■ Lightweight concrete, like that used on this

Miami postal facility, not only provides a sound

New substrate for membrane application, but it can

be formed to achieve proper slope without adding
tapered insulation.

Lightweight points. Advances in pumping equipment

and mixing ratios have provided materi-
als that are consistent in compressive
strength and density.

Concrete Advantages
There are several benefits for the use
of lightweight concrete on current roof

Technology applications. When provided with insula-

tion, a thermal R-value of R-30 can be eas-
ily achieved without insulation delamina-
tion, warping or attachment concerns. The
by John A. D’Annunzio lightweight concrete also provides a sound
substrate for membrane application, and
it can be formed to achieve proper slope
he use of lightweight con- increase can also be attributed to the without adding costly and complicated

T
crete as a roof decking economic and environmental advantag-
and insulation system has es that lightweight insulating concrete
expanded in the past five (LWIC) provides in roof assemblies. The
years. Increased usage increased use in specific regions of the
can be attributed to the country has spawned new technology to
recent industry-wide insulation short- meet the demands of the market from
ages and delamination deficiencies. The the economic and environmental stand-
tapered insulation. It also provides a high-
er fire rating for the system.
In addition, lightweight concrete pro-
vides the building owner with long-term
cost savings. Since the lightweight construc-
tion becomes part of the structure, replace-
ment is not required during remedial roof-
Lightweight Concrete
■ Concrecel USA® has developed patented pumping equipment that accurately weighs the ingredients
and mixes the foam and cement to achieve consistently blended batches of lightweight concrete.
ing applications, as is the case with insula-
tion. Rather, only the membrane removal is
required. This frees space in landfills and
substantially reduces removal costs, which
can be as high as 50 percent of the total
project costs.
In overall construction practices, light-
weight concrete is used to reduce the
dead load of a structure. The decrease
of the dead load allows the designer to
save costs through reduction in the size
of the columns, footings and other load-
bearing elements. The decrease in size
does not decrease strength. Lightweight
concrete can achieve similar strengths
as standard concrete, and it produces a
more efficient strength-to-weight ratio in
structural elements.
Lightweight concrete derives its name
from the fact that standard concrete typical-
ly weighs about 150 pounds per cubic yard,
whereas lightweight concrete could weigh
in the range of 90 to 120 pounds per cubic
yard. Insulated lightweight concrete could
weigh in the range of 20 to 70 pounds per
cubic yard.
The primary factor in decreasing the
weight per cubic yard is that aggregate — a
mainstay in standard concrete — is omitted
from most lightweight concrete composi-
tions. Lightweight concrete used in roof
deck construction typically consists of Port-
land cement, foam, water, and admixtures.
Lightweight insulating concrete includes
the application of expanded polystyrene
(EPS) insulation boards. The EPS insula-
tion must have a minimum density of 1
pound per cubic foot and have keyholes
properly spaced throughout the boards for
concrete flow through the boards.
Lightweight concrete is typically applied
as composite slabs over vented metal decks
that meet the requirements of ASTM A653
and are of the proper type and gauge to
withstand the structural live and dead
loads for the facility. Lightweight concrete
can also be applied as a topping slab over
structural concrete decks. In LWIC applica-
tions, the EPS board is set in a slurry coat
of lightweight concrete and allowed to set
up for up to 24 hours. The lightweight con-
crete is then poured over the EPS on the
following day. The thickness and density
of the lightweight pour depends on slope
factors and height requirements at exist-
ing penetrations, flashings and perimeter
edges. The lightweight concrete pour is
typically a minimum of 2 inches when it is
applied over the EPS board.
Disadvantages
Lightweight concrete applications do
have limitations and associated liabilities.
The system is installed on site and a suc-
cessful application depends on the skill of
the installing contractor. As with all site-
installed materials, the quality of the fin-
ished product is based on the skill level of
the applicator. Lightweight concrete has
additional constraints because the success
of the system is based on the proper mix
ratio. An improper mix can create voids in
the concrete that lead to deficiencies.
One of the major disadvantages of light-
weight concrete has been the inability to
provide consistent compressive strengths
and density throughout the entire area.
Lightweight concrete derives its com-
pressive strength from the molecules in
the foam additive that — when properly
mixed — form around the cement and
serve as aggregate does in standard con-
crete mixes. If the foam additive is not
properly mixed, there is a probability of
foam collapse, which weakens the prod-
uct’s compressive strength.
A contributing factor of failure has been
that the mixes are compiled by hand at the
jobsite and are thus prone to human error.
To eliminate this problem, Concrecel USA®
has developed new pumping equipment
that accurately weighs the ingredients and
mixes the foam and cement through equal
spacing to achieve a consistently blend-
ed batch every time. Concrecel USA has
national and international patents and pat-
ents pending on the pumping equipment.
New Technology
The importance of the pour consisten-
cy is determined in fastener pullout tests
that are required to determine the holding
strength of the lightweight concrete. David
Gembala, the president of Concrecel USA,
explained that the consistency of the mix
provided by his company’s technology pro-
vides outstanding pullout values. “Within
12 hours (not the industry standard 36
hours), the Concrecel USA lightweight can
reach pullout values of 100 pounds,” he
said, noting that the industry requirement
is 45 pounds after 36 hours. Concrecel USA
has reached 200 pounds after 24 to 36
hours, he notes.
The high compressive strength is pro-
duced by a combination of the consistent
mix and a low water-to-cement ratio. “We
use less water per mix than other light-
weight insulating concretes,” stated Gem-
bala. “This allows the moisture content to
reach ambient equilibrium in less than 14
 Lightweight Concrete

