Plystone Beauty, security, and high resistance
Impact testing
Lightweight and Strong
www.plycem.com
Termite Resistant
Water Repellent
Moisture Resistant
Non-combustible Easy installation
Multiple Certification
Fibercement Advanced Technology
servicioalcliente@plycem.com servicioalcliente@plycem.com
Advantages
Plystone
• Does not contain hazardous products. • Not aggressive in its application. • They may be cut, sanded, nailed, perforated, and screwed with conventional tools. • They provide isolation from noise and heat.
• They accept all type of finishing • Resistant to humidity. Interior or exterior use. • Resistant to the attack of fungus. • Non-inflammable.
Description Plystone represents our high-performance products. With special characteristics that broadly satisfy technical parameters demanded in higher-demand applications, they have special features such as high thicknesses and water repellent treatments, supplied with a high level of durability and safety in constructions. For interior and exterior use.
Product Components Portland Cement, calcium carbonate, cellulosic fibers, and other minor aggregates. The surface of the Plystone sheets is treated with an impregnating emulsion that makes it water resistant while maintaining its permeability to water vapor.
Manufacturing and Quality Control Plycem sheets are manufactured at plants certified in the regulations ISO 9001:2004, ISO 14001:20 04, and OHSAS 18001:2007. Plystone sheets are Type B Grade I according to the regulation ASTM C 1186-07 and Type B Category 2 according to the regulation INTE/ISO 8336:2007.
Technical Specifications of the Product Description
Minimum Value
Maximum Value
Resistance to Flexion (dry)(N/mm2)/A
7.0
Elastic Module (dry) (kN/mm2)/A
2.5
4
Density (kg/dm3)
0.9
1.2
Humidity (%)
10
Total Absorption (%)
40
Superficial Absorption (%)
25
Humidity Movement (mm/m)
1.3
Total Contraction (mm/m)
4.0
Storage and Manipulation
Water Absorption (Karsten) (ml/24 h) Exposed face
1.5
Smoke development
0
Flame propagation
0
Fixations
Store the product over dais in horizontal position, in a dry and ventilated place, where it will not be damaged and it can be protected from bad weather and humidity. Sheets of 1.22 x 2.44m or more must be transported from the edges by two people.
SCREWS 15 mm
Plycem screws countersink the sheet in order to hide the head of the screw. For a correct fixation the points of fixation must be located respecting the minimum distance between them, with regard to the edges and the corners. Place the screws in a perpendicular position regarding the sheet and going through the structure at least 3 threads of the screw. INCORRECT
50 mm
150 mm
150 mm
When You Build Demand Certified Products
50 mm
CORRECT
15 mm 200 mm (max)
Environment
Product Certification (Costa Rica)
INCORRECT
3mm
PLYCEM SCREW PH 8-125 (MIN).
Occupational Security
Quality
Learn more about certification UL in www.ul.com under the name of Plycem
Plystone
Advantages
Roof Bases
• Easy installation • Adaptable to metallic or wood structures • Light 15 kg/m2. • Resistant to flexion
• Water resistant • Fireproof
Description Roof bases on buildings act as support to the final finish of its roof or ceiling. Plystone roof bases offer a high-performance superior covering, with unbeatable conditions of durability, comfort, and security.
Product Components Portland Cement, calcium carbonate, cellulosic fibers, and other minor aggregates.
Manufacturing and Quality Control Plycem sheets are manufactured at plants certified in the regulations ISO 9001:2004, ISO 14001:20 04, and OHSAS 18001:2007. Plystone sheets are Type B Grade I according to the regulation ASTM C 1186-07 and Type B Category 2 according to the regulation INTE/ISO 8336:2007.
