Alamein Downtown Towers

SECTION 035216 - LIGHTWEIGHT INSULATING CONCRETE

PART 1 - GENERAL

1.1 RELATED DOCUMENTS

A. Drawings and general provisions of the Contract, including General and Supplementary
Conditions and Division 01 Specification Sections, apply to this Section.

1.2 SUMMARY

A. This Section includes Cast-in-place cellular-type lightweight insulating concrete for roof
decks.

1. Use for providing deck slopes in all roofs indicated on Drawings.

B. Related Sections include the following:

1. Division 03 Section "Cast-in-Place Concrete" for structural lightweight concrete.

2. Division 07 Section "Ethylene-Propylene-Diene-Monomer (EPDM) Roofing" for
sheet roofing waterproofing, roof insulation and roofing ancillary layers and acces-
sories.

1.3 DEFINITIONS

A. Lightweight Insulating Concrete: Low-density concrete, with an oven-dry unit weight not
exceeding 800 kg/cu. m, placed with or without embedded rigid insulation board.

1. Cellular Lightweight Concrete: Low-density concrete made with portland cement,

water, and air-producing foaming agents.

1.4 ACTION SUBMITTALS

A. General: Submit in compliance with Division 01 Section “Submittal Procedures.”

B. Product Data: For each type of product indicated. Include mixing and application
instructions for each type of lightweight insulating concrete.

1. Comply with Division 01 Section "Product Requirements".

C. Shop Drawings: Include plans, sections, and details showing roof slopes, lightweight
insulating concrete thicknesses, embedded insulation board, roof penetrations, roof
perimeter terminations and curbs, control and expansion joints, and roof drains.

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1.5 INFORMATIONAL SUBMITTALS

A. Design Mixtures: For each lightweight insulating concrete mix.

B. Qualification Data: For Installer and testing agency.

1. Qualification data for firms and persons specified in "Quality Assurance" article to
demonstrate their capabilities and experience. Include list of completed projects with
project name, addresses, names of Engineer and Employers, and other information
specified.
2. For Testing Agency Qualifications include proof of qualifications in the form of a
recent report on the inspection of the testing agency by a recognized authority.

C. Material Test Reports: For lightweight aggregates, from a qualified testing agency,
indicating compliance with requirements. Test report shall include manufacturer name and
contacts in addition to tested product name and detailed description.

D. Product Certificates: For each of the following, signed by manufacturers:

1. Cementitious materials.
2. Foaming agents.
3. Admixtures.

E. Method statement for mixing, placing, curing and surface finishing of lightweight insulating
concrete.

F. Field quality-control test reports.

1.6 LOCAL REGULATIONS AND CODES

A. Comply with applicable requirements of the laws, codes, and regulations of authorities
having jurisdiction.

1. Obtain necessary approvals from authorities having jurisdiction.

2. Comply with Egyptian Codes and Standards requirements and latest circulars.

1.7 QUALITY ASSURANCE

A. General: Comply with Division 01 Section “Quality Requirements.”

B. Manufacturer Qualifications: A firm experienced in manufacturing products or systems

similar to those indicated for this Project and with a record of successful in-service
performance, as well as sufficient production capacity to produce required units. As
applicable, procure products from manufacturers able to meet qualification requirements,
warranty requirements, and technical or factory-authorized service representative
requirements. Experience: Minimum of 10 years.

C. Installer Qualifications: An entity that employs installers and supervisors who are trained
and approved by manufacturer.

D. Testing Agency Qualifications: Qualified according to ASTM C1077 and ASTM E329 for

testing indicated.

E. Preinstallation Conference: Conduct conference at Project site.

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1.8 DELIVERY, STORAGE, AND HANDLING

A. Deliver materials in manufacturer's original undamaged packages or acceptable bulk

containers.

B. Store packaged materials to protect them from elements or physical damage.

C. Do not use cement that shows indications of moisture damage, caking, or other
deterioration.

1.9 PROJECT CONDITIONS

A. Do not place lightweight insulating concrete during rain or on surfaces covered with
standing water.

1.10 WARRANTY

A. Comply with Division 01 Section "Warranties".

B. Special Warranty:  Provide complete system warranty in which Manufacturer, Installer, and
Contractor are jointly and severally responsible and to replace lightweight insulating
concrete that fail in materials or workmanship within specified warranty period.

