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HomeMy WebLinkAboutEvaluation ReportILE ER-5703 REPORTT'" Reissued September 1, 2002 ICBO Evaluation Service, Inc. - 5360 Workman Mill Road, Whittier, California 90601 - www.icboes.org Filing Category: INSULATION HUNTSMAN EXPANDABLE POLYSTYRENE BEADS 2. There are no interconnected attic or basement areas. HUNTSMAN CORPORATION 3. Air in the attic or crawl space is not circulated to other 3040 POST OAK BLVD, l:: parts of the building. HOUSTON, TEXAS 7705 T t i j k 'y's,4 1.0 SUBJECT Huntsman Grades 54 and 40 Expandable Polystyrene Beads. 2.0 DESCRIPTION 2.1 General: Expandable polystyrene beads designated as Huntsman Grades 54 and 40, produced by Huntsman Corporation, are used by independent manufacturers in producing expanded polystyrene (EPS) insulation board. Products are produced solely through the introduction of heat, without other additives. Boards manufactured from Grade 54 beads at a maximum density of 1.75 pcf (28 kg/m') and a maximum thickness of 5 inches (127 mm), and boards manufactured from Grade 40 beads at a maximum density of 2.0 pcf (32 kg/m') and a maximum thickness of 5 inches (127 mm), have a flame -spread rating of25 or less and a smoke -developed rating of 450 or less when tested in accordance with UBC Standard 8-1 (ASTM E 84). Boards manufactured from Grade 54 and Grade 40 beads at a maximum density of 2.0 pcf (32 kg/m') and a maximum thickness of 5 inches (127 mm) have a flame -spread rating of 25 or less and a smoke - developed rating of 450 or less when tested in accordance with UBC Standard 8-1 (ASTM E 84). Huntsman Grade 54 and Grade 40 expandable beads can be used to produce expanded polystyrene products that comply with Types I, II, VIII and IX [1.0, 1.5, 1.25 and 2.0 pcf (16, 24, 20 and 32 kg/m) nominal density, respectively] of ASTM C 578-95, provided the final product is recognized in a current ICBO ES evaluation report and has been qualified in accordance with Section 6.11.1.2 of the ICBO ES Acceptance Criteria for Foam Plastic Insulation (AC12). 2.2 Installation: 2.2.1 General: Foam plastic boards produced from the Huntsman beads must be installed in accordance with the ICBO ES evaluation report on the boards and the applicable code. 2.2.2 Special Use: Foam plastic boards produced from the Huntsman Grade 54 beads can be used on walls in attics and crawl spaces with no covering applied to the attic or crawl space side of the foam plastic, provided all of the following conditions are met: 1. Entry to the attic or crawl space is only to service utilities, and heat -producing appliances are not permitted. Attic ventilation is provided that complies with Section 1505 of the 1997 Uniform Building Coderm, Section 1202.2 of the 2000 International Building Code® or Section R806 of the 2000 International Residential Code®, as applicable. Under -floor ventilation is provided that complies with Section 2306.7 of the UBC, Section 2304.11.9 of the IBC or Section R408.1 of the IRC, as applicable. 5. Boards produced from Grade 54 beads have a maximum thickness of 3 inches (76 mm) for 1.0 pcf (16.0 kg/m') density boards and a maximum thickness of 3 inches (76 mm) for 2.0 pcf (32 kg/m') density boards. 2.3 Identification: Each container of beads bears a label with the Huntsman Corporation name and address, the bead identification, the evaluation report number (ICBO ES ER-5703) and the name of the quality control agency (Underwriters Laboratories Inc.). 3.0 EVIDENCE SUBMITTED Reports of tests in accordance with UBC Standard 8-1 (ASTM E 84), ASTM C 578-95, and NFPA 259-98; reports of comparative crawl space fire tests; and a quality control manual. 4.0 FINDINGS That the Huntsman expandable polystyrene beads described in this report comply with the 1997 Uniform Building CodeTM (UBC), the 2000 International Building Code® (IBC) and the 2000 International Residential Code® (IRC), subject to the following conditions: 4.1 The maximum density and thickness of the expanded beads are as noted in this report. 4.2 Use of the beads is limited to products recognized in an ICBO ES evaluation report 4.3 Except as noted in Section 2.2.2 of this report, the insulation boards produced from the Huntsman beads are separated from the building interior by a thermal barriercom plying with Section 2602.4 ofthe UBC, Section 2603.4 of the IBC or Section 318.1.2 of the IRC. 4.4 The beads are produced by Huntsman in Peru, Illinois, and Mansonville, Quebec, Canada, under a quality control program with inspections by Underwriters Laboratories Inc. (AA-668). This report is subject to re-examination it REPORTS -are not lu he cons mied as representing ,c,Ihvd,c nr miv other ntbthwes not specifically oddre•sce•d. nor are ihey to he construed as an endorsement o/ the snhyi i of the report, or it rcc ammendation for cis rise There it no warrnmt)• by ATO 1•. volua Iron Service. Inc.. express or Implied, n.v to amp hndrn.l or other ma tier in this reporr, or a.! Io any product covered by the repo ri. Copyright © 2002 two years. Page 1 of 1 ICC-ES Evaluation