• What is Cellular Concrete?
  Lightweight Cellular Concrete (LCC) is a composite material consisting of Type I or II-V Portland cement, water, and a preformed foam. The foam, resembling shaving cream, is introduced in varying quantities to control the unit weight of the final product. The inclusion of either protein-based or synthetic-based foaming agents creates stable air voids within the matrix, resulting in a lightweight material with densities as low as 24 pounds per cubic foot (PCF). This unique structure allows cellular concrete to retain its lightweight properties while forming a uniform matrix of air voids.

• Are Foam Concrete and Cellular Concrete the Same?
  Yes, the terms “foam concrete” and “cellular concrete” are often used interchangeably, alongside other designations such as flowable fill, permeable lightweight cellular concrete, low-density cellular concrete, cellular grout (often for pipeline and tunnel applications), flowable soil cement, plastic soil cement, controlled density fill, and controlled low strength material (CLSM). All refer to forms of lightweight cellular concrete designed for various applications.

• Why Should I Use Cellular Concrete for My Project?
  Cellular concrete offers numerous advantages: it is lightweight, cost-effective, flowable, self-compacting, and readily available. As construction timelines shorten and site footprints reduce, cellular concrete provides a reliable solution tailored to unique project challenges. It cures rapidly without the need for additional compaction and requires minimal setup space, allowing for efficient material placement.

• How Much Does Cellular Concrete Cost?
  The cost of cellular concrete varies based on several factors, including project size, location, material density, and site conditions. While comparing costs on a cubic yard basis, it’s essential to consider the broader impacts on the project, such as time savings, reduced construction traffic, minimal job site footprint, and lower associated costs (e.g., compaction, foundations, retaining walls, and distribution slabs).

• How is Cellular Concrete Manufactured?Cellular concrete is produced on-site, where cement and water are mixed, and preformed foam is integrated to achieve the desired density. The mixture is then pumped into place in lifts, typically around four feet high, although this can vary based on specific project requirements.

• Is Cellular Concrete Permeable?
  Cellular concrete exhibits high porosity due to its air content; however, these air pockets can or cannot be interconnected, resulting in modifiable permeability (ranging from 1×10^-1 to 1×10^-7 cm/s).

• Do You Offer Other Materials for My Project?
  Absolutely! We provide a comprehensive range of Value Engineering solutions tailored to project needs. Contact us to explore additional products, including geofoam and specialty grouts.

• Is Cellular Concrete Excavatable?
  Yes, cellular concrete is a low-density, low-strength material that can be easily excavated with mechanical equipment, such as backhoes.

• Can I Place Equipment on Top of Cellular Concrete?
  While it is possible to place equipment on cellular concrete, it is advisable to use a protective layer (such as backfill or plywood) on top to prevent surface damage.

• Can Cellular Concrete Be Used as Flowable Fill Around Pipelines?
  Yes, cellular concrete is suitable for use as flowable fill around pipelines; however, buoyancy and heat of hydration must be considered.

• How is Cellular Concrete Placed, and What Are the Pumping Distances?
  Cellular concrete is typically placed using a 2”–4” concrete hose. Ideally, the pumping distance should be within 800 feet of the mobile batch plant; however, with proper positioning of the foaming system, distances exceeding 800 feet can be achieved. Please consult us to discuss the specifics of your project.

• How Long Do I Need to Wait Before Placing Additional Lifts or Walking on Cellular Concrete?
  Cellular concrete generally cures within 12 hours. Subsequent lifts can typically be placed the following day, and the surface can be walked on shortly after to continue project work.

• What Are the Water Demands for the Mobile Batch Plant on My Site?
  Water requirements will vary based on project size, but we recommend a minimum of 60 gallons of water per cubic yard as a baseline. The rate of placement on-site is influenced by the gallons per minute (GPM) needed, with 125 GPM being the typical requirement for mid-level jobs (approximately 800 cubic yards per day).

• Where Can I Find More Information About Cellular Concrete?
  For detailed technical information , please visit our technical resources page. We encourage you to reach out to us to discuss your project needs. Follow us on social media platforms like  Twitter, Facebook and LinkedIn to find out additional insights and updates!

• Who Can I Speak With to Learn More About Cellular Concrete?
  Our in-house expert, Jeff Wykoff, is available for informational presentations tailored to your project needs, providing insights into the various applications and benefits of lightweight cellular concrete. You can contact us through our website or reach Jeff directly at jwykoff@cell-crete.com. Depending on state licensing board rules, we can also offer an hour of continuing education for verified attendance at our webinars. 

• What Advantages Does an LWIC Roof Deck System Provide?
  LWIC Roof Deck Systems effectively mitigate thermal bridging, a common issue in competing systems that utilize mechanical fasteners through insulation boards. Such fasteners can compromise the system’s R-value by up to 30%. In contrast, LWIC systems employ mechanical fastening solely to the top LWIC layer, preserving the thermal integrity of the encapsulated EPS insulation board. Furthermore, LWIC systems are designed with a stair-stepped EPS board combined with custom sloping, achieving positive drainage more efficiently and cost-effectively than conventional tapered insulation systems.

• How Does Cell-Crete’s Implementation of LWIC Differ from Industry Norms?
  With over 45 years of experience, Cell-Crete is recognized as an approved applicator for LWIC Roof Decks, ensuring compliance with manufacturer specifications and standards and is the only Nationwide LWIC installer. This extensive experience equips us with the knowledge and tools necessary for optimal performance and reliability.