Technical Specifications of the Product Description
Minimum Value
Maximum Value
Resistance to Flexion (dry)(N/mm2)/A
7.0
Elastic Module (dry) (kN/mm2)/A
2.5
4
Density (kg/dm3)
0.9
1.2
Maximum Loads Allowable: positive pressure kg/m2 Distance (m)
Thickness (mm)
Between Supports Sheet placed transversally
12
14
LOAD
LOAD
Humidity (%)
10
Total Absorption (%)
40
0.41
350
425
Superficial Absorption (%)
25
0.61
224
305
Humidity Movement (mm/m)
1.3
Total Contraction (mm/m)
4.0
Admissible loads considering a maximum deflection of L/240
Water Absorption (Karsten) (ml/24 h) Exposed face
1.5
Smoke development
0
Flame propagation
0
Maximum Deflection
Applications Supports roofs: • Mud or clay tiles • Asphaltic tiles • Fibercement tiles
Roof Bases Thickness
12mm
14mm
SMOOTH
SMOOTH
Width (cm)
122
122
Length (cm)
244
244
Presentation
Average Weight (kg/sheet) 40,7 | 49,2 | 54,6
43,7
Coverage (m2)
2,97
2,97
When You Build Demand Certified Products
Environment
Product Certification (Costa Rica)
Occupational Security
Quality
Learn more about certification UL in www.ul.com under the name of Plycem
Plystone
Roof bases on buildings act as support to the final finish of its roof or ceiling. Plystone roof bases offer a high-performance superior covering, with unbeatable conditions of durability, comfort, and security.
Roof Bases Typology
1 2 3 4 5 6
We classify roof bases simultaneously considering their internal appearance and the type of finish used as ceiling.
Base for asphaltic tile (Shingle) Base for mud tile or cement tile Base for PLYCEM tiles Base for metallic roofs Base for exposed roofs Base for non-exposed roofs
1 Base for asphaltic tile (Shingle) The PLYSTONE sheet offers a flat, firm, and leveled surface over which the asphaltic felt that acts as a waterproof base and vapor barrier to the asphaltic tiles is installed. No other type of support structure is required for the covering. The application of the asphaltic tile or asphaltic shingle must be carried out following the manufacturer’s instructions.
2 Base for mud tile or cement tile The traditional mud tile, of a general use in many of our countries can be placed over PLYSTONE sheets, after a previous placement of an asphaltic layer or vapor barrier. When the tiles are applied directly over PLYSTONE, it must be verified that the workloads do not exceed the admissible support capacity of the sheets because it could present deformations. It is necessary to carry out a structural evaluation in order to determine if it is necessary to install an additional substructure that transmits the loads of the main structure.
3 Base for PLYCEM Baroque Tile A substructure is installed over PLYSTONE sheets transversally to the main structure that acts as direct support to the tiles and transmits the loads to the main structure. The PLYCEM tiles must be installed following the regulations and recommendations offered by PLYCEM.
4 Base for metallic roofs Similarly to the aforementioned, once the PLYCEM sheets have been installed as the base, it is necessary to install a substructure transversal to the main structure that acts as support to the different types of metallic roofs available in each market.
5 Base for exposed roofs The one where the lower face of the PLYSTONE sheet wants to be used as ceiling, visible from the inside of the building.
6 Base for non-exposed roofs A ceiling independently hides the lower face of the PLYSTONE sheet. A space is created between the ceiling and the base, which allows the passing of installations, the placement of ducts and isolations. The scope of application for the PLYCEM roof base is mainly residential, although it can also be used in any Scope of Application other type of building. The slope of the roof base must be that recommended by the manufacturer of the type of covering that is going to be used.
Plystone Roof Bases Demands and requirements Besides the aesthetic aspect, the design of the roof base must consider: • Acoustic isolation: from aerial noise and the noise caused from impact on the covering • Thermal isolation: Necessary to achieve adequate comfort conditions • Ventilation: The renewal of the air contained between the ceiling and the roof base must be allowed • Leveling: The entire surface of the roof base must guarantee the leveling of the covering surface • Inclination: The minimum slopes depending on the type of finish to be installed must be respected • Stability: All the structures of the roof base must be stable, thus the estimation and design must be carried out by a specialized professional • Impermeability: Total protection against the passing of rain waters • Drainage: A fast and safe evacuation of rain waters must be guaranteed It is important to follow the recommendations of the manufacturers of the complementary products used.
Components Each of the types of roof bases is made up by different products, either proper or complementary, which constitute the portfolio of raw materials necessary to obtain a roof base of an optimal quality. The lack of or change in these components may affect the final result.