Report ESR-2195 Reissued March 1, 2013 This report is subject to February 1, 2015. www.icc-es,orq 1 (800) 423-6587 1 (562) 699.0543 A Subsidiary of the International Code Council° DIVISION: 07 00 00—THERMAL AND MOISTURE PROTECTION Section: 07 21 00—Thermal Insulation REPORT HOLDER: CHEIL INDUSTRIES INC. 332-2, GOCHEON-DONG, UIWANG-SI GYEONGGI-DO, 437-711 KOREA (82) 31-596-3671 www.st,arex.co.kir EVALUATION SUBJECT: STAREX SF GRADE H AND .L EXPANDABLE POLYSTYRENE BEADS 1,0 EVALUATION SCOPE Compliance with the following codes: ■ 2012, 2009 and 2006 International Building Code" (IBC) ■ 2012, 2009 and 2006 International Residential Code° (IRC) ■ 1997 Uniform Building CodeT"' (UBC) Properties evaluated: ■ Surface -burning characteristics ■ Physical properties ■ Attic and crawl space installation 2.0 USES Starex SF Grade H and L expandable polystyrene beads are used by independent manufacturers to produce expanded polystyrene (EPS) insulation products. 3.0 DESCRIPTION EPS insulation products manufactured with the beads are produced through the introduction of heat, without additives. This process expands the beads, which are then molded into insulation products. At thicknesses and densities specified in Table 1, EPS insulation products produced from the beads have a flame -spread index of 25 or less and a smoke -developed index of 450 or less when tested in accordance with ASTM E84 (UBC Standard 8-1). The end use of the beads, including the manufacture of the EPS products, is outside the scope of this report and must be addressed in product -specific evaluation reports. SF Grade H and L beads have been qualified in accordance with Section 4.5.15.1.1 of the [CC -ES Acceptance Criteria for Foam Plastic Insulation (AC12). The beads can be used to produce EPS products that comply with ASTM C578, for the types specified in Table 1, provided the final product is recognized in a current ICC- ES evaluation report and has been qualified in accordance with Section 4.5.15.1.2 of AC12. 4.0 INSTALLATION Installation must be as noted in the corresponding current ICC-ES evaluation report on the EPS insulation product, or as otherwise permitted by the code official under IBC Section 2603, 2012 and 2009 IRC Section R316, 2006 IRC Section R314 or UBC Section 2602, as applicable. . 4.1 Attics and Crawl Spaces: EPS insulation products produced from EPS beads of the resin type, density, and thickness shown in Table 2 of this report can be used on walls in attics and crawl spaces without a code -prescribed ignition barrier applied to the attic or crawl space side of the foam plastic, provided all of the following conditions are met: a. Entry to the attic or crawl space is only to service utilities, and no storage is permitted. b. There are no interconnected attic or crawl space areas. c. Air in the attic or crawl space is not circulated to other parts of the building. d. Attic ventilation is provided in accordance with IBC Section 1203.2 or IRC Section R806, as applicable. e. Under -floor (crawl space) ventilation is provided in accordance with IBC Section 1203.3 or IRC Section R408.1, as applicable. f. Combustion air is provided in accordance with IMC (International Mechanical Code) Section 701. g. Maximum thickness and density are limited to values listed in Table 2. 5.0 CONDITIONS OF USE The expandable polystyrene beads described in this report comply with, or are suitable alternatives to what is specified in, those codes listed in Section 1.0 of this report, subject to the following conditions: 5.1 The nominal density and thickness of EPS insulation products produced from the expanded beads must be as indicated in Tables 1 and 2. 1CC-ES Evaluation Kepom are nor to be cossmued as representing aesdzetics or am other am-ibutes nor specij`tcalh addressed, nor are then to be construed as an endorsemnt eofrhe subiec, o(rhe repot o' a recommendation,%o' its use, There is no xan•ann• by ICC Evaluation Se -vice, Inc., express or unplied, as to am;/indnzg or other matter in this report, or as to ann product covered by the repot Copyright © 2013 fm- 'e`= Pagel of 2 ESR-2195 I Most Widely Accepted and Trusted Page 2 of 2 6.2 Products manufactured from the beads must be 6.0 EVIDENCE SUBMITTED recognized in a current ICC-ES evaluation report. Data in accordance with the ICC-ES Acceptance Criteria 5.3 Except as noted in Section 4.2, EPS insulation for Foam Plastic Insulation (AC12), dated June 2012, products produced from the beads must be separated including reports of tests in accordance with Appendix B of from the building interior by a thermal barrier AC12. complying with IBC Section 2603.4, 2012 and 2009 7.0 IDENTIFICATION IRC Section R316.4, 2006 IRC Section R314.1.2, and Each container of beads must be labeled with the UBC Section 2602.4, as applicable. manufacturer's name (Cheil Industries Inc.) and address, 5.4 The beads are manufactured in Yosu-Si, Cheon Nam, the bead type, the name of the inspection agency (Intertek Korea, under a quality control program with Testing Services NA Inc.) and the evaluation report inspections by Intertek Testing Services NA Inc. number (ESR-2195). (AA-690). TABLE 1—ALLOWABLE EPS PRODUCT DENSITY AND THICKNESS EPS TYPE' MINIMUM DENSITY (pcf) MAXIMUM THICKNESS (in) 1 0.90 6 11 1.35 6 II (High Density) 1.60 6 VIII 1.15 6 IX 1.80 6 For SI: 1 pcf = 16.02 kg/m', 1 inch = 25.4 mm. 