Document KGOK2YvjkvMyjJopQoGozp2QQ

STR-UCTOLITE CONCRETE FLOOR AND ROOF SLABS OVER STEEL JOISTS INTERIOR LOAD BEARING DIVIDING WALLS FIREPROOFING STRUCTURAL STEEL HISTORICAL FIkfEEPERand saddle fills -: \i c. .6 Cectioiv / .... OMJL~........ DO LjV DZjTROY UNITED STATES GYPSUM COMPANY CHICAGO \ BB024 0470 STRUCTOLITE CONCRETE factured by a special process from cal careous rock. When mixed with water it sets rapidly and acquires rocklike characteristics. How Is It Used1 Structolite Cement is used similarly to ordinary Portland cement. It is mixed on the job with water and aggregate in a con crete mixer and poured into place. Where Is It Used? Structolite Cement may be used wherever a non-hydraulic quick set insulating cement is advantageous. Concrete made with Structolite Cement is being used for floor and roof slabs over steel joists, fire proofing structural steel, load bearing walls in apartments and residences, an insulating back up concrete for stone faced houses, sleeper fills, roof saddles and other fire stopping fills. Why Is It Used? Structolite Cement is used because it pro duces concrete that combines fireproof ness, quick set, heat and sound insulation and light weight with many other desired advantages at no increase in the cost of the material, or the labor of handling. Some Advantages in Using Structolite Concrete Obtains 60% of Its Strength in 60 Minutes Setting time is ideal. There is ample time to pour yet the slab sets up quickly, and can be worked over shortly after pouring. There is no need to wait for days for slabs to set and cure. This speeds the entire building schedule. A Good Non-Conductor of Heat Tests run at Columbia University show that the actual insulating value with a stone aggregate is 1.7 times (with a cinder aggregate 2.7 times) that of ordinary stone concrete for the same thickness. Even if insulating aggregates are used with Portland cement, the use of these same aggregates with Structolite Cement will give a considerably better value. A good insulator, possessing structural qual ities, is of the highest value, particularly in roof slabs and in protecting steel. Lighter in Weight A 100-pound bag contains one and onehalf cubic feet of Structolite Cement in stead of the usual one cubic foot. This greater quantity of cement for the same weight contributes more bulk. Less sand and aggregates are used than with Port land cement to get the same volume, which accounts for the lighter weight of Structolite Concrete. Structolite Concrete with a stone aggregate weighs approximately 115 pounds a cubic foot. Structolite cinder concrete weighs between 85 and 90 pounds a cubic foot. These are dry weights. BB024 o c* STRUCTOLITE CONCRETE Excels for Use with Light Weight Aggregate When even lighter weight, or still better nailability, or greater insulation is de sired, clean graded cinders or any of the light weight manufactured aggregates of burnt clay or similar materials may be used to excellent advantage with Structolite Concrete. When higher priced aggregates are used Structolite Concrete provides a real saving as the quantity of fine and coarse aggregate required per cubic yard is about one-third less than ordinary concrete. Is an Excellent Sound Deadener Structolite sets up in microscopic needle shaped crystals which make up a closely knit mass, enclosing myriads of tiny air cells within the structure. These air cells entrap sound vibrations dissipating their energy. This is the technical explanation. A job demonstration is a revelation. Has Good Nail Holding Power Concrete made with Structolite may be nailed into practically as easily as wood. Bucks can be toe-nailed into place and if stud partitions are used, the base plate may be nailed directly into the floor, eliminating nailing strips. Carpet strips may be anchored directly by nailing, eliminating the necessity of drilling and placing expansion shields or other expen sive anchors. After a nail has been in place a few days it is very difficult to re move. Cross nailing is recommended and for best results cut nails should be used. Can Be Used in Freezing Weather Structolite Cement generates heat within itself upon setting. When the usual pre cautions of heating the mixing water and removing the frost from the aggregates are employed, the concrete will set before it freezes at the temperatures at which mechanics will ordinarily work. While it is advisable to protect the finished slab from the weather by covering, it is not necessary except in extreme cases to apply heat to protect it. Minimizes Loss Through Sag and Dripping Over Metal Lath Concrete that remains plastic for a num ber of hours causes the metal lath to