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

Varies in Density- 20 to 120 pcf

Strength Varies from 1000 – 3000 PSI

Characteristics of Cellular Concrete

Strong & lightweight

Batched on site

Easy to apply

Has many densities

Designed density does not vary

Uses for Cellular Concrete

Engineered Fills Flooring Roof Decks

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

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

Engineered Fill

Roadways

Bridges

Voids

Tunnels

Retaining Walls

Soil Stabilization

Plaza Fills

Before After

St. Louis Arch Project

Bridge Approach Fills

Poor soils usually exist at

bridges

Compaction is not necessary

Replace longer bridge with

roadway

Reduce maintenance and life

cycle costs

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

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.

Swimming Pool Void Fill

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

Roof Deck Problems & Solutions

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

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

LIGHT WEIGHT CONCRETE FLOORS

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

GYPSUM CONCRETE

FLOORS

What is Gypsum?

Hydrated Calcium Sulfate

CaSO4 2H2O

NaturalChemicalSynthetic

Gypsum Concrete Flooring

Specially formulated gypsum concrete plaster

Chemically sets (does not “cure”)

Does not shrink

1000-8000 compressive strengths

Gypsum Concrete Floors

Pumped

Poured

Feather edge

Up to 3”

CELLULAR CONCRETE

FLOORS

Cellular Concrete Floors Portland Cement Based

Calcium Silicate Hydrated

Ca SiO3

Natural Chemical

Cellular Concrete Floors

Portland cement based

Resists abrasive damage

Not damaged by water –

below grade

Steel trowel finish

1000-3000 compressive

strengths

Lightweight Concrete Floor Toppings

Trade ready next

morning

Excellent substrates

Economical

Lightweight

Fire resistant

Sound rated

Perform density/slump test

Take test cylinder/cube sample

on job site

Quality Controls & Tests

New & Rehab Lightweight Concrete Applications Multifamily

Apartments Condos Hotels

Senior Living

Commercial Office Building Hospitals

Residential Custom Homes Radiant Heating

Solutions for Rehab Projects

Out of Level Substrates

Load Limited Structures

Sound Mat Option

Plaza Decks

Decorative Surfaces

Gypsum Concrete Stain the surface

Seal the surface

Cellular Concrete Integral Color

Stain the surface

Seal the surface

The Construction Trend….Lighter Weight Materials

Thinner Floors Gypsum Light Weight Concrete

Light Weight Decking

Light Weight Joists

Sound Control Issues

Airborne and Structure Borne Noise

Airborne = STC Structure Borne = IIC (Impact Noise)

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

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

• Intensity, or loudness

• Generally expressed in dB’s

• dB’s = a range of sound from very quiet to very loud

• dB, dBA, dBC, others

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

Hard Finished Flooring Trends

Tile and Vinyl Tile

Hardwood and Laminate Floors

Concrete

Is Sound Control an Amenity ? Yes !

Poll of Residents - # 1 Preference Peace and Quiet

Biggest Problem – Vertical Sound Transmission Floor to Floor

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

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

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

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

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