'Type as designated in ASTM C578. TABLE 2— MAXIMUM DENSITY AND MAXIMUM THICKNESS FOR EPS PRODUCTS USED IN ATTICS OR CRAWL SPACES MAXIMUM DENSITY MAXIMUM THICKNESS (inches) FOR STAREX SF GRADE H AND L (pcf) 2.0 3 For SI: 1 pcf = 16.02 kg/m3, 1 inch = 25.4 mm. Technical Bulletin No. 7-7.3 MTSMA� Page lof3 Flammability, Combustibility, Toxicity FLAMMABILITY Both the expandable polystyrene and expanded polystyrene products must be considered combustible when directly exposed to fire of sufficient intensity and heat. Therefore, neither should be stored nor installed near open flame or ignition sources. The modified grades of expandable polystyrene contain flame -retardants designed to decrease flammability due to accidental ignition from a small flame source. The expanded polystyrene manufactured from these products have been tested in numerous small scale fire tests and meet the requirements of the nation's building codes and applicable industrial, federal, and state requirements. THE RESULTS OF THESE TESTS ARE NOT INTENDED TO REFLECT HAZARDS UNDER ACTUAL FIRE CONDITIONS. Flammability Characteristics Recommended Maximum Use Temperature: 165°F (75°C) Melting Point: As a thermoplastic, polystyrene does not exhibit a true melting point. It will begin to soften at about 212°F (1001C) and, as more heat is applied, melting occurs. Flash Ignition Temperature*: The lowest initial temperature of air passing around a molded sample of EPS at which a sufficient amount of combustible "gas is evolved to be ignited (ASTM D 1929). Self Ignition Temperature*: The lowest initial temperature of air passing around the specimen at which, in the absence of an ignition source, the self -heating properties of the EPS lead to ignition or ignition occurs of itself. (ASTM D1929) Potential Heat of Building Materials ** A property -type measurement of the heat that could be potentially released Grade 40 from building materials when exposed to high heat exposure of 1382°F (7501C). (NFPA —259) * results as reported in Radco Test report No. RAD-2725 dated Feb. 2001 ** results as reported in SwRI project report No. 01.030490303 dated July 2000 698°F (370°C) 752°F (400°C) 17,293 BTU 17,269 BTU Grade 54 July 2001 Technical Bulletin No. 7-7.3 Page 2 of 3 COMBUSTION TOXICITY For over 20 years, the public has been concerned about the potentially hazardous effects of toxic fumes in building fires. Attention has focused on how construction materials can be reliably tested for combustion toxicity, and the meaning of those results relative to the overall hazard of the fires. There are currently two recognized tests —one developed at the University of Pittsburgh and the other at the National Bureau of Standards (NBS)—that yield consistent results and are reproducible from one laboratory to another. Both tests are based on the lethal effects of combustion gases on animals (rats or mice). The toxicity of smoke generated by the combustion of products has been defined as "the propensity of smoke to produce adverse biochemical or physiological affects." Toxicity is the study of degrees of effects in relation of degrees of dose; it is not an absolute. The nature of the products of combustion of a material are highly dependent upon the conditions of combustion.') A literature review of the combustion toxicity of expanded polystyrene by the Southwest Research Institute (SwRI) for the Society of the Plastics Industry, suggests that all the studies performed to date indicate that in laboratory tests the combustion products from expanded polystyrene are no more toxic than those from wood.(Z) It should be noted that the combustion products resulting from burning any organic material produces toxic gases such as carbon monoxide and carbon dioxide. Other gases may be produced from products containing elements other than carbon and hydrogen. Expanded polystyrene is an organic compound consisting of carbon and hydrogen and, consequently, one would expect that the products of combustion would be predominantly carbon dioxide and carbon monoxide. This was aptly shown in studies in the late 1970's utilizing Military Specification M-14-G wherein the following results were obtained: COMPOSITION OF THE PRODUCTS OF COMBUSTION (PPM) Product Expanded Polystyrene Standard Wood Hydrogen Chloride 0 0 Aldehydes as HCHO 0 0 Ammonia 0 0 Carbon Monoxide less than 10 119 Carbon Dioxide 500 13,500 Oxides of Nitrogen 4 10 Cyanides of HCN 0 0 July 2001 Technical Bulletin No. 7-7.3 Page 3 of 3 Degrees of Toxicity: Degrees of toxicity are frequently reported in terms of LC50. This term refers to the "concentration" of smoke that will produce Lethality of 50% of the test animals with a specified exposure, and possibly also including post exposure. In practice, the LC50 for combustion toxicity