSTEMS APPROVALSNoncombustible & 1-60 Windstorm Rated (minimum):
1. 26 Gage minimum metal deck.2. 1 thru 12 inch thick EPS board may be used.3. Ratings over metal deck and structural concrete, with mechanically fastened bas sheet FM 1-60, FM 1-90, FM 1-120, FM 1-150.4. Ratings over metal deck and structural concrete, with fully adhered single ply membranes FM 1-60, FM 1-90, FM 1-120, FM 1-150, FM 1-180, FM 1-270.5. Types of approved roof covers: Asphaltic BUR, Modified Bitumen and Single Ply.6. Recover application Approvals for placement over asphaltic vapor retarder on structural concrete decks for ratings
to FM 1-270
UNDERWRITERS LABORATORIES FIRE RESISTANCE DESIGN APPROVALS
Metal Deck Roof Assembly DesignsNumber: P214Hourly Rating: 1
METROPOLITAN DADE COUNTY, FLORIDAPRODUCT CONTROL NOTICE OF ACCEPTANCE
Product Control No: 97-0127.01For current information consult with an authorized Celcore Applicator or Celcore’s Electronic Information Services.
Celcore® IncorpratedFactory Mutual Approvals
CELCORE FACTORY MUTUAL LISTING
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Celcore Inc 775 US Hwy 70 W Black Mountain NC 28711 Deck:Celcore Cellular Concrete Roof Covers: Asphaltic BUR, ModifiedBitumen and Single PlyConstruction #1: Steel Form Deck Construction. A slurry coat ofCelcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced on the deck filling the corrugations plus min 1/8 in. (3 mm) thickabove the top flange immediately followed by a single layer of min 1 in.(25 mm) thick Apache Holey Board Polystyrene Insulation. Thefollowing day, min 2 in. (51 mm) thick Celcore Cellular Concrete, min36 lb/ft3 (577 kg/m3 ) wet cast density, is placed. After setting to supportfoot traffic, Celcore PVA Curing Compound is applied at a nominal rateof 300 ft2 /gal (7.2 m2 /L). After curing several days a roof covering isapplied as described in Constructions #4, #4a, #4b, #4c, #5, #5a, #5b,#5c and #5d.Construction #2:Structural Concrete Deck, New or RecoverConstruction. New Structural concrete deck is covered with an asphalticvapor retarder (optional). Min 1/8 in. (3 mm) thick slurry coat ofCelcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced on the deck, asphaltic vapor retarder or existing asphaltic BURroof followed by a single layer of min 1 in. (25 mm) thick Apache HoleyBoard Polystyrene Insulation. The remainder of the Celcore CellularConcrete system is constructed as described in Construction #1 above.After curing several days a roof covering is applied as described inConstructions #6, #6a, #6b, #6c, #7, #7a, #7b or #7c.Construction #3:Structural Concrete Deck, New or RecoverConstruction. Min 2 in. (51 mm) thick Celcore Cellular Concrete, min36 lb/ft3 (577 kg/m3 ) wet cast density, is placed on the substratesdescribed in Construction #2 followed by Celcore PVA CuringCompound applied as in Construction #1. After curing several days aroof covering is applied as described in Constructions #6, #6a, #6b, #6c,#7, #7a, #7b or #7c.Construction #4: Steel Form Deck, New Construction. Min 0.029 in.(0.74 mm) thick, 1.5 in. deep Wheeling Corrugating Company BWgalvanized deck is secured to min 0.25 in. (6.4 mm) thick structuralsupports with ITW Buildex ICH Traxx/5 screws placed at each bottomrib [6 in. (152 mm) o.c.] with structural supports spaced at max 4 ft (1.2m) o.c. Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet castdensity is placed as described in Construction #1. Min 0.048 in. (1.2mm) thick Sarnafil G410 Felt Back roof cover is then adhered withSarnacol 2121 Adhesive squeegee [1/4×1/4 in. (6.4×6.4 mm) notches]applied at a nominal rate of 2.25 gal/sq (0.92 L/m2 ) or with Sarnacol2170 Adhesive roller applied as a primer at a rate of 0.8 to 1.0 gal/sq(0.33 to 0.41 L/m2 ) and allowed to dry followed by a second coat ofSarnacol 2170 roller applied at the same rate. The roof cover isimmediately rolled into the wet adhesive and rolled with a weightedroller and the seams sealed with a min 1.5 in. (38 mm) wide heat weld.Meets Class 1-180.Construction #4a:Steel Form Deck, New Construction. Steel form deckper Construction #4 is secured to structural supports spaced at a max of5 ft (1.5 m) o.c. as described in Construction #4. Celcore CellularConcrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, is then placed asdescribed in Construction #1 followed by Sarnafil G410 applied asdescribed in Construction #4. Meets Class 1-150.Construction #4b:Steel Form Deck, New Construction. Steel form deckper Construction #4 is secured to structural supports spaced at max 6 ft(1.9 m) o.c. as described in Constructions #4 or #4 with the addition oftwo deck side lap fasteners evenly spaced between supports. CelcoreCellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, is thenplaced as described in Construction #1 utilizing a min 2.5 in. (64 mm)thick top coat of Celcore Cellular Concrete followed by Sarnafil S327adhered as in Construction #4. Meets Class 1-120.