sag appreciably and continues to leak through the openings in the lath. The quick set of Structolite Concrete and its light weight reduces the usual loss from this sag and leakage to about half. Is a Permanent Material Manufactured from rock, Structolite Ce ment has the quality of permanence. We have installed upwards of 40,000,000 square feet of gypsum floor and roof slabs, over a period of thirty years. Structolite Cement has been used in the majority of these installations since its inception eleven years ago. Costs No More to Use Despite the many advantages attendant to its use, the combined cost of the quan tities of Structolite Cement, sand and aggregate required to make a cubic yard of Structolite Concrete are no more in the average market than the combined cost of the materials required to make a cubic yard of Portland cement concrete. 3 BB024 0472 STRUCTOLITE CONCRETE CCturto tUNNlg. 1x2 Sleepers clipped diagonally Co joists and imbedded in Structolite Concrete Linoleum (or similar) wearing course applied over Structolite Concrete slab Finished cement (or similar) wearing course applied over Structolite Concrete slab 4 Estimating Data Equipment Ordinary tools for concrete. Structolite is mixed with sand and aggregate in a concrete mixer. The tilting drum type works best, as it is self cleaning. Materials For Structural Uses Over metal lath to determine yardage required figure net quantity as shown on plans and add sufficient for sag and leakage. Structolite Cement concrete being lighter in weight than Portland cement concrete will cause less sag. Its plasticity decreases leakage; its quick set prevents continued leakage. As a rule, this loss from sag and leakage is figured as less than half that of ordinary concrete. For uses other than over metal lath determine the yardage required from the plans. A cubic yard of Structolite Cement concrete mixed one part of Structolite Cement to one part of sand and two parts coarse aggregate by volume will require: Structolite.................................. 600 pounds Sand................................................. 33 yards Coarse aggregate............................66 yards For Sleeper and Saddle Fills Determine the yardage required from the plans. A cubic yard of Structolite Concrete for use as a fill mixed one part of Structolite Cement to two parts of sand and three parts of coarse aggregate by volume will require: Structolite.................................. 400 pounds Sand................................................. 44 yards Coarse aggregate............................66 yards For Topping to Level Off Slab Determine the yardage required from the plans. A cubic yard of sanded Structolite for topping to level off slab mixed one part of Structolite to one part of sand by volume will require: Structolite................................................. 1100pounds Sand................................................. 62 yards Labor Labor costs should he less than with Portland cement concrete for the following reasons: Since Structolite Concrete weighs less itself and the leakage is less, the hoisting charge will be only about 759c that of ordinary concrete. Quick set means rapid erection and a shorter building schedule. Structolite sets in about an hour. Workmen can work over the slabs, setting partitions, storing materials, etc., within two hours after pouring as a rule. A Structolite slab reduces the cost of winter work as the Structolite sets before it freezes. ro 03 oro -Cs o .> CO STRUCTOLITE CONCRETE 8 Uses Floor and Roof Slabs Over Steel Joists Modem apartments, hospitals, schools, residences, and multi-storv office buildings employing steel joists to obtain a light fire-safe construction that is economical can materially improve their serv iceability and comfort at no added cost by using Structolite Concrete in place of ordinary concrete. The minutely porous nature of this concrete re sists sound transmission and its reduced hardness lessens echoing and vibration. These qualities contribute materially to an air of restful comfort and quiet that increases the value of the finished building. - The slab itself is not used as a wearing surface, but its strength and lightness lend them selves to excellent economical advantage in the structural slab. Sleeper and Saddle Fills Over a structural slab such as Reinforced Con crete, Clay Tile arches, or Reinforced Structolite Concrete a leaner fill mix may be used for roof saddles and sleeper fills. In addition to its light weight and quick setting properties Structolite Concrete sleeper fill offers this unique advantage, there is a slight expansion in setting so that floor sleepers are put