experiments has often been considered to be the amount of material charged to the furnace, rather than the concentration of smoke. TOXICITY BY CONTACT OR INGESTION Products molded from Huntsman expandable polystyrene are not toxic by contact or ingestion. Toxicity is a matter of degree, not an absolute, and is the ability of a substance to cause some degree of injury to a living organism. In other words, a toxic substance is one that produces some adverse physiological response that would not normally occur if that substance were not present in or on the organism. The responses may be as minor as a barely perceptible mold irritation or it may be lethal. In most cases, toxicity is markedly dose -dependent. As an example, Sax (3) lists toxicity hazard ratings for such common substances as baking powder, coffee, flour, whiskey and even ordinary table salt. These substances are not normally considered to be deadly, yet, under certain circumstances, they can cause permanent damage, even death to living organisms, including man. To present a better perspective, it is more accurate to describe materials of this sort as "hazardous under certain conditions". As with most industrial materials, some degree of hazard exists in the use, or more particularly, in the misuse of expandable and expanded polystyrene. The degree of hazard is influenced by the physical, chemical and physiological properties of the material and the circumstances of use or misuse. Expanded polystyrene can be, and has been, used with no apparent harmful effects when a potential hazard is recognized, suitable precautions are taken, and good housekeeping practices are maintained. REFERENCES (1) Stacy, H.W. Evaluation of the Toxic Potence of the Combustion Products of Polystyrene Materials. SwRI Project No. 01-1374-714 (2) Grand, A.F., H.L. Kapan, Hartzell, G.E. A Literature Review of the Combustion Toxicity of Expanded Polystyrene, SwRI Project No. 01-8818 507 (3) N.I. Sax, "Dangerous Properties of Industrial Materials" The information contained herein is provided for general.purposes only. By providing the information contained herein, Huntsman Expandable Polymers Company, L.C. makes no guaranty or warranty, and does not assume any liability with respect to the accuracy or completeness of such information, or the product results in any specific instance and hereby expressly disclaims any implied warranties of merchantability or fitness for a particular purpose, or any other warranties or representations whatsoever, expressed or implied. Nothing contained herein shall be construed as a license to use the products of Huntsman Expandable Polymers Company, L.C. in any manner that would infringe any patent. July 2001 Plastbaum Technology INSUL9*33ECK® 65 Grady Knight Industrial Blvd Villa Rica, GA 30180 Phone (727) 230-1717 Fax (727) 216-7946 Email insuldeck@insuldeck.com www.insuldeck.com Insul-Deck panels are steel -reinforced, foamed plastic insulation boards used as permanent, stay -in -place concrete formwork for floor and roof slab construction. Their properties are determined mostly by its main raw material, expanded polystyrene ("EPS") at a density of 1.25 PCF (Type VIII). The raw material vendor's evaluation and test reports, and any reports referenced below are available on request. The EPS is treated with a flame-retardant for use in building insulation. Most jurisdictions and building codes require that exposed foamed plastic insulation be covered with a minimum 15- minute rated thermal barrier, such as 112" gypsum drywall. 1. Surface Burning Characteristics - ASTM E84/ UL723 Flame Spread < 25 ; Smoke Developed < 450 (prior to floor ignition) per Preliminary Investigation report by Underwriters Laboratory Inc dated August 2.8, 2006. 2. Insulation Values - ASTM C578 Insul-Deck Size: 7" 8" 9" 10" 11" 12" 121/2 R-Value of EPS: 16 19 22 25 28 32 33 The R-Values were calculated based on the average EPS thickness (cross section) of the respective panel size (excluding holes, though they typically add to the installed insulation unless vented), Average EPS thickness was multiplied by the R-Value of Type VIII EPS board and rounded. Notes: Per ASTM C578, R-Value for Type VIII EPS is 3.8 per inch thickness @ 75°F. The ASHRAE Handbook allows using higher and more accurate R-Values for EPS, especially in cold conditions, in contrast to many other insulation materials that perform worse than advertised when heating or cooling is actually required. To determine the R-value of the concrete slab, concrete is about R-0.09 per inch thickness. 3. STC Sound Tests (Sound Transmission Loss — Airborne Noise) - ASTM E90 Four tests were performed on different floor tvoes as follows: Floor Tye STC 12" Floor Assembly 9" Insul-Deck and 3" Concrete 46 12" Floor Assembly 9" Insul-Deck and 3" Concrete + 1 layer 5/8" gypsum board 49 12" Floor Assembly (9" Insul-Deck and 3" Concrete) + 1 layer 5/8" gypsum board over resilient channel 50 12" Floor Assembly 9" Insul-Deck and 3" Concrete + 2 layers 5/8" gypsum board 53 Per reports by Architectural Testing dated January 23, 2007, testing Floor Assemblies with Insul-Deck Panels. 