Support Structures
Anchorages
The sheets transversally support themselves over a modulated support structure or at a maximum distance of 610 mm between axes. Depending on the fixation system chosen, the minimum width of the support at the union site of two sheets can vary between 44mm and 50mm. The height and thickness are determined through the structural estimate, carried out by a specialist. The system allows the use of different materials to make up the structure:
Screws, plastic plugs, expansion bolts, nails, anchors, and other elements constitute the most common solutions for the anchorage or fixation of the structures that make up the ceiling base for the primary construction structure. It is recommendable to use elements protected against corrosion, following the recommendations for their correct installation.
Galvanized Steel Structures Laminated, galvanized, and cold-figured steel profiles designed to work as elements submitted to loads. The minimum specifications for the steel for this type of use are: Fluency limit 2,400 kg/cm2 Minimum thickness 0.9 mm (caliber 20) Galvanization degree: Z180/G60, corresponding to 180 grs/m2 or 0.60 ounces/foot2 Commercial geometry is generic, its commercial availability is very varied in sizes, forms, and thicknesses. Black Steel Structures Laminated steel, molded in cold or heat. The sections and thicknesses of the elements depend of the structural estimate previously elaborated by a specialized professional. In order to guarantee its durability, the material must be protected against corrosion. Wooden Structures The wood must be classified, of a structural quality, treated, dry, and straight. The dimensions of the elements are determined by the structural estimate.
Sheets The PLYSTONE sheets used in this application must be of a minimum thickness of 12mm and waterproof. They may be smooth, slotted, or with a wooden texture. The nominal commercial sizes available are: 1220x2440mm 1220x3050mm.
Fixations The good performance of the PLYCEM roof base system depends in great measure of the adequate fixation of the sheets to the support structure. Additionally, factors such as the following intervene in this: • Types of structures • Distribution and placement of the structure • Selection of the screws • Trace for the correct location of the screws • Use of the appropriate tools • Movements of the structural system • Dilations and contractions of the sheets. The system’s fixations are divided into two large families:
Anchorages Fixations for the assembly of galvanized steel structures #8x1/2” galvanized steel screws (LD8.050), extra flat non-slip head, High screw. Low, fine auto-perforating tip. Used to assemble galvanized steel structures of up to 0.8mm in thickness. #8x1/2” galvanized steel screws (LD8.050), extra flat non-slip head, “S” type screw. Auto-perforating bit tip. Used to assemble galvanized steel structures of up to 0.8mm in thickness and 1.4mm. #10x3/4” (MM10.076), #10x1”1/2” (MM10.150), and #10x2” (MM10.200) galvanized steel screws, hexagonal head, S4 screw, auto-perforating bit tip. Used to assemble beams, trusses, and other galvanized steel structures of up to 2mm in thickness. Fixations for the assembly of PLYSTONE sheets #8x1” ¼” (PL8.125) and #8x1” ¾” (PH8.175) galvanized steel or ceramic screws, trumpet head with auto-countersinking grooves, High.Low screw, with a fine tip. Used for the fixation of 11mm and 14mm PLYCEM sheets to wooden and galvanized steel structures of up to 0.8 mm. #8x1” ¼” (PL8.125) and #8x1” 5/8” (PH8.162) galvanized steel or ceramic screws, trumpet head with auto-countersinking grooves, S12 screw with self-perforating bit tip and blades for dilated perforations. Used for the fixation of 11mm to 17mm PLYCEM sheets to wooden and galvanized steel structures of between 0.8 mm and 2mm.
Screws, nails, anchors, and other elements constitute the most usual solutions for the anchorage or fixation of the roof base to the building’s primary structure. Use elements protected against corrosion and follow the installation recommendations supplied by the manufacturers.
Seals and Additives Some cases may require the use of chemical seals, either rigid or flexible, regulating and textured mastic, repellants, adhesives, dyes, etc.; very specific products; in these cases PLYCEM has worked along with specialized companies to develop the most suitable complementary products and offer them to its clients.