under com pression, gripping them firmly in place. Any tendency for green lumber to shrink on drying or become loose in the fill is appreciably reduced and the tendency for a wood floor with Structolite Concrete sleeper fill to squeak, is minimized. LOADING TABLE STRucrouTE concurrz with bib lath uintocong TA6LE Of SAFE SUPERIMPOSED LOADS IN POUNDS PCX SQ FT. UNIFORMLY DISTfil&UTEO mott:- the Loads are the safe loaos foe the slab only. THE TABULATED LOADS ABE BASED ON A STBUCTOUTE CONCOCTS MKTU1E OF A) PAlT STtUCTCUTT, (1) PART SAKD AND ft) PARTS AGGREGATE AND THE FOLLOW!NS MAXIMUM STRESSES. Fc*2 30. W. E*l.Z50,000 fc-WJJOO* PK3Q.IR SLAB DEPTH 2 INCH Zl INCH 3 INCH Sk INCH 4. INCH 4k INCH Lath Size JOIST 3PNCINO 12 INCH 6Z5 IB INCH 457 IS INCH 340 312 21 INCH 275 416 522 24 INCH 28 INCH 30INCH 32 MCH 22J 159 134 1J7 332 239 206 178 460 332 286 250 348 396 361 2S7 436 395 343 449 391 X3* lx 3k* 1X4* Interior Load Bearing Dividing Walls Often, where forms are readily available it is eco nomical to pour in place a dividing wall that must be both fire-safe and load bearing. It can be plastered directly on both sides, offering a rugged construction of excellent strength that is an excep tionally good barrier to both sound and fire trans mission. If the loads to be carried exceed 150 pounds per square inch, a plate should be used to distribute them. Reinforcement over openings, forms and mix are covered in the specifications. (Continued on Next Page) 5 BB024 0474 6its STRUCTOLITE CONCRETE Fireproofing Structural Steel One of the most important advantages in Structolite Concrete is its fireproof quality. Fire applied to a Struetolite slab cannot raise the temperature of the slab higher than -21-2 Fahrenheit until com plete calcination has taken place and the water of crystallization entirely vaporized. The appli cation of fire results in a thick steamy area of uncalcined gypsum which is the most effective "Some of the form marks were still visible, indicating that calcination from this intense heat and the washing action of the hose stream had not progressed to a depth suffi cient to damage materially the structural strength of the wall." Due to the comparatively low temperatures at which structural steel begins to lose its strength authorities are agreed that the best fireproofing material is that which also insulates. On steel buildings using metal joist floors, structural steel beams and columns can be eco nomically fireproofed with Struetolite Concrete. The light weight of the material appreciably reduces the dead load in the building and the rapid set reduces the number of built up forms required in pouring as they can be reused immediately after the Struetolite Concrete has set. The nailability of Struetolite Concrete makes it a very simple matter to fur out around beams barrier to fire. The fire test curve in the following diagram shows the remarkable results of a fire test conducted by the Building Department of the City of Xew York, co-operating with the Civil Engineering Department of Columbia University, at the University Testing Laboratories in Decem ber, 1923. Walls 3 in. thick and 9 ft. high by 14 ft. long were subjected to a maximum tem perature of 4810 F. '`An average temperature of 1707 F. was maintained within this structure for one hour and yet the outside surface of these 3-in. walls did not exceed 210 F." Immediately follow ing, a stream of water from a l Vg-in. nozzle at a distance of approximately 8 ft. and a nozzle pres sure of 30 lbs. was directed against the super heated wall for two and one-half minutes. The Official Report on this test states: "The exterior surface of these partitions as they appeared on the day following the tests showed no visible sign that they had gone through a one hour fire and water test." AT \r1 V X \ g r 1r 2 iV 1 1 Sj T a z r TEMP tCAFUBtS JF Rtf NA EXTtCIOtt &U&VACU1 OF Paotitwmw ITlQt 1 .TtOTi 11 MAPI on DLL- "n 1 1 l-'lTWO MONOUTHIG 3TBUCTOUTL Cl 1DEB piOTl IMOR4 | i Iun uu. TJRMACl TEMPI ATU&E x weiyr pa run*.GATliOt OLTrsiot 5UQFA ?t;ti rirwfcUatu^l UU" I 1 1 -'`1i i 1 5 Si a 1L1ttSLjU ACJ3L si ** This curve shows the average temperature on the interior walls, which was maintained at 1707 Fahr. for the required period. The maximum was 1810 Fahr. No tice that the outsides of these walls, only three inches thick, did not exceed 210 Fahr. 6 BB024 0475 STRUCTOLITE CONCRETE 6u,s-- - Specifications for Structolite Concrete Proportions All Structolite Concrete used structurally in this work shall be of the following proportions which shall be volumetric: 1 part Structolite Cement 1 part Sand 2 parts Coarse Aggregate Structolite Cement The Structolite Cement