4. FIIC (Impact Sound Transmission Loss- Field Test) - ASTM E1007-04 Four tests were performed on different floor Woes as follows: Floor Type I FlIC 15" Floor Assembly 12" Insul-Deck and 3" Concrete raw floor with no finish on ceiling nor floor 17 15" Floor Assembly 12" Insul-Deck and 3" Concrete with 2 Layers of 5/8" Type X ceiling finish 26 15" Floor Assembly 12" Insul-Deck and 3" Concrete with 12" the on floor and Sheetrock ceiling finish 26 15" Floor Assembly (12" Insul-Deck and 3" Concrete) - with 5/8" Jute Carpet on floor and '/i' Sheetrock ceiling finish 70 Per report by Southwest Research Institute dated October 06, 2008, testing Floor -Ceiling Assemblies with Insul-Deck panels. 5. Fire Resistance Ratings Actual Fire Resistance Ratings shall be determined by the licensed professional engineer. The below ACI Fire Ratings were estimated based on Table 2.1 of ACI 216.1-97 and only consider the concrete slab thickness: Slab Thickness 3'/2" 1 41/2" 1 5" ACI Fire Rating 1 hour 1 1.5 hours 2 hours Copyright Insul-Deck@ LLC Plastbau(& Technology IINSUE9933ECK. 935 Main St. Suite A2 Safety Harbor, FL 34695 Phone (727) 230-1717 Fax (727) 216-7946 Email insuldeck@tilt-deck.com Web -site www.insul-deck.ort Insul-Deck Furring Strip Load Test Average Supported Load 410 lbs (max) by 1 (one) attachment point on,1 linear foot of metal strip Test Specimen Mounted in Load Testing Machine Excerpt of Test results Material/Background: • 10" Section of lnsul-Deck panel with molded in galvanized Metal Channels. • Load testing was performed to obtain failure data.. Test Procedure and Results: • The customer provided two 2 ft. sections of foam decking. • The sections were cut into 1 ft. sections in order to fit the test equipment. • the steel reinforcement was pulled perpendicular to the large decking surface. • 1-he part was loaded at a rate of 1.0 in/min. • The parts were loaded until the reinforcement was completely removed. • Maximum load data recorded during testing is resumed in Table below. Sample Number Maximum Load (lbs) Average 1 366 2 429 3 393 4 452 410 LBS Load Test was conducted and certified by APPLIED TECHNICAL SERVICES, INC of Marietta. Georgia. Test Date: March, 2008. A complete copy of Test results is available upon request. lnsul-Deck® by Plastbau® Technology A APPLIED TECHNICAL SERVICES, INCORPORATED COM 1049 Triad Court, Marietta, Georgia 30062 - (770) 423-1400 Fax (770) 424-6415 LOAD TESTING OF STEEL REINFORCED FOAM DECKING ATS JOB # D 122445-1 Rev. 1 * PURCHASE ORDER # VERBAL -MIKE NAPIER Prepared for GEORG HOFER INSUL-DECK, LLC 935 MAIN STREET BLDG. A SUITE 2 SAFETY HARBOR, FL 34695 f Prepared by Eric Shiner, Materials Testing Approved by awn Murray, Materia esting This Report May Not Be Reproduced Except In Full This report represents interpretation of the results obtained from the test specimen and is not to be construed as a Guaranty or Warranty of the condition of the entire material lot. Professional Engineers and Scientists Design - Consulting - Testing and Inspection Members in AAFS, ACS, ASM, ASAIE, ASNT, ASQC, ASTA ,, AWS, FSCT, MAL NACE, NCSL, NFPA, SAFS, TAPPI GEORGIA SOCIETY OF PROFESSIONAL ENGINEERS, NATIONAL SOCIETY OF PROFESSIONAL ENGINEERS APPLIED TECHNICAL SERVICES, INCORPORATED • ' " 1049 Triad Court, Marietta, Georgia 30062• (770) 423-1400 Fax (770) 424-6415 MATERIALS TEST REPORT Ref. D 122445-1 Rev I* Date: October 3, 2008 Page I of 4 Purchase Order # Verbal- Mike Napier Georg Hofer Insul-deck, LLC 935 Main Street Bldg. A Suite 2 Safety Harbor, FL 34695 Subject Load testing of steel reinforced foam decking for failure data Material Styrofoam with zinc plated steel reinforcement Objective and Background Load testing was performed to obtain failure data. The force required to pull the steel reinforcement from the foam decking was recorded. Test Procedure and Results The customer provided ATS with two 2 ft. sections of foam decking. The sections were cut into 1 ft. sections in order to fit the test equipment. The parts were mounted in a fixture which held the part in place at the radiused shoulder, as specified by the customer. This fixture was mounted on a tension/compression testing machine (see Figure 1). The steel reinforcement was then pulled perpendicular to the large decking surface. The part was loaded at a rate of 1.0 in/min. The parts were loaded until the reinforcement was completely removed. Maximum load data recorded during testing can be seen in Table 1. Photographs of test fixture and tested specimen can be seen in Figures 1-3. Sample Number Maximum Load (lbs 1 366 2 429 3 393 4 452 Table 1: Pull Test Data J APPLIED TECHNICAL SERVICES, INCORPORATED 1049 Triad Court, Marietta, Georgia 30062• (770) 423-1400 Fax (770) 424-6415 MATERIALS TEST REPORT Ref. D 122445-1 Rev I* Date: October 3, 2008 . Page 2 of 4 Discussion and Conclusions These data are compiled, presented, and to be analyzed by the customer. The average load required to pull the steel reinforcement from the decking was 410 lbs. X APPLIED TECHNICAL SERVICES, INCORPORATED 1049 "Triad Court, Marietta, Georgia 30062• (770) 423-1400 Fax (770) 424-6415 MATERIALS TEST REPORT Ref. D 122445-1 Rev 1 * Date: October 3, 2008 Page 3 of 4 f rr'c. �4✓'.'t`` ,rm "�Jf tr .r � "r Y 1 Sr�+lsry w N :4 1 Z k A uP C 7 yrrrkt k }rG �. •`'iG �.