Construction #4c:Steel Form Deck, New Construction. Steel form deckper Construction #4 is secured to structural supports spaced at max 5 ft(1.5 m) o.c. with min 5/8 in. (16 mm) dia. puddle welds or with 1/2 in.(13 mm) dia. puddle welds and washers placed at every corrugation andat each support where sides lap or as described in Constructions #4 and#4a. Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet castdensity, is then placed as described in Construction #1 followed bySarnafil S327 adhered as in Construction #4 or by Flex Membrane FlexFB White Tripolymer adhered as in Constructions #6a or #6b or aGAFGLAS #75 Base Sheet, GAFGLAS #80 Premium Base Sheet orGAFGLAS STRATAVENT Nailable Base Sheet or a Celotex Hydro-Stop Vapor Barrier/Venting Base Sheet or a Johns Manville PermaPlyR, DynaBase, Ventsulation Base Sheet or a Tremco BURmasticComposite Ply Base Sheet, max 39.37 in. (1000 mm) wide, secured tothe deck with Olympic CR Base Felt Fasteners and Discs or ITWBuildex Lite Weight Concrete Fasteners and Discs or GAF GAFTITEBase Sheet Fasteners and Plates spaced at max 7 in. (178 mm) o.c.through min 3 in. (76 mm) wide laps and at max 7 in. (178 mm) o.c. intwo rows in the field of the sheet. The lap fasteners are in-lineperpendicular to the laps. The fastener rows in the field of the sheet areevenly spaced between side laps with the fasteners in these rows offset3.5 in. (89 mm) from lap fasteners. A min 3 ply glass felt asphaltic BURor min 3 ply asphalt adhered modified bitumen roof covering is thenapplied. Meets Class 1-90.Construction #5:Steel Form Deck, New Construction. Min 0.0179 in.(0.45 mm) thick Tensilform S-75 form deck or min 0.0205 in. (0.52mm) thick Tensilform 75 form deck by Wheeling Corrugating Companyis secured to the structural supports with Approved deck fasteners orwith 1/2 in. (13 mm) dia. puddle welds and washers placed at everyother corrugation [7.5 in. (191 mm) o.c.] and at each support wheresides lap. Structural supports are spaced at max of 5 ft (1.5 m) o.c.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isthen placed as described in Construction #1 and covered with a roofcovering installed as described in Constructions #5a, #5b #5c or #5dbelow. Meets Class 1-60.Construction #5a:Celotex Vapor Bar Base Sheet, min 4 in. (102 mm)wide laps or Johns Manville PermaPly No. 28 Base Sheet, min 3 in. (76mm) wide laps, both max 36 in. (914 mm) wide is secured to the deckwith ES Products FM-90 Base Ply Fasteners or with Olympic C-R BaseFelt Fasteners and Discs spaced max 8 in. (203 mm) o.c. through thelaps and at max 16 in. (406 mm) o.c. staggered in two rows in the fieldof the sheet. The base sheet is covered with a min 3 ply glass felt BURor a min 3 ply asphalt adhered modified bitumen roof covering. MeetsClass 1-60.Construction #5b:Soprema Sopra G Base Sheet, 36.37 in. (1000 mm)wide is secured to the deck with either ES Products FM-90 Base PlyFasteners or with Olympic C-R Base Felt Fasteners and Discs spacedmax 6 in. (152 mm) o.c. through min 4 in. (102 mm) wide laps and atmax 12 in. (305 mm) o.c. staggered in two rows in the field of the sheet.The base sheet is covered with min 3 ply glass felt BUR or min 2 plyasphalt adhered modified bitumen roof cover. Meets Class 1-60.Construction #5c:GAF GAFGLAS #75 Base Sheet or US Intec UltraBase, 39.37 in. (1000 mm) wide with min 2 in. (51 mm) wide laps issecured to the deck with ES Products FM-90 Base Ply Fasteners or withOlympic C-R Base Felt Fasteners and Discs spaced at max 8 in. (203mm) o.c. through the laps and max 8 in. (203 mm) o.c. in two rows inthe field of the sheet. The lap fasteners are in-line perpendicular to thelaps. The fastener rows in the field of the sheet are evenly spacedbetween side laps with the fasteners in these rows offset 4 in. (102 mm)from lap fasteners. The base sheet is then covered with a min 3 ply glassfelt BUR or a min of 1 ply of an asphalt or torch adhered modifiedbitumen roof cover. Meets Class 1-60.