shall be as manufactured by the United States Gypsum Company, and shall be delivered to the job in the original packages. Storage The Structolite Cement shall be stored in a dry place, and shall be well protected from the weather. Sand The sand shall be clean, sharp and well graded. It shall be free from loam and other organic materials. Coarse Aggregate Coarse aggregate shall be cinders, crushed stone, gravel or slag. Cinders shall be a good grade of power house cinders, containing no unbroken large lumps, and shall be free from unburned coal. Cinders shall be screened over a K-ineh screen and all fines removed. Crushed stone, gravel and slag, shall be crushed to such a size as will pass through a J^-inch ring and be retained on a }d-inch sieve. Gravel shall be clean and well graded. Gravel and slag shall be free from clay or other soft material. Slag shall be air cooled, clean and properly graded. Note: Where special light weight aggregates such as burned clay are used follow the specifications of the manufac turer for both fine and coarse aggregate sizes. Water The water used for mixing shall be clean and free from organic substances. Mixing and Placing The mixing of Structolite Concrete shall be done in the ordinary concrete mixer, preferably of the tilting drum type. Care must be exercised in dumping ail of each batch, and keeping the mixer clean generally, so that the particles of set Structolite Concrete do not remain to accelerate the next batch. The speed of the drum shall not exceed 20 revolutions per minute. The pre determined amount of water shall be introduced into the drum first, and the drum allowed to revolve until the paddles and sides are cleaned from any material left from the previous mix. The feeding hopper shall be charged, so that the coarse aggregate is delivered into the drum first to help scour it out. For the same reason, if no hopper is used, the coarse aggregate shall be placed in the drum first, then the water, and the Structolite last. Just enough water shall be used to insure a thorough mixing of the mass into a workable consistency. (The amount of water required will vary with the dampness of the aggregate.) As soon as the mass has become thoroughly mixed, it shall be removed immediately and placed in the forms. With the drum speed of 20 revolutions per minute, the entire mixing time shall not exceed two minutes after the Structolite and aggregate have been introduced into the drum. Dump at once; do not allow the drum to idle with all or part of the mix therein, and further agitate the mass once the mixing is complete. Forms Forms may be of wood or metal. They shall be well built, tight and rigid, shall be erected plumb and in true alignment and well braced. The inside surfaces of forms shall be kept clean at all times. The forms shall not be removed in less than to minutes after the Struc tolite Concrete has set. All inside wall surfaces to be plastered are to be well scored as soon as the forms are removed, so as to provide a proper key. Reinforcement In interior load bearing dividing walls all window and door openings not exceeding 5 feet clear span shall be reinforced with not less than three JA-inch round rods. When the location of the opening is such that the depth of the lintel is less than 18 inches, a steel or reinforced concrete lintel shall be used. Spans in excess of 3 feet shall have steel or reinforced concrete lintels. The rods shall extend not less than 24. inches beyond the clear opening on either side and shall have hooked ends to provide anchorage. Floor and Roof Slabs Scope of Work All floor and roof slabs over steel joists shall be the United States Gypsum Company's reinforced Structo lite Concrete construction. All slabs are to be installed in accordance with the directions of the United States Gypsum Company and shall be of the thickness shown on the plans and shall be laid level and true and left in the proper condition required for the type of finish to be used. Slab Reinforcement For temperature and slab reinforcement an electrically welded galvanized steel mat, having No. 12 wires spaced not more than 4 inches on centers across the joists and No. 12 wires spaced not more than 8 inches on centers parallel with the joists shall be used. This mat shall be placed directly on top of the ribbed lath. (Joist spacings over 24 inches in floors and 30 inches in roofs are not recommended. If used, a heavier mat is necessary.) Protection of Finish At all times during construction protect the slab from heavy traffic such as loaded wheelbarrows, etc., by suit able plank runways. If the slab is troweled to a smooth finish protect same during construction from undue moisture. Wher- BB024 0476 7 CONTINUED FROM PAGE 7 ever traffic occurs cover with a heavy building paper or a layer of dry sand to prevent scuffing. Note: All Structulite Concrete used for sleeper fills and roof saddle fills over a structural slab in this work shall be of the following proportions which shall be volumetric. 