�r9 f s �, �r k '�. ., Y.r,.i,A` �.s='�i %� Figure 1: Test Specimen Mounted in Load Fixture Y { Fite Et {� r 4r3�, f f y��hGKr ¢�3 S CTi a t .. a . ''1,�yi vl Figure 2: Tested Specimen and Load Fixture 1 Eal APPLIED TECHNICAL SERVICES, INCORPORATED • ' ' ' 1049 Triad Court, Marietta, Georgia 30062• (770) 423-1400 Fax (770) 424-6415 MATERIALS TEST REPORT Ref. D122445-1 Rev 1* Date: October'3,2008 Page 4 of 4 Figure 3: Test Specimen and Fixture Mounted in Load Testing Machine Building with Insul-Deck Floor & Roof System What is Insul-Deck? Insul-Deck panels are steel -reinforced, foamed plastic insulation boards used as permanent, stay -in -place concrete formwork for floor and roof construction. Reinforced concrete joists are spaced at 24" [61Omm] on center and poured monolithi- cally with the slab to form a T-Beam reinforced concrete structure. The "pan -form" Insul-Deck panels are available in several thicknesses / beam -depths to allow varying spans and loads of the one-way concrete slabs. Each Insul-Deck panel is custom -cut to the exact length required and reinforced with two continuous, galvanized steel, Z-shaped furring strips (22 Gauge [O.8mm thickness]), which provide attachment points for ceiling finishes and serve as secondary shoring/formwork support. Primary shoring must be designed and erected as per shoring supplier, project engineer, or applicable building codes (see below). Insul-Deck panels do not provide. any permanent structural support. Structural support is provided by the reinforced concrete joists and slab topping only, which are designed by a licensed engineer in accordance with ACI 318, ACI 301, or other applicable standards. Span and Floor Loads for Insul-Deck Depending on live and dead loads assumed in the structural design, clear spans of up to 33 feet [1Om] - measured from the center of the sup- porting elements - can be accomplished without modification to standard Insul-Deck profiles. Live loads exceeding 100 psf (488kg/m2) can be supported for shorter spans (see next page). Longer spans and/or higher loads may be achieved by: increasing the T,-beam height profile with extra foam -blocks glued to the top of Insul-Deck panels; high -strength concrete, additional reinforcing steel, stirrups, post tensioning, and/or camber. Contact the Insul-Deck Technical Department for details. A licensed engineer has to provide the structural design for each building. Reinforcement Reinforcing requirements are a function of the desired span between supporting points and the live loads imposed on the structure. The size, grade, and frequency of reinforcing bar should be determined by a licensed engineer for each project. For estimating purposes, Insul-Deck provides span tables showing suggested reinforcement. Minimum concrete cover as per ACI 318 or other applicable codes: • Concrete for slabs, walls, joists not exposed to weather and not in contact with ground: 3/4" [2Omm] • Concrete cast against and permanently exposed to earth: 3" [75mm] • Concrete exposed to earth or weather, #6 [2OM] and higher bars: 2" [50mm]; #5 [15M] bar, W31 or D31 [016mm] wire, and smaller: 11/2" [38mm] The installer is responsible for placement of all reinforced concrete in accordance with ACI 318 "Building Code Requirements for Reinforced Concrete". Any variance from these standards must be provided and certified in advance by the Engineer of Record. SLAB REINFORCEMENT AS SPECIFIED (6x6 (150x150) WWM OR LONG 8 TRANS REBAR) ---. CONCRETE JOIST REINFORCEMENT AS SPECIFIED MIN. j" (20mm1 CONCRETE COVER OR AS SPECIFIED EFFECTIVE BEAM DEPTH 7"-16.5" 1178mm-419mm) BEAM DEPTH 1127mm - 267", t INSULATION THICKNESS 2"(51n"n1-- Qy m -- INSUL-DECK DOUBLE REBAR CHAIR j SPACED @ 4'-0" (1.2m) O/C MAX & 12" 1300mm) AWAY FROM ENDS i \ -- FLOOR/ROOF FINISH AS SPECIFIED jCONCRETE TO BE 6"SLUMP, MAX. e" (10mm) AGG., COMPRESSIVE STRENGTH AS SPECIFIED JOIST WIDTH 4;" 1108mm] SLAB THICKNESS RANGE: 2"-6" (50mm150mm) 0 1 /O O l� S8L-D . 10- P' ,12 & ZKSNESS AVAILABLE: 1(178mm. 203mm, 229mm. 254mm, 279mm, 305mm & 318mm) O, O I [�� 0- - - - - —J METAL FURRING FOR FINISH ATTACHMENT SPACING 12"1305mm)OIC i.