Finishes Asphaltic roof systems Made up of felt, tiles, ridges, fixations, and related accessories. • Mud and cement tiles Elements of a handcrafted or industrial production, marketed in different formats and textures. • PLYCEM or metal wavy roof systems Made up of wavy colored or gray sheets, fixations, ridges, and other accessories designed to complement the cover. In all cases, the installation of the finishes must be carried out following the rules and recommendations indicated by the manufacturer of the cover.
Plystone Roof Bases
D8
D10
Index of Details
D12 D13
D14 D14
D11 D9 D5
D6 D7
D3
D2 D4 DETAIL 2 Distribution of the support structure in one direction – metal
DETAIL 3 Distribution of metal structure 30
30 32
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12
20
30
30 30
12 20
4
0
61
30. Wooden structure 32. Connecting angle 34. Screw for wood
61
0
0 61
61
32
12
61
0
2-3
30
20
0
2-3
30
30 34
61
34
0
32 34
30. Wooden structure 32. Connecting angle 34. Screw for wood
32
30
Plystone Roof Bases DETAIL 5 Distribution of the support structure in both directions - wood
DETAIL 4 Distribution of the support structure in both directions â&#x20AC;&#x201C; metal
1
1
0
2-3
</=
122
1
12 20
1
61 0
2-3
20
0 61
2-3
61
2-3 6
0
0 61
32
12
32
0 61
1
10
0 61
1 1. Mooring profile (MP) 2. Encounter profile (EP) 3. Intermediate profile (IP) 6. Screw LD/LH8.050 10. Screw MM10.050 32. Connecting angle
2-3 32
2. Encounter profile (EP) 3. Intermediate profile (IP) 10. Screw MM10.050 32. Connecting angle
34
DETAIL 7 Distribution of fixations on sheets over a structure in both directions
DETAIL 6 Distribution of fixations on sheets over a structure in a single direction
360
360
360
70
20
70
70
360
360
70
20
610
20
610
360
610
=
30
1220mm
=
70
2440mm
610
610
30 38
1
2-3 610
610
38 27
1220mm
610
2-3
1220mm
2. Encounter profile (EP) 3. Intermediate profile (IP) 27. Assembly clip 30. Wooden structure 38. Screw PH8 125/150
1. Mooring profile (MP) 2. Encounter profile (EP) 3. Intermediate profile (IP) 30. Wood beam 38. Screw PH8 125/150
Plystone Roof Bases DETAIL 8
PLYSTONE 14mm
Horizontal union between structure sheets in a single direction
3 2
DETAIL 9
1
Horizontal union between structure sheets in both directions PLYSTONE 14mm 3 2 1
1. Mooring profile (MP) 2. Encounter profile (EP) 3. Intermediate profile (IP) 27. Assembly clip 38. Screw PH8 125/150
38
27
1
1. Mooring profile (MP) 2. Encounter profile (EP) 3. Intermediate profile (IP) 38. Screw PH8 125/150
38
DETAIL 10
Fixation of PLYSTONE to different types of support A 20mm
3 a 4mm
PLYSTONE
PLYSTONE
B
B
A
DETAIL 11
Placement of asphaltic plush
3
38
50mm
PLYSTONE
m
100m
mm
19
50mm A - SUPPORT IN UNIONS
@400
30
47
50mm B - INTERMEDIATE SUPPORT 25m
12
30
100mm
38
PLYSTONE
Variable According to estimate
20
31mm
Variable According to estimate
3 a 4mm
Variable According to estimate
38
2
Variable According to estimate
PLYSTONE 14
2. Encounter profile (EP) 3. Intermediate profile (IP)
30. Wooden structure 38. Screws PL/PH8 125/150
m
14. Asphaltic plush 19. Drain 47. Galvanized wire clip
Plystone Roof Bases DETAIL 13
Other flat coverings
PLYSTONE
PLYSTONE
PLYSTONE
PLYSTONE
14
14 48b
48c
48a
48d 14 31
14. Asphaltic plush 31. Wooden base 48a. Asphaltic shingle cover
48b. Asphaltic roll cover 48c. Concrete/clay flat cover 48d. Metal shingle cover
DETAIL 12
Asphaltic Shingle Cover
DETAIL 14
Cubierta ondulada y teja de barro (no venĂa traduccion)
14. Asphaltic plush 19. Drain 48. Shingle cover 49. Cornice 50. Gutter Support 51. Gutter
1. Mooring profile (MP) 2. Encounter profile (EP) 3. Intermediate profile (IP) 14. Asphaltic plush 30. Wooden structure 31. Wooden base 34. Screw for wood 38. Screw PL/PH8. 125/150 48e. Wavy roof 48f. Mud/clay tile 51. Gutter
Plystone
Advantages
Roof Bases
• Easy installation • Adaptable to metallic or wood structures • Light 30 kg/m2 versus 125 kg/m2 in 5 cm concrete slabs. • Resistant to flexion
• Water resistant • Fireproof
Description The mezzanines are construction elements that create a firm and stable horizontal plane; they define vertical limits between the spaces. The Plystone mezzanines act as slabs transmitting the loads to the support structures and they have the capacity to safely support the efforts generated by the action of the temporary and permanent loads present.