days. We have had projects were it reached

equilibrium within six days.” The low
water content also provides higher bond
strength to other surfaces, such as metal
and concrete decks.
The pumping equipment is fully auto-
mated. It measures the foam and weighs
the cement and is housed in a safe self-
contained unit. According to John Nocella
of Concrecel USA, “We believe that this
is a revolutionary self-contained concrete
mixer, foam generator and pump housed in
a Department of Transportation-approved
mobile application system.” The pumping
equipment has a high yield and the capaci-
ty to produce 50 percent more product than
competitors’ pumps, allowing for double
the productivity on the job while producing
up to 65 batches per hour. The foam used
is of high quality and is environmentally
safe, according to the company.
The equipment is designed with mainte-
nance in mind. “If there is a malfunction,
the equipment is set up for quick repairs,” ■ The Concrecel USA pumping equipment is fully automated and self-contained. It measures the foam
Nocella said. “It can be field maintained and weighs the cement, and it has the capacity to produce up to 65 batches per hour.
with virtually no project downtime.”
problem sample has a thinner concrete wall and new product development is the core
LWIC Testing between the voids.” The Concrecel sample emphasis of the company,” said Gembala.
In 2004, Concrecel USA sent samples illustrated consistency in foam distribution Concrecel USA has joined with the devel-
of different lightweight pours to the and there were no voids. The competitor’s opers of a metal blocking system (ARBS)
Material Analysis Group Inc. in Suwanee, sample illustrated an even distribution of and Advanced Roof Systems to promote roof
Ga., for product comparisons. A sample void sizes throughout the sample. Accord- assemblies that meet high-velocity wind
of Concrecel USA’s pour, in block form, ing to Hubbard, “The void distribution conditions. Gembala feels that the asso-
was sent with a sample of a competitor’s at the top surface of the problem sample ciation of roof systems incorporating light-
pour. The materials (LW blocks) were leaves a thin surface layer that is weak weight insulating concrete, ARBS blocking
not identified so that testing person- compared to the good sample.” Test results and Advanced Roof Systems’ workman-
nel remained unbiased throughout the revealed that the thickness and the density ship will provide the necessary attachment
test procedures. The samples of both of the concrete in the Concrecel sample requirements to meet the most stringent
materials were examined using an opti- remained consistent throughout. high-velocity wind codes. The focus of the
cal microscope and a scanning electron product and system development has been
microscope (SEM) and analyzed for ele- Concrecel USA to minimize the exposure to roof damage for
mental content in the SEM using energy Concrecel USA has obtained approv- insurance companies and building owners.
dispersive X-ray (EDX) spectroscopy. als from Factory Mutual, Underwriters “ARBS has been on the Florida and Carib-
The testing concluded that although Laboratories and Miami-Dade County. The bean markets for the past five years and has
there were similarities in the sample mixes focus of the company has been on product not experienced any damage from the recent
and the concrete structure appeared good development. The company was formed by hurricanes,” Gembala states. Gembala also
in both samples, there were some differ- experienced roofing contractors and light- notes that Concrecel USA is open to working
ences. The testing agency found discrepan- weight concrete experts with a combined with other roof membrane manufacturers in
cies in the competitor’s sample (fractures industry experience level of over 200-plus the continuation of the system development.
and voids) that could contribute to failure. years. In the past 25 years, the company “We are committed to continual implemen-
James Hubbard, the senior consultant of has maintained its commitment to provid- tation of new products and application
MAGI, reported, “The problem sample has ing revolutionary high-quality products methods and we welcome other manufac-
a lower density than the good product and that have been developed through exten- turers participation with the program.”
the size of the voids produced by the foam sive research and development. “Research Concrecel USA also intends to expand
introduced into the product is such that the and development is continually ongoing, its contractor base in 2007. The company
Lightweight Concrete
is currently working with two Florida-
based contractors on a pilot program.
Each of the contractors has completed
over $5 million a year in Concrecel USA
system applications. “The success of the
pilot program has provided incentive to
expand the program into other regions,”
Gembala says.
Beginning at the International Roof-
ing Expo in March, Concrecel USA will
be seeking a limited number of proven
contractors throughout the costal regions
from New York to California to be part
of a network of applicators. Gembala is
quick to point out that “expansion into
Middle America will also be considered if
the interest is there.”
Reprinted with permission from Roofing Contractor, March 2007 © 2007, BNP Media.
Approved applicators will be provid-
ed with the patented lightweight pump
equipment and application rights for all
associated products and systems. Through
their headquarters in Florida, Concrecel
USA will furnish the applicators with all
technical and training requirements. Con-
crecel USA will also provide a centralized
ordering system for all materials, parts and
system components. This will help reduce
material costs from price breaks obtained
through bulk ordering. The company has
also set up an estimating department that
will be helping the applicators obtain proj-
ects in their regions. For more information
about Concrecel USA, call 866-981-5942 or
visit www.concrecelusa.com.
The advancements in lightweight pump-
ing equipment that Concrecel USA has
developed will be a benefit to the industry.
As Concrecel USA and other lightweight
concrete manufacturers strive for techno-
logical advancements, the resulting compe-
tition will provide lightweight concrete that
is consistent in density and strength. As the
product improves, use will increase, to the
benefit of building owners, contractors, and
the roofing industry.
John A. D’Annunzio is president of IRT
Inc., with offices in Florida and Michigan.
For more information, call 954-630-0201,
e-mail jdannunzio@irtarcon.com or visit
www.irtarcon.com.