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Lite-Deck
is a proven insulating concrete forming system for roofs,
floors, and walls that combines the strength, fire
resistance, and dimensional stability of steel, with the
insulating properties of high-density expanded polystyrene
to create a structural panel of exceptional performance.
The panels are available in 24" and 48" wide sections and can be ordered in any
length or thickness desired, without extra charge. The 18-gauge integrated steel
beams run parallel at 12 inches on center to provide the panel with
strength and a continuous mechanical attachment point for
drywall or any other type of covering.
The
panels interlock with a user-friendly tongue-and-groove
design at the base of a 6-inch wide cavity that forms the
concrete beam, or "joist" which creates the
structural support member of the entire system. Rebar is
placed in each joist, as required, and shoring is spaced
every 6 to 8 feet as required by an engineered
design. The thickness of the Lite-Deck
material and/or the concrete slab poured on top of the
panel determines the height of the concrete joist and the
unsupported span of the deck. Lite-Deck
is available in a variety
of thicknesses from 6 to 16 inches. American
PolySteel has developed a basic engineering design table,
shoring guidelines, and multiple-span estimating tables that
represent the most comprehensive technical support available.
FREQUENTLY ASKED QUESTIONS
1. How wide is a Lite-Deck section?
Standard sections are 24-inches wide and feature 2 steel stiffeners, 12-inches
apart. Sections can also be provided which are 48-inches wide (4 steel
stiffeners). They reduce the amount of handling at the jobsite. Because of
weight, the 48-inch sections are not recommended for lengths over 30'.
2. How long is a Lite-Deck section?
Sections are provided in custom lengths (+ or - 1/4 inch) as ordered. Lengths up
to 53-feet can be shipped on commercial flatbeds.
3. How far can Lite-Deck clearspan?
Clear (unsupported) spans of 40-feet and more can be engineered. Most short
spans (up to 12 feet) can be accomplished with 6-inch deep sections. Spans of 30
to 40-feet are accomplished with 16-inch deep sections.
4. Can I cut a Lite-Deck section? Yes. The form and steel stiffener can be
cut with a reciprocating saw.
5. What is the R-value? The R-value
will vary, depending on the thickness of the sections. The polystyrene has an
overall R-value of 4.5 per inch. So, 6-inch deep sections have a nominal R-value
of 27 prior to interior and exterior finishing. The insulating value for the
load-bearing joist portion is an R-9.
6. Does Lite-Deck have to be covered on the
interior? Nearly all building codes require that exposed polystyrene be
covered with a fire-resistant material. If Lite-Deck is being used as a home's
floor or roof, insulation exposed to the living area can be covered with drywall
(gypsum board). Some commercial or institutional applications may require that
the sections be covered with a commercial grade coating such as polyurethane.
7. How much concrete is poured on top of Lite-Deck? To get the full
strength of the load-bearing joist, the concrete cover must be a minimum of
2-inches. Engineers may require covers of 3" or more, for special applications.
8. How do I run plumbing and electrical
lines? Blockouts should be cut into the forms as they are being placed.
Lengths of plastic pipe will serve as a blockout. Blockouts should be located
between the joists and steel stiffeners.
9. Must all of the concrete be placed in
one operation? No. Concrete can be placed into the joist portion only and be
allowed to cure. The concrete cover can then be placed in a separate operation.
Leave shoring or bracing in place, for both operations. A 2-stage placement may
not be appropriate for some projects. Consult with the project's structural
engineer for their guidelines on placement.
10. Can the concrete cover be colorized or
stamped? Yes.
11. How do you finish the Lite-Deck floor
in a home? The concrete cover can be troweled to a smooth finish or a skin
coat of lightweight concrete can be placed, for a finished appearance. When
applying finishes or materials directly to the concrete cover, always follow the
manufacturer's instructions for proper application. If the floor is being
carpeted, 1/2" plywood should be placed, anchored directly to the concrete with
mastic or masonry nails.
12. What is used to seal a Lite-Deck roof?
Commercial roofs can be sealed with an Elastomeric coating applied directly to
the concrete cover. Rubber Membranes can Steel Rib systems can also be applied
directly. More conventional finishes (such as residential shingles) can be
installed over furring strips which are anchored directly to the concrete cover.
Always follow the manufacturer's instructions for proper applications.
13. Do you have to use special concrete?
Typical concrete specs: 4,000 to 5,000 PSI - 4 to 6 inch slump - 1/2 to 3/4 inch
aggregate. Structural engineer or local building codes may require slightly
different specs.
14. Can I use plasticizers? Yes, water
reducers can be used to increase workability.
15. Can Lite-Deck be vibrated? Yes.
Vibrator should be used by an experienced operator.
16. How much rebar (reinforcing steel) do I
need? That is determined by the Structural Engineer for the project. Rebar
is placed in the joist and the cover. In addition, rebar is used to structurally
tie the Deck and walls together.
17. Do I have to use a concrete pump?
No. However, the installer should avoid accumulating concrete in one spot. This
can overburden the shoring and cause it to fail. A concrete pump is preferred
because delivery can be closely controlled.
18. Does Lite-Deck provide structural
engineering specs? No. That must be provided by a structural engineer who is
licensed for the type and location of the project. The engineer's specs will
show the best joist depth and the rebar needed, to support the dead and live
loads of the deck or floor.
19. Can the forms be removed? No. They are designed to stay in place and
provide insulation protection. Research is being done on removable, re-usable
sections.
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