Celcore® IncorpratedFactory Mutual Approvals
CELCORE FACTORY MUTUAL LISTING
2Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
®
Construction #5d: Sarnafil G410 is applied as described inConstruction #4 or Flex Membrane Flex FB White Tripolymer appliedas in Constructions #6a or #6b. Meets Class 1-60.Construction #6: Structural Concrete Deck, New Construction. CelcoreCellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, is placedas described in Constructions #2 or #3 for new construction. SarnafilG410 is then applied as described in Construction #4. Meets Class 1-270.Construction #6a:Structural Concrete Deck, New Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for new construction. Thedeck is primed with Monsey Asphalt Primer applied at a rate of 200 ft2
/gal (4.8 m2 /L). After drying overnight, min 0.045 in. (1.1 mm) thickFlex Membrane Flex FB White Tripolymer felt backed roof cover isadhered with hot asphalt. The roof cover is then rolled with a weightedroller and the seams sealed with a min 2 in. (38 mm) wide heat weld orwith Tetrohydrofuron. Meets Class 1-270.Construction #6b:Structural Concrete Deck, New Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for new construction. Thedeck is primed with Monsey Asphalt Primer applied at a rate of 200 ft2
/gal (4.8 m2 /L). After drying overnight, min 0.045 in. (1.1 mm) thickFlex Membrane Flex FB White Tripolymer felt backed roof cover isadhered with Flex Rubber Emulsion Adhesive applied at a rate of 60 ft2
/gal (1.4 m 2 /L). The roof cover is then rolled with a weighted roller andthe seams sealed with a min 2 in. (38 mm) wide heat weld or withTetrohydrofuron. Meets Class 1-210.Construction #6c:Structural Concrete Deck, New Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for new constructionfollowed by a glass felt or modified bitumen roof cover as described inConstruction #4c. Meets Class 1-90.Construction #6d:Structural Concrete Deck, New Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for new constructionfollowed by a glass felt or modified bitumen roof cover as described inConstruction #5a, #5b or #5c. Meets Class 1-60.Construction #7:Structural Concrete Deck, Recover Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for recover construction.Sarnafil G410 is then applied as described in Construction #4 or FlexMembrane Flex FB White Tripolymer felt backed roof cover is thenapplied as in Construction #6a. Meets wind uplift rating of the existingroof, max Class 1-270.Construction #7a:Structural Concrete Deck, Recover Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isplaced as described in Constructions #2 or #3 for recover construction.Flex Membrane Flex FB White Tripolymer felt backed roof cover isthen applied as in Construction #6b. Meets wind uplift rating of theexisting roof, max Class 1-210.Construction #7b:Structural Concrete Deck, Recover Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isas described in Constructions #2 or #3 for recover construction followedby a glass felt or modified bitumen built up roof covering as described inConstruction #4c. Meets wind uplift rating of the existing roof, maxClass 1-90.Construction #7c:Structural Concrete Deck, Recover Construction.Celcore Cellular Concrete, min 36 lb/ft3 (577 kg/m3 ) wet cast density, isas described in Constructions #2 or #3 for recover construction followedby a glass felt or modified bitumen roof cover as described inConstruction #5a, #5b, #5c. Meets the wind uplift rating of the existingroof, max Class 1-60.