-.. CEILING FINISH AS SPECIFIED --- — - JOIST WIDTH AT BASE 5" (127mml 12.5" [318m m] 12" [305mm] 11" [279mm] 10" [254 m m] 9" [229mm] 8" [203mm] 7" [178mm] INSUL-DECK SPANS (FOR ESTIMATING PURPOSES ONLY!) [1.5m] [3.0m] [4.6m] [6.1m] [7.6m] CLEAR SPAN (Center to Center of Load Bearing Support) [9.1] [10.7m] LEGEND: r-- 20 psf [0.95 kN/m'] Live Load, 3" [75mm] Slab Thickness, 3000 psi [21 mPa] Concrete, 246 [2-20M] Rebar Bot. 0 40 psf 11.92 kN/m'] Live Load; 3" [75mm] Slab Thickness, 3000 psi [21 mPa] Concrete, 246 [2-20M] Rebar Bot. 100 psf [4.77 Mrnl] Live Load; 3" [75mm] Slab Thickness, 3000 psi [21 mPa] Concrete, 246 [2-20M] Rebar Bot. -- 4" [100mm] Slab Thickness, 4000 psi [28 mPa] Concrete, 247 [2-22M] Rebar Bot. & 146 [1-20M] Rebar Top Slab Thickness Because of the support provided by the reinforced concrete joists every 24 inches (610mm), a much thinner slab section is required. Slab sec- tions between 2 and 5 inches (50 and 125mm), depending on live loads and other forces applied to the slab, are commonly used. This design results in 30 to 40% concrete savings in most jobs, and therefore eliminates 30 to 40% of the mass of the floor or roof. A 3" [75mm] slab thickness is common for most residential floors and 5" [125mm] slab is recommended for high point loads such as garage floors. Construction Details Typical construction details are available on the Insul-Deck website, www.insuldeck.com, and can be downloaded at no charge in PDF or DWG file formats. Many common design features are shown, including multiple story applications, pitched roofs, cantilevers and more. Shoring & Bracing Insul-Deck requires only primary shoring for support or, if required, camber. This means that less shoring is generally required, ap- proximately every 61-0" [1.8m] on center and perpendicular to Insul- Deck Panels. First and last shoring beams must start at maximum 6" [150mm] from panel ends. Installer is responsible for the design and correct installation of shoring for Insul-Deck forms in accordance with ACI (American Concrete Institute) 347.2R "Guide for Shoring/ Reshoring of Concrete Multistory Buildings", Chapter 2, Design. It is recommended that an analysis of the shoring for each project be carried out by a licensed engineer (often provided by shoring suppli- ers), in addition to the design of the structure. Shoring Removal The concrete structure must be able to support its own weight (dead load) and the loads imposed during construction (construction load) without excessive deflection that will harm the structure. Preferred Method: Determination of the length of time required before removal of shoring (or re -shoring) should be made by the Engineer of Re- cord, based on the compressive strength of the concrete and curing con- ditions. A ready -mixed concrete supplier can supply high -early -strength concrete for early removal of shoring. Alternate Method: If plans and contract documents contain no speci- fication for minimum compressive strength of concrete at the time of formwork and shoring removal, ACI 347, Section 3.7 provides guide- lines pertaining to one-way floor slabs and the removal of shoring. See standards list at the end of this bulletin. I . BLAG TIK_,Ss"NOE: rB'150n�n"15Pm,1 INSUL-DECK PANEL THICKNESS AMLABLE 3 Mn"n. )O:+mn1 J,W�nq r _- �`'•� RI,GRINN tltAMs MAA.4Pnr,ING B'al'I'.BnI 1C i A I, STAF(TINGDT M RU,f, SUPPORT (R(Y,I I"A"11E?RING SUCPpRT +f 47 �a1 ,MP d `�hggFF r CONTNUOUS I.UnYiCR FOR SNORING LOAD DISTRIBUTION .� ON SOFT SUUSTRNTES Finishes Ceiling finish (GWB or eq.) can be attached directly to metal Z strips integrated in Insul-Deck Panels. Dropped ceilings can be installed for proj- ects requiring more room for HVAC or other utilities - a 15min thermal barrier (e.g. GWB) must be installed on the underside of the Insul-Deck prior to installing a suspended ceiling. In cases where a fire resistant floor is needed it is recommended that non -corrosive fasteners be placed at least every 8'-0" [2,5m] o/c through top of panels prior to concrete pour to connect the metal furring to the concrete slab. Contact Insul-Deck for more details. Testing has been performed to determine the pullout strength of Insul-Deck Z Strip furring with the average result being 410 pounds (185kg] per linear foot of furring. (October 2008 - Applied Technical Services, Inc,) Contact Insul-Deck for more details. EPS Board Type -ASTM C578 Insul-Deck is manufactured from expanded polystyrene ("EPS") at an average density of 1.25 pcf [20 kg/m']. The EPS material is Type VIII in the USA as per ASTM C578 and Type 1 in Canada as per CAN/ULC-S701. The EPS is treated with a flame-retardant for use in building insulation. In most design scenarios, building codes require that exposed foamed plastic insulation be covered with a minimum 15-minute rated thermal barrier, such as 1/2" [13mm] gypsum drywall. The raw material vendor's evaluation and test reports, and any reports referenced below are available on request to building officials in your local jurisdiction. Surface Burning Characteristics - ASTM E84/ UL723 Flame Spread < 25: Smoke Developed < 450 (prior to floor ignition) per Preliminary Investigation Report by Underwriters Laboratory Inc. dated August 28, 2006. Fire Resistance Ratings Actual Fire Resistance Ratings shall be determined.by the licensed professional engineer. The below Fire Resistance Ratings were estimated based on Table 2.1 "Fire resistance of singular layer concrete walls, floors and roofs" of ACI 216.1 and only consider the concrete slab thickness: t i 1 hr ;1 5 hr_ 2•hr 3 hr 4.hr Siliceous 3 5 [89mm] 4 3 [109mm] 5 0 [127mm] 6.2" [157mm] 7.0" [178mm] Carbonate 3 2 [81 mm] 4 0' [102mm] 4 6 (117mm] 7 [145mm] 6.6" [168mm] Semi -lightweight 2 7' [69mm] ! 