1. Warranty Period:  5 years from date of Substantial Completion.

PART 2 - PRODUCTS

2.1 MATERIALS

A. Cementitious Material: Portland cement, ASTM C 150, Type I.

B. Foaming Agent: ASTM C 869.

C. Water: Clean, potable.

D. Joint Filler: ASTM C 612, Class 2, glass-fiber type; compressing to one-half thickness

under a load of 172 kPa.

E. Separation and Protection Layer: Polyethylene sheeting, ASTM D 4397, 0.15 mm thick.

F. Curing Materials: As proposed by Contractor based on the curing system selected by him.

2.2 DESIGN MIXTURES

A. Prepare design mixtures for each type and strength of lightweight insulating concrete by
laboratory trial batch method or by field-test data method. For trial batch method, use a
qualified independent testing agency for preparing and reporting proposed mixture designs.

B. Limit water-soluble chloride ions to the maximum percentage by weight of cement or

cementitious material permitted by ACI 301.

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2.3 CELLULAR LIGHTWEIGHT INSULATING CONCRETE

A. Produce cellular lightweight insulating concrete with the following minimum physical
properties using cementitious materials, air-producing liquid-foaming agents, and the
minimum amount of water necessary to produce a workable mix.

1. As-Cast Unit Weight: 640 to 770 kg/cu. m at point of placement, when tested
according to ASTM C 138/C 138M.
2. Oven-Dry Unit Weight: 510 to 640 kg/cu. m, when tested according to
ASTM C 495.
3. Compressive Strength: Minimum 5 MPa, when tested according to ASTM C 495.

PART 3 - EXECUTION

3.1 PREPARATION

A. Control Joints: Install control joints at perimeter of roof deck and at junctures with vertical
surfaces, including curbs, walls, and vents, for full depth of lightweight insulating concrete.
Fill control joints with joint filler.

1. Provide 25-mm- wide control joints for roof dimensions up to 30 m in length; 38-
mm- wide control joints for roof dimensions exceeding 30 m.

3.2 MIXING AND PLACING

A. Mix and place lightweight insulating concrete according to manufacturer's written

instructions, using equipment and procedures to avoid segregation of mixture and loss of air
content.

B. Deposit and screed lightweight insulating concrete in a continuous operation until an entire
panel or section of roof area is completed. Do not vibrate or work mix except for screeding
or floating. Place to depths and slopes indicated.

C. Finish top surface smooth, free of ridges and depressions, and maintain surface in condition
to receive subsequent roofing system.

D. Begin curing operations immediately after placement, and air cure for not less than three
days, according to manufacturer's written instructions.

E. Thickness:

1. Roof Screed: As indicated on Drawings according to roof slopes shown. Minimum

thickness at drains is to be 30-40 mm.

F. Roof Screed: Place screed continuously in a single layer, tamping and consolidating to
achieve tight contact with bonding surface. Do not permit cold joints or seams to develop
within pour strip.

1. Screed surface with a straightedge and strike off to correct elevations.

2. Slope surfaces uniformly where indicated or where necessary to drain surface water
to floor drains.
3. Begin initial floating using bull floats to form a uniform and open-textured surface
plane free of humps or hollows.

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G. Finish top surface smooth, free of ridges and depressions, and maintain surface in condition
to receive subsequent roofing system.

H. Begin curing operations immediately after placement, and air cure for not less than three
days, according to the approved method statement.

3.3 FIELD QUALITY CONTROL

A. Testing Agency: Engage a qualified independent testing and inspecting agency to sample
materials, perform field tests and inspections, and prepare test reports.

B. Testing of samples of lightweight insulating concrete obtained according to ASTM C 172,

except as modified by ASTM C 495, shall be performed according to the following
requirements:

1. Determine as-cast unit weight during each hour of placement, according to

ASTM C 138/C 138M.
2. Determine oven-dry unit weight and compressive strength according to ASTM C 495.
Make a set of at least six molds for each day's placement, but not less than one set of
molds for each 450 sq. m of roof area.
3. Perform additional tests when test results indicate that as-cast unit weight, oven-dry
unit weight, compressive strength, or other requirements have not been met.

a. Retest cast-in-place lightweight insulating concrete for oven-dry unit weight

and compressive strength.

3.4 DEFECTIVE WORK

A. Refinish, or remove and replace, lightweight insulating concrete if surfaces are excessively
scaled or too rough to receive roofing according to roofing membrane manufacturer's
written instructions.

B. Remove and replace lightweight insulating concrete that fails to comply with requirements.

END OF SECTION 035216

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