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Elastizell of St. Louis

Elastizell of St. Louis. Solving Engineered Fill, Flooring & Roofing problems for over 40 years. 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

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Elastizell of St. Louis

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  1. Elastizell of St. Louis Solving Engineered Fill, Flooring & Roofing problems for over 40 years.

  2. 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

  3. Characteristics of Cellular Concrete • Strong & lightweight • Batched on site • Easy to apply • Has many densities • Designed density does not vary

  4. Uses for Cellular Concrete Engineered Fills Flooring Roof Decks

  5. Differences of Cellular Concrete • Engineered Fills • Strength Varies from 40 to 1000 psi • Density Varies from 20 to 70 pcf • Roof Decks • Minimum Strength 160 psi • Density Varies from 36 to 50 pcf • Flooring • Strength 1000 to 3000 psi • Density is 100 - 125 pcf

  6. 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

  7. Engineered Fill • Roadways • Bridges • Voids • Tunnels • Retaining Walls • Soil Stabilization • Plaza Fills Before After

  8. St. Louis Arch Project

  9. Bridge Approach Fills • Poor soils usually exist at bridges • Compaction is not necessary • Replace longer bridge with roadway • Reduce maintenance and life cycle costs

  10. 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

  11. BecauseCellular Concrete flows, it completely fills voids. Basements Tanks Sinkholes Pipeline abandonment Fills around pipes, Annular space fills of one pipe within another. Void Fills

  12. Swimming Pool Void Fill

  13. Insulating Roof Deck Systems • Slope to drain eliminates ponding • Lightweight • High R value • Low cost • Superior to insulation board

  14. Roof Deck Problems & Solutions

  15. 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

  16. 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

  17. LIGHT WEIGHT CONCRETE FLOORS

  18. 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

  19. GYPSUM CONCRETE FLOORS

  20. What is Gypsum? • Hydrated Calcium Sulfate CaSO4 2H2O • Natural • Chemical • Synthetic

  21. Gypsum Concrete Flooring • Specially formulated gypsum concrete plaster • Chemically sets (does not “cure”) • Does not shrink • 1000-8000 compressive strengths

  22. Gypsum Concrete Floors • Pumped • Poured • Feather edge • Up to 3”

  23. CELLULAR CONCRETE FLOORS

  24. Cellular Concrete Floors Portland Cement Based • Calcium Silicate Hydrated Ca SiO3 • Natural • Chemical

  25. Cellular Concrete Floors • Portland cement based • Resists abrasive damage • Not damaged by water – below grade • Steel trowel finish • 1000-3000 compressive strengths

  26. Lightweight Concrete Floor Toppings • Trade ready next morning • Excellent substrates • Economical • Lightweight • Fire resistant • Sound rated

  27. Quality Controls & Tests • Perform density/slump test • Take test cylinder/cube sample on job site

  28. New & Rehab Lightweight Concrete Applications • Multifamily • Apartments • Condos • Hotels • Senior Living • Commercial • Office Building • Hospitals • Residential • Custom Homes • Radiant Heating

  29. Solutions for Rehab Projects • Out of Level Substrates • Load Limited Structures • Sound Mat Option • Plaza Decks

  30. Decorative Surfaces • Gypsum Concrete • Stain the surface • Seal the surface • Cellular Concrete • Integral Color • Stain the surface • Seal the surface

  31. The Construction Trend….Lighter Weight Materials • Thinner Floors • Gypsum • Light Weight Concrete • Light Weight Decking • Light Weight Joists

  32. Sound Control Issues

  33. Airborne and Structure Borne Noise Airborne = STC Structure Borne = IIC (Impact Noise)

  34. Sound Measurement and People’s Reaction • STC Sound Transmission Class • If the STC = 35clearly 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

  35. 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

  36. Intensity, or loudness • Generally expressed in dB’s • dB’s = a range of sound from very quiet to very loud • dB, dBA, dBC, others

  37. 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

  38. Hard Finished Flooring Trends • Tile and Vinyl Tile • Hardwood and Laminate Floors • Concrete

  39. Is Sound Control an Amenity ? Yes ! • Poll of Residents - # 1 Preference Peace and Quiet • Biggest Problem – Vertical Sound Transmission Floor to Floor

  40. 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

  41. Other Sound Improvements Improvement IIC 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

  42. 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

  43. 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

  44. 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

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