• What Are the Structural and Performance Benefits of Lightweight Insulating Concrete?
  Low Density Insulating Concrete Roof Decks form a cohesive, monolithic system that provides inherent fire resistance and wind uplift ratings at a competitive cost. Unlike traditional systems, which may require complete replacement upon membrane failure, LWIC decks permit localized remediation—only the membrane needs to be replaced. Should leaks occur, the underlying deck can be dried and re-membraned, avoiding costly full system replacement. Additionally, the monolithic structure functions as a thermal mass, mitigating temperature fluctuations that can lead to membrane degradation, thereby extending the service life of the roofing system.

• What Is the Equilibrium Moisture Content (EMC) of LWIC?
  The equilibrium moisture content of cellular concrete typically ranges from 12% to 20%. The time required for LWIC to reach this equilibrium is variable and contingent upon environmental conditions, paralleling the moisture content behavior of wood materials within the same range.

• Which Roofing Membrane Systems Are Compatible with LWIC?
  LWIC roof deck systems can be effectively paired with both built-up roofing systems and single-ply roofing systems, including mechanically fastened and fully adhered applications. This compatibility enhances design flexibility and material selection.

• What Substrates Are Suitable for LWIC Installation?
  LWIC can be cast over various substrates, including galvanized metal decking, structural concrete, wood decks, and existing roof systems. This versatility allows for broad application across different construction scenarios.

• What Technical Advantages Do Lightweight Insulating Concrete Systems Provide?
  LWIC Roof Decks are characterized by their permanence, superior thermal insulation, and dimensional stability. They are non-combustible and economically advantageous, facilitating easy re-roofing when the membrane requires replacement. LWIC systems exhibit excellent fire and wind uplift ratings, contributing to overall structural efficiency and resilience.

• Is Vented Metal Decking a Requirement for Insulating Concrete Systems?
  No, LWIC systems can utilize non-vented galvanized steel decking as an acceptable substrate alternative to vented galvanized steel decking. Given that insulating concrete contains only one-fourth the mix water of expanded aggregate concrete, it provides sufficient moisture relief at the side and end laps of steel decking.

• What Is the R-Value of LWIC?
  LWIC exhibits an R-value between 1.0 and 1.34 per inch, while the encapsulated EPS insulation board contributes an approximate R-value of 4.0 per inch, with specific values varying by manufacturer.

• What Are the Minimum Slope Requirements for LWIC?
  LWIC systems necessitate a minimum slope of 1/8 inch per inch to ensure effective drainage and prevent water accumulation.

• What Is the Typical Weight of the LWIC System?
  LWIC Roof Deck Systems generally weigh approximately 8 to 9 pounds per square foot (psf), providing an effective R-value of around R-30. This low weight contributes to reduced structural loads and facilitates ease of installation.

• What Additional Benefits Do LWIC Systems Offer?
  LWIC systems provide enhanced durability and reduced lifecycle costs, coupled with superior thermal performance. Their lightweight nature minimizes structural loads, allowing for increased design flexibility and integration with diverse architectural elements. This makes LWIC an optimal choice for a wide range of roofing applications, enhancing both performance and sustainability.

For further technical inquiries or to discuss your specific project requirements, please contact us. EPD’s are available for this material.

• What kind of water access and pressure do you need?
  We require faucet or well access within 200′ of the pour with 35–40 lbs. of pressure. Specific location/requirements will be discussed prior to the pour.

• We have a stairwell. What do we need to do in this area?
  A bulkhead (piece of wood) needs to be installed at the top of the stairway. This provides a place for the pour to stop, and eliminates crumbing at the stair’s edge. The bulkhead will need to be the same depth as the pour depth. This allows an even floor/step surface. The bulkhead will become a permanent fixture or it may be replaced with finished lumber. Example: If you are pouring 1 1/2″ of gypsum underlayment on the floor above the stairwell, you will also need to provide a piece of wood that is 1 1/2″ tall and runs the width of the stairs and/or landing.

• What is the best way to secure our radiant floor heat tubing?
  Tubing needs to be as flat as possible to ensure that it is covered with the proper depth of product and does not incur damage once the pour is complete. The tubing or cable will be secured by stapling or gluing (depending on the type of subfloor) every 24 to 30 inches.

• How long will it take for my floor to dry and how can I tell when it is?
  Under normal drying conditions, our product dries 1/8″ per day. Normal drying conditions require good ventilation and dry air. Air movement is the key factor in drying time. Humidity and cold weather tend to increase drying time; direct sunlight tends to decrease drying time.

  To see if the floor is dry and ready for floor goods, you may perform the following steps:

  • Cut a piece of 2′ x 2′ plastic film.

  • Tape all four sides to the floor.

  • Leave the plastic in place for 48–72 hours.

  • Once you remove the plastic, if the covered floor is darker than the uncovered area, the floor is still wet.

  • Repeat this process until the covered and uncovered areas are the same color. Additional moisture-testing techniques can be found in Maxxon’s Procedures for Attaching Finished Floor Goods to Maxxon Underlayments. Download further information on best drying techniques here.

• How do I install floor goods over your products?
  All of the Maxxon underlayments we install provide an excellent base for your finished floor goods. Our customers have successfully installed glue down vinyl and composition tile; ceramic, quarry and marble tile; glue down, “floating” or nail down wood flooring; and carpet.

• How do I know which sound mat is right for me?
  There are many factors that go into determining which sound control mat you should choose:

  • Floor/ceiling assembly

  • UL design number

  • Acoustical requirement

  • Budget

• What are allowable expenses under the research budget proposal?

  Costs that drive and are related to the research of the application proposal, such as: research consumables, capital equipment, external CRO costs and salary and hourly wage of lab and/or research personnel (to include undergraduate, graduate and postdoctoral student salaries). The award funding can also be applied to travel, conference attendance, or publication costs and long as they are directly associated to the research proposal within the application.

  Costs that are considered non-allowable are: tuition payments, university fees, benefit costs, health insurance coverage costs as well as costs considered as overheard or fringe.