PERLITE
CONCRETE
ROOF DECKS
SCHUNDLER

MIX DESIGNS
INSULATION VALUES
CONSTRUCTION GUIDE
The Schundler Company
150 Whitman Avenue, P.O. Box 513
Metuchen, New Jersey 08840-0513
732-287-2244 www.schundler.com



PERLITE CONCRETE ROOF DECKS

LIGHTWEIGHT AND INSULATING


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
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
FOOTNOTES:

  1. R Values are expressed as 0F.ft2h/Btu.
  2. U Factors expressed as Btu/h.ft20F. Includes air films and roofing.
  3. Dead Loads include weight 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 based on constant thickness insulation. For sloped insulation, 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

U.L. FIRE RATED SYSTEMS
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




PHYSICAL PROPERTIES AND MIX PROPORTIONS FOR PERLITE CONCRETE

TYPICAL PROPERTIES
TYPICAL MIX PROPORTIONS
CEMENT TO
AGGREGATE RATIO
(BY VOLUME)
DRY DENSITY
RANGE
LB/FT3
MINIMUM
COMPRESSIVE
STRENGTH
LB/IN2
WET DENSITY
RANGE
LB/FT3
CEMENT
FT3
PERLITE
FT3
WATER
GALLONS
AEA
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.
  • (b)The 1:6 mix ratio is the standard mix used on most roof deck applications.

Ask your perlite supplier for more information about these mix designs, or contact: The Perlite Institute



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.

Another site with lots of useful information about perlite concrete complete with can be found at The ConDeck Corporation


For more information, please call or contact:

The Schundler Company
150 Whitman Avenue
Edison, New Jersey 08817
732-287-2244 or www.schundler.com
mailto:info@schundler.com

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