3 3" [84mm] 3 8 [97mm] f -5 4 6 [117mm] 5.4" [137mm] Lightweight _ - 2 5' [64mm] 3 1" [79mm] 3 6" [91 mm] 4.4" [112mm] 5.1" [130mm] Insulation Values - ASTM C578 Per ASTM C578, R-Value for Type VIII EPS is 3.8 per inch thickness @ 75°F. The ASHRAE Handbook allows using higher and more accurate R-Values for EPS, especially in cold conditions, in contrast to many other insulation materials that perform worse than advertised when heating or cooling is actually required. Calculated R-Values for Insul-Deck & concrete assemblies per ASTM C578 values are: i 7 `l° r t..,.� °4.w ti,w.Mis,lh-s y.'.I s, f i; J- �ri.A.�Y-�<e 1 f• J r' �. ( �'r. �" Thermal Resistance R-Value (h-m-T/BTU) 1 16 19 22 25 28 32 33 0.23 0.20 0.18 0.17 Heat Transfer Co -efficient U-Value (WW-K) i 0.35 0.3 ! 0.26 STC Sound Tests (Sound Transmission Loss - Airborne Noise) - ASTM E90 Per reports by Architectural Testing dated January 23, 2007, four tests were performed on different floor types as follows: 12" [305mm] Floor Assembly (9" [228mm] Insul-Deck & 3" [75mm] Concrete) 46 12" [305mm] Floor Assembly (9" [228mm] Insul-Deck & 3" [75mm] Concrete) + 1 layer 5/8" [16mm] gypsum board 49 ------- ----- 12" [305mm] Floor Assembly (9" [228mm] Insul-Deck & 3" [75mm] Concrete) + 1 layer 5/8" [16mm] gypsum board over resilient channel 50 12" [305mm] Floor Assembly (9" [228mm] Insul-Deck & 3" [75mm] Concrete) + 2 layers 5/8" (16mm] gypsum board 53 IIC Sound Tests (Impact Insulation Class - Field Test) - ASTM E1007-04 Per report by Southwest Research Institute dated October 06, 2008, four tests were performed on different floor types as follows: 15" [381 mm] Floor Assembly (12 [305mm] Insul-Deck & 3" [75mm] Concrete) - no finish on ceiling or floor 17 15" (381 mm] Floor Assembly (12" (305mm] Insul_Deck & 3 [75mm] Concrete) - 2 Layers of 5/8 [16mm] Type X GWB ceiling finish - — 26 ^ 15" [381 mm] Floor Assembly (12" [305mm] Insul-Deck & 3" [75mm] Concrete) - 1/2' [13mm] file on floor and 1/2" (13mm] GWB ceiling finish 26 15" [381 mm] Floor Assembly (12" (305mm] Insul-Deck & 3" [75mm] Concrete) - 5/8" [16mm] Jute Carpet on floor and 1/2" [13mm] GWB ceiling finish 1 70 - - — - - -- --- ------ --- - —. - ------ -- ---- - ------ — --------�— -- ---I Insul-Deck Floor Weights 3�'T"..k..'� gff 7" 451 514 1 57.6 63.9 70.1 76.4 82.6 59.8 66.1 72.3 78.6 84.8 55.8 62.0 68.3 74.6 80.8 87.0 -_ 58.0 64.2 70.5 76.7 83.0 89.2 101. 51.7 - -- -- ...__..... - - - - ill. - -------- _ 53.9 -.- _.-- - - 60_2- - 66.4 72.7 78.9 85.2 _ 91.4 12" 56.2_ 1 62.5 68.7 75 0 81 2 87.5 93.7 12.5" 57.3 1 63.5 69.8 76 0 I 82.3 88.5 _ 94.8 Notes: The above are unfactored estimated weights which include concrete (150pc1), reinforcement (31b/sgft), lnsul-Deck Panel (21b/sgft) & mist. (2lb/sgft) t i <�,•r-J...•--.H.�V ,-tr.."rl \� :.t. � ��lU.�l� ,. � t :�. r l7 i i -J- tel: ;I-yl^L`i•4'+50mm-75mm k 90mm, - •100mm . 110mm 120mm 130mm 178mm I -, 218.8 278.8 314.8 _ 338.8 362.8 386.8 , 410 8 203mm 229.6_ 289.6 325.6 349.6 373.6 397.6 _ _ 421.6 228mm 254mm 240.4 251.2 300.4 336.4 360.4 384.4 311 2 347.2 I 371.22.0 395.2 408.4 43_2.4 443.2 1 419.2 279mm 262 0 _ 322.0. 358.0 38406.0 430.0 - 454.0 305mm 272 8 332 8 368.8 392.8 416.8 440.8 464.8� 318mm i.. 278 2 338 2 374 2- _ _ 398 _ 422.2 - _446_2 Notes: These are unfactored estimated weights which include concrete (24001<gW), reinforcement (15Kg/m2), Insul-Deck Panel (10Kg1m2) & mist. (10Kg1m2). Publications More information, code requirements, and guidelines can be found in these publications: Document Title ACI 216 Standard Method for Determining Fire Resistance of Concrete and Masonry Construction Assemblies ACI 301 Specifications for Structural Concrete ACI 318 Building Code Requirements for Structural Concrete ACI 332 Guide to Residential Cast -in -Place Concrete Construction ACI 347 Guide to Formwork of Concrete ACI 347.2R Guide for Shoring/Reshoring of Concrete Multistory Buildings ANSI A10.9 American National Standard for Construction and Demolition Operations ASCE 24 Flood Resistant Design and Construction CSA A23.1 Concrete Materials & Methods of Construction CSA A23.2 Methods of Test and Standard Practices for Concrete CSA A23.3 Designing Concrete Structures CSA S269.1 Falsework for Construction (Reaffirmed 1998) CSA S269.3-M92 Concrete Formwork FEMA 320 Taking Shelter From The Storm: Building a Storm Room for your House or Small Business FEMA 361 Design and Construction Guidance for Community Safe Rooms NBC 2010 National Building Code of Canada 2010 OSHA 29 CFR Construction Safety and Health Regulations for Construction SEI/ASCE 37 Design Loads on Structures During Construction UL 723 Surface Burning Characteristics of Building Materials (ASTM E84) I n a i.e or as:i t; E; ai is if tr ;i'i atli..r ii: `vV'.'V-,M1r'.I t-lSt,i I e, ev.".P;Ci`1"i This document is for information purposes only. No representation is made or warranty given as to its contents. User assumes all risk of use. Insul-Deck and its suppliers assume no responsibility for any loss or delay resulting from such use.