Product Components Portland Cement, calcium carbonate, cellulosic fibers, and other minor aggregates.
Manufacturing and Quality Control Plycem sheets are manufactured at plants certified in the regulations ISO 9001:2004, ISO 14001:20 04, and OHSAS 18001:2007. Plystone sheets are Type B Grade I according to the regulation ASTM C 1186-07 and Type B Category 2 according to the regulation INTE/ISO 8336:2007.
Maximum Loads Allowable: positive pressure kg/m2
Technical Specifications of the Product Descripción
Minimun Value
Maximun Value
Distance
Thickness (mm)
Between Supports
Resistance to Flexion (dry)(N/mm2)/A
7.0
Elastic Module (dry) (kN/mm2)/A
2.5
4
Density (kg/dm3)
0.9
1.2
Humidity (%)
10
Total Absorption (%)
40
Superficial Absorption (%)
25
Humidity Movement (mm/m)
1.3
Total Contraction (mm/m)
4.0
20
22
LOAD
LOAD
0.41
468
566
0.61
320
390
Sheet placed transversally
Admissible loads considering a maximum deflection of L/240
Water Absorption (Karsten) (ml/24 h)
Maximum Deflection
Exposed face
1.5
Smoke development
0
Flame propagation
0
Applications
Mezzanine Sheets Thickness
20mm
22mm
Width (cm)
122
122
Length (cm)
244
244
Texture
LISO
LISO
Average Weight (kg/sheet)
67,9
74,7
Average Weight (kg/m2)
22,8
25,1
Projects with a light construction system such as: • Homes • Attics • Mezzanines • Expansions • Terraces, etc When You Build Demand Certified Products
Environment
Product Certification (Costa Rica)
Occupational Security
Quality
Learn more about certification UL in www.ul.com under the name of Plycem
Construction element whose objective is to create a firm, horizontal, stable level, with the capacity to safely support the efforts generated by the action of its own loads and the work loads that act over it; transfers the loads to the primary construction structures and defines a vertical limit between two spaces.
Plystone Mezzanines
The PLYSTONE mezzanine system is based on the use of a duly distributed structure calculated according to the rules and procedures recommended by the institutions that regulate construction in each country; a PLYSTONE sheet with a minimum thickness of 20mm is placed over the level created as a cover and it is appropriately fixed to the structure. The PLYSTONE sheet makes up the substrate over which the elements that conform the final pavement are subsequently applied.
Typology
1 2
Dry Mezzanines Formwork
1 Dry Mezzanines Those in which the PLYSTONE sheet that makes up the substrate acts as paving of the mezzanine, the final coverings are of a flexible and light nature and at no time is the PLYSTONE sheet submitted to the action of humidity.
2 Formwork Those in which the PLYSTONE sheet behaves like a permanent formwork of a low-thickness cement flagstone, which acts as the substrate to rigid coverings.
The PLYCEM mezzanines have been designed for dry use, exclusively in interior areas they result efficient Scope of Application when installed in constructions of a residential, commercial, and institutional nature, in new buildings or in remodeling works.