1 part Structolite Cement 3 parts Sand 3 parts Coarse Aggregate Composition Finish Where a composition finish is indicated on the plans it shall be laid according to the specifications of the manufacturer. Where the composition finish is less than inch thick the total thickness of the Structolite Concrete slab shall be not less than 2H inches. Acid mixed finishes shall not be applied without first protect ing the slab with an acid-proof covering. Sanded Structolite Topping for Leveling Off Slabs This is not a wearing surface. Where thin finishes requiring a smooth and level base are to be laid, apply a topping of sanded Structolite not less than l/i inch and preferably inch thick, mixed one part of Structolite to one part of clean sharp sand by volume, adding just sufficient water to obtain the consistency of brick mor tar. In all cases apply the topping after the plastering has been done and preferably just before the building is trimmed. Before applying the topping, clean and sweep the floor thoroughly, removing all loose particles and wet it down. Then apply the topping and strike off level with the screed strips. Float and trowel as required to a smooth level surface, using a procedure similar to that employed in surfacing walls. Once the slab is smooth do not continue to trowel. Prolonged troweling will work the material through its set. (If the slab is very dry first spread out a layer of Structo lite and sand about l/s inch thick, mixed wet and allowr to set.) Wood Floor Finish Where wood floor finish is indicated on the plans, it shall be laid as specified under "Carpentry." Carpeting Finish WThere this finish is indicated on the plans it shall be applied as per manufacturers' directions. Under this finish the total thickness of the Structolite Concrete shall not be less than 2 Yi inches. The slab shall be painted with an approved non dusting paint. The carpeting shall be applied over an ozite or equivalent padding. Linoleum, Rubber and Cork Tile Finish Where these finishes are indicated on the plans they shall be applied as per manufacturers' directions. Under these finishes the total thickness of the Structo lite Concrete slab shall be not less than 2 Yi inches. Preferably cement a sheet of linoleum felt to the slab first and then cement the linoleum, rubber, or cork tile finish to the felt. Where the Structolite topping has been omitted this procedure is required to cushion against trowel marks or minor unevenness in the slab. Tile or Marble Floor Finish Where a tile or marble finish is indicated on the plans, it shall be applied according to the standard specifica tions of the tile manufacturer. Terrazzo Finish Where terrazzo finish is indicated on the plans it shall be applied according to the standard specifications of the Portland Cement Association. The combined thickness of the finish and bed shall be not less than 1 yi inches thick on top of the Structolite Concrete slab. Cement Finish Where cement finish is indicated on the plans, it shall be applied according to the latest specifications of the Portland Cement Association. It shall be applied as a free standing, reinforced finish, positively separated from the base with an approved provision for expansion and contraction. A'n economical method of separating the finish from the slab is to-bring the top of the slab to a smooth surface by spreading and screeding thereon a layer of sand. (Use just enough sand to even up the high spots in the rough slab.) Then cover the slab surface with a layer of Slaters Roofing Felt weighing approximately 32 pounds to a roll of 500 square feet. The Structolite Concrete slab will carry the load, but a sufficient thickness of finish to make it self-sus taining under the traffic conditions to be encountered shall be used. Roof Slab Surface The Structolite Concrete roof slabs shall be troweled smooth and level to receive the roof covering. Roof Covering The slab shall be covered with a water and weather proof covering within 20 days after completion of the Structolite slab and preferably immediately after com pletion. Anchorage To anchor desks or equipment to a Structolite slab, toggle bolts extending through the slab shall be used. BB024 0477 STRUCTOLITE CEMENT Is Manufactured Only by the UNITED STATES GYPSUM COMPANY STC-5 Copyright 1923 United States Gypsum Co. CHICAGO