Construction #8: Steel Form Deck, New Construction. Min 0.029 in.(0.74 mm) thick, 1.5 in. deep Marlyn Steel Decks or WheelingCorrugating Company Type B Wide Rib galvanized deck is secured tothe structural supports spaced at max 5 ft (1.5 m) o.c. with 1/2 in.(13mm) diameter puddle welds and washers placed at every corrugationand at each support where sides lap or as described in Constructions #4.Celcore Cellular Concrete, min 42 pcf (673 kg/m3 ) wet cast density, isthen placed as described in Construction #1. A base sheet is then securedas described in Construction #4c. Meets Class 1-150.Construction #9:Structural Concrete Deck, New Construction. CelcoreCellular Concrete, min 42 pcf (673 kg/m3 ), is placed as described inConstruction #2 or #3 for new construction. A roof cover is applied perConstruction #8. Meets Class 1-150.Construction #10: Structural Concrete Deck, Recover Construction.Celcore Cellular Concrete, min 42 pcf (673 kg/m3 ), is placed asdescribed in Construction #2 or #3 for recover construction. A roofcover is applied per Construction #8. Meets the wind uplift rating of theexisting roof, max Class 1-150.
Celcore® IncorporatedDensity Determinations
CELCORE DENSITY LOG
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711• (704) 669-4875 • Fax (704) 669-4874
Average Density:____________ Standard Deviation:___________
CELCORE BULLETIN: WATER INTRUSION
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711 • (704) 669-4875 • Fax (704) 669-4874
®
Celcore ® Bulletin: Water Intrusion
After the placement of a cellular concrete roof deck and prior to the installation of the roof membrane system, roof deckssubjected to prolonged or heavy rain events occasionally can contain intruded water. This water generally enters thesystem around areas of penetration and collects in low areas under the system. Often, intruded water can be detected by apersistent shadowing along cracks or around penetrations.
When intruded water isdetected, Celcore recommendsremoval by method ofvacuuming. The sketch on thispage is the device to be used inaddressing intruded water.These devices are mosteffective when placed at low-points in the substrate. Therubber boot causes a vacuumwhich pulls water to the coreopening for removal by thevacuum unit. Several units canbe run simultaneously for afaster removal. Membraneinstallation can proceed whileconducting the water removaloperation.
It has been our experience thatthis is an effective method ofwater removal. Celcore hasnever had a report of asubsequent problem in the finalroof cover. It should be notedthat the topping pour of the cellular concrete is always dry, even in roof decks containing intruded water. Intruded watertends to accumulate at the bottom of the deck system. The topping segment of the insulating system is the segment mosteffected by the solar loads of daytime heating. Temporary one-way roof vents can be placed at the core locations ifdesired, but are generally not effective. This is due to the fact that venting requires moisture to undergo a transformationto vapor to escape through the vents. The solar loads of daytime heating do not penetrate the deck enough to causemoisture at the bottom of the system to transform into vapor.
The best way to prevent the possibility of water intrusion is timely scheduling of roof cover installation after theplacement of the insulating concrete deck. Also it is a good practice to be sure that the roof drainage system is operationalthrough-out the construction period.
Celcore®
GeoTechnical Fills
CELCORE GEOTECHNICAL
1Celcore Incorporated US Highway 70 West, Black Mountain, NC 28711 • (704) 669-4875 • Fax (704) 669-4874
®
1. Scope of work
The certified Celcore applicator shall furnish labor,materials, equipment and supervision for theinstallation of Celcore GT Fills in accord withthe Plans and Specifications.
2. Materials
a. Celcore Foam Concentrate shall be supplied byCelcore, Inc. Black Mountain, NC and shallcomply with ASTM C 869 when tested inaccordance with ASTM C 796.
b. Portland Cement shall comply with ASTM C150, Type I, II or III. Pozzolans and othermineral admixtures may be sued whenspecifically approved by Celcore Inc
c. Mixing Water shall be potable and free fromdeleterious amounts of acid, alkali, salts, oilsand organic materials which would adverselyaffect the setting and/or strength of the GT Fill.
d. Admixtures may be used when specificallyapproved by Celcore Inc.
3. Mix Design
Mix design shall be in accordance with Celcore Inc.’srecommendations for a cast density (at point ofplacement) of _________ pcf ± _______pcfwith a minimum compressive strength of_______ psi at 28 days.
4. Mixing and Placing
Celcore GT Fills shall be job site batched, mixed andplaced with equipment approved by CelcoreInc. Multilayer casting is an acceptablemethod of installation.
5. Testing
Four (4) test specimens shall be taken at the point ofplacement for each days pour. Specimens shallbe prepared, handled, cured and tested forcompressive strength in accord with ASTM C495 except that the specimens shall not be ovendried prior to compression testing.
6. Special considerations
Contact Celcore Inc. for design assistance andapplication recommendations