Demands and requirements In the design of a mezzanine the analysis and solution to different technical, functional, and construction demands related to the following must be met: • Load transmissions • Acoustic protection • Fire protection • Thermal isolations • Sealing • Condensation • Passing of installations • Visual limit Each of these demands is linked to one or several parts of the mezzanine’s components: Paving Related with the covering of the floor, sealing, isolation, leveling Support Structure Related with the beams and the transmission of loads to the construction’s primary structure
Central Area Linked to the air chamber, the passing of ducts and pipes Inferior Area Related to the covering of beams, the support and installation of the ceiling The complexity and high security demand for this type of solutions makes necessary the intervention of a professional trained in the subject so he/she may determine the design’s parameters, estimate and supervise the construction works of the structures.
Support Structures Given the structural characteristic of the PLYCEM mezzanines, the support structure constitutes the fundamental nucleus of the mezzanine, receives the vertical loads made up by its own weights and the overloads are transmitted to the primary structure. It also receives horizontal loads due to the wind or other causes (seismic movements) and transmits it to the construction’s bracing elements. The materials used for the construction of the skeleton that makes up the mezzanine’s structure must have very specific resistance characteristics. In this sense, the steel and structural wood offer many advantages in comparison with traditional materials. Galvanized Steel Profiles made of laminated, galvanized, and cold-formed steel, designed to work as elements submitted to loads. The minimum specifications of the steel recommended for this type of use are:
Yield Stress: 2400 kg/cm2 Minimum thickness: 0.9mm (20 caliber) Galvanization degree: Z180/G60, equivalent to 180g/m2 or 0.60 ounces/foot2 The technical specifications demanded in the normal regulations or any other codes in force in each country are applicable. The commercial geometry is generic, its commercial availability is very varied in sizes, forms, and thicknesses. Woods The wood must be selected, of a structural quality, with controlled humidity content, industrially immunized against deterioration due to humidity and the attack of insects. The sections and lengths vary according to the availability and commercial offer. A qualified
professional in the area must carry out the estimate, design, and construction. Black Steel Alternative of general use in all the markets; the offer and availability is very varied; demands the use of protection processes and paints; assemblies require a detailed analysis. As in previous cases, its design, estimate, construction, and supervision require the intervention and responsibility of a professional specialized in this subject.
Plystone Mezzanines Components PLYCEM mezzanines are made up by several products, both their own and complementary, that constitute the portfolio of products necessary to build a safe, high-quality mezzanine. The lack of or change in these components can affect the final result, therefore their selection must be very cautious.
Anchorages The anchorage systems in the mezzanines are submitted to high demands, thus the use of industrially elaborated elements, of a proven quality, such as screws, expansion bolts, mechanical or chemical anchors, reinforcement angles and platens, welds, protection coverings, and other accessories is recommended. All the elements must be protected against corrosion; their installation must be made following the manufacturer’s rules and technical recommendations.
Mezzanines with a wooden structure. Index of details
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Sheets PLYSTONE sheets of 20, 22, and 30 millimeters in thickness, either standard or slotted. . The commercial nominal sizes available are: 1220x2440mm (4”x8”) 1220x3050mm (4”x10”) Dry Mezzanines When the sheets comply with the duty of the surface, base for the flexible floor, PLYSTONE of at least 20mm in width must be used; if the use is different to a residential one we recommend using PLYSTONE of 22 or 30mm in width, depending on the load conditions. Formworks If the idea is to melt a concrete flagstone over the PLYSTONE sheets it will act as a lost formwork, and the minimum thickness recommended is a 20mm PLYSTONE. A specialist must make the estimate.
