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3230 Matthew Ave., N.E., Albuquerque, NM 87107 Tel.: (505) 837-1112 Fax: (505) 837-1529 |
PERLITE CONCRETE ROOF DECKS ROOF INSULATION
Perlite concrete roof deck insulation is an ideal base for built-up and
single-ply roofing systems. It has superior wind and fire resistance over other
roof insulation materials and with the addition of polystyrene insulation board
sandwiched in the perlite concrete, high thermal resistance values, are
economically achieved.
Positive drainage is easily accomplished by varying the thickness of perlite
concrete or by stair stepping different thicknesses of polystyrene insulation
board and then covering it with a uniform layer of perlite concrete.
Perlite concrete insulation may be placed over vented or slotted galvanized
steeldecking, precast or poured-in-place concrete, or existing roofing materials
providing a seamless, smooth, and hard surface ready for roofing. If exposed to
water it will not deteriorate.
REROOFING BASE
Perlite concrete insulation is ideally suited for reroofing applications. It
provides permanent, cost effective, slope-to-drain designs with high R-values
over flat and often-irregular substrates found in reroofing projects. Using a
perlite concrete slurry coat, the polystyrene insulation board is positively
attached to the substrate and covered with a uniform layer of perlite concrete
insulation. If the existing substrate is sound and capable of the additional
loading required, then the perlite concrete insulation can be applied to the
existing roof thereby eliminating costly tearoffs.
R-VALUE1, U-FACTOR2 AND DEADLOAD
TABLE3
FOOTNOTES:
LIGHTWEIGHT AND
INSULATING
BASED ON 1:6 MIX RATIO, 24-30 PCF PERLITE INSULATING
CONCRETE
2 INCHES OF
PERLITE CONCRETE
OVER
POLYSTYRENE
THICKNESS IN INCHES
DEPTH OF CORRUGATIONS
STRUCTURAL
CONCRETE 4 INCHES
26 GAUGE 15/16 INCH
24 GAUGE 1-5/16 INCH
22 GAUGE 1-1/2 INCH
R
U
D.L.
R
U
D.L.
R
U
D.L.
R
U
D.L.
0
3.9
.187
5.87
4.1
.177
6.65
4.1
.180
6.85
3.1
.216
4.00
1
7.9
.106
6.20
8.2
.103
6.98
8.1
.104
7.18
7.2
.115
4.33
2
11.7
.075
6.28
12.0
.074
7.06
12.0
.074
7.26
11.0
.080
4.41
3
15.6
.058
6.36
15.9
.058
7.14
15.8
.058
7.34
14.9
.061
4.49
4
19.4
.048
6.44
19.7
.047
7.22
19.7
.047
7.42
18.7
.049
4.57
5
23.3
.040
6.52
23.6
.040
7.30
23.5
.040
7.50
22.6
.042
4.65
6
27.1
.035
6.60
27.4
.035
7.38
27.4
.035
7.58
26.4
.036
4.73
of metal, polystyrene and perlite concrete
roof insulation. Dead loads of structural concrete are not included.
NOTES:
- Insulation values are for summer conditions, heat flow down. To calculate
winter conditions, heat flow up, substract 0.39 from the R-value, then add 1.5
for air films and roof, and divide into 1 for the U-value.
- U factors are based on series-parallel heat flow caluculations defined in the ASHRAE Handbook of Fundamentals and on test data by recognized, independent test laboratories. Thermal conductivities of roof deck components are based on 400F mean temperature except perlite concrete which is based on 750F
.- Perlite concrete properties are bsed on constant thickness insulation. For sloped insulattion, calculate average thickness.
- The U factors shown are calculations based on thermal conductivity data derived from laboratory testing of dry materials in accordance with ASTM Specification C 177. The values shown are intended only as guidelines. Actual insulation performance for all materials and systems is affected by design of building, environment, and installation, and will be lower than calculated values.
TESTING AND APPROVALS
Perlite roof deck insulation systems have been tested and approved for wind and fire ratings by Underwriters Laboratories, Factory Mutual, and other code authorities. The system is rated as non-combustible by Factory Mutual. U.L. Design P-920 successfully achieved the first 2-hour rating for any system of this kind under full scale fire conditions. Perlite concrete roof decks with polystyrene insulation board meet criteria for U.L. Class 90 and FM 190 wind resistance.
CODE APPROVALS AND GUIDE REFERENCES
- International Conference of Building Officials (ICBO)
- Building Conference of America (BOCA)
- Southern Building Code Congress (SBCC)
- South Florida Building Code
- Ferderal Construction Guide Specification FCGS 03501
- U.S. Army Corps of Engineers Guide Specificatoins: CEGS 03510
TECHNICAL SUPPORT
- FM I-90 Wind Uplist
- FM Serial Report No. OC2AO-AC
- U.L. Wind Uplift Construction No. 143
- U.L. Wind Uplift Construction No. 250
- U.L. Fire Rated Designs
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U.L. FIRE RATED SYSTEMS | ||
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P405 -- 3 HOURS P406 -- 3 HOURS P215 -- 2 HOURS P241 -- 2 HOURS P251 -- 2 HOURS P407 -- 2 HOURS P410 -- 2 HOURS P708 -- 2 HOURS P810 -- 2 HOURS P812 -- 2 HOURS |
P902 -- 2 HOURS P905 -- 2 HOURS P907 -- 2 HOURS P908 -- 2 HOURS P910 -- 2 HOURS P913 -- 2 HOURS P916 -- 2 HOURS P920 -- 2 HOURS P921 -- 2 HOURS P922 -- 2 HOURS P923 -- 2 HOURS |
P231 -- 1-1/2 HOURS P513 -- 1-1/2 HOURS P919 -- 1-1/2 HOURS P214 -- 1 HOUR P216 -- 1 HOUR P246 -- 1 HOUR P509 -- 1 HOUR P511 -- 1 HOUR P678 -- 1 HOUR P903 -- 1 HOUR |
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AGGREGATE RATIO (BY VOLUME) |
RANGE LB/FT3 |
COMPRESSIVE STRENGTH LB/IN2 |
RANGE LB/FT3 |
FT3 |
FT3 |
GALLONS |
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| 1:4 | 36-42 | 300 | 48-56 | 6.75 | 27 | 61 | (a) |
| 1:6b | 24-30 | 125 | 38-44 | 4.5 | 27 | 54 | (a) |
| 1:8 | 18-24 | 80 | 34-40 | 3.5 | 27 | 50 | (a) |
FOOTNOTES AND NOTES:
a)Consult your perlite manufacturer for recommended types and
proportioning of air entraining agent.
Whatever type and proportion is
used, try to obtain 10-15 percent air in the wet mix.
Ask your perlite supplier for more information about these mix designs, or contact:
Perlite concrete aggregate combined with portland cement and water produces a lightweight insulating concrete used for lightweight roof decks, floor fills, lightweight structural decks, insulation for steam and coolant lines, bases of cryogenic storage tanks, oven insulation, interstitial spaces in reconditioned water and sewer lines, interstitial floors in hospitals, lightweight pre-cast forms and blocks, statuary, basic fills, and many other applications where a lightweight permanent concrete is desired. Although many uses could be described in greater detail, the most common and well-established use has been for insulating flat roof decks, and much of the information later on this page has been focusing only on this particular use.