A specialist must estimate the load beam based on the workloads, the separation between beams, and the distance between supports
DETAIL 2
Mezzanines with a wooden structure Union between the load tie beam and the mooring peripheral tie beam, anchorage on cement
DETAIL 1
Mezzanines with a wooden structure anchored with a peripheral tie beam against a wall
Fixations The fixation of the sheets to the support structure constitutes a fundamental aspect and a priority in order to achieve a correct operation of the application. The fixation is not an isolated element; different aspects related to the following must be taken into consideration: • Types of structures • Distribution and placement of the structure • Selection of the fixations • Distribution and location of the fixation elements • Use of the appropriate tool to install the elements • Movements of the structural system • Dilations and contractions of the sheets • Treatment of the unions
a. The anchorage elements must be designed and selected according to the data obtained from the structural estimates. d. Distance determined in the structural estimates. 1. Beam 2. Masonry 3. Peripheral tie beam 4. Anchorage bolt
1. Beam 2. Peripheral tie beam 3. Anchorage bolt 4. Lower girder 5. Connector in angle 6. Load tie beam 7. Lag-screw
Plystone Mezzanines
1. Beam 7. Transversal tie beam 11. Structural connector in angle 3. Perimeter tie beam 5. Inferior support 6. Connector in angle 7. Transversal load tie beam 8. Lag-screw 9. Stud
DETAIL 4
Mezzanines with a wooden structure – structure assembly
DETAIL 3
Mezzanines with a wooden structure Encounter between the load beam and the perimeter mooring beam, anchorage to the wall with wood DETAIL 5
DETAIL 6
Mezzanines with a wooden structure Cantilever with load tie beams
Mezzanines with a wooden structure – structure assembly
5. Inferior support 7. Transversal load tie beam 9. Stud 11. Structural connector in angle 12. Structural connector
Maximum L Maximum L: 0.61 m (2’) for constructions with a maximum of 2 floors, for greater lengths the estimator must make the corresponding analysis. 5. Inferior support 6. Hinge 7. Transversal load tie beam 9. Stud 11. Structural connector in angle
DETAIL 7
Mezzanines with a wooden structure Cantilever perpendicular to load tie beams
DETALLE 8 Minimum 1.22 m (4’)
Maximum 0.61 m (2’) Cantilever 3. Perimeter tie beam 5. Inferior support 6. Connector in angle 7. Load tie beam 8. Lag-screw 9. Stud 11. Structural connector in angle
Mezzanines with a wooden structure Auxiliary support for the fixation of Plystone sheets
6. Connector in angle 7. Transversal tie beam 14. Auxiliary tie beam
Plystone Mezzanines DETALLE 10
Mezzanines with a wooden structure Distribution of Plystone sheets
DETAIL 9
Mezzanines with a wooden structure Encounter between the load tie beams and perimeter tie beams
End sheets supported by three tie beams
3. Perimeter tie beam 6. Connector in angle 6. Load tie beam 7. Lag-screw
3. Perimeter tie beam 7. Load tie beam 14. Auxiliary tie beam
d = 610 mm (24”) max 406 mm (16”) 305 mm (12”)
The estimator must establish the space between the load tie beams according to the load conditions and the distance between the supports.
DETAIL 11
Mezzanines with a wooden structure Location of fixations on the Plystone sheet
DETAIL 12
Mezzanines with a wooden structure Fixation of Plystone sheets to tie beams
7. Load tie beam 17. Plycem Screw PL 10 175 18. Anti-vibration tape 19. Multiuse adhesive for construction 20. Pegacem Note: Avoid placing the sheets on the building’s border
DETAIL 11
Foresee dilatation unions on the sheets every 6.10 m (20’)
Plystone Mezzanines Mezzanines with a galvanized steel structure r
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The load profiles must be estimated in function of the workloads, the distance between profiles, and the distance between supports.
DETAIL 1
Mezzanines with a galvanizedsteel structure Anchorage of the perimeter tie beam against the wall
DETAIL 2
Mezzanines with a galvanized steel structure â&#x20AC;&#x201C; encounter between the load profile and the mooring profile, anchorage over foundations a. The anchorage elements must be designed and selected according to the data obtained in the structural estimates b. Distance determined in the structural estimates 1. Beam 2. Masonry 4. Anchorage bolt 24. PE load profile
1. Beam 2. Masonry 4. Anchorage bolt 11. Structural connector in angle 22. Stiffener 23. PA Profile 24. PE load profile 25. Screw MM 10-050 26. Screw LH 8-050
Plystone Mezzanines DETALLE 3
DETAIL 4
Mezzanines with a galvanized steel structure â&#x20AC;&#x201C; encounter between the load profile and the mooring profile, anchorage over a wall with a steel structure
Mezzanines with a galvanized steel structure â&#x20AC;&#x201C; encounter between the load profile and vertical profiles of a bearing wall
6. Connector in angle 24. Load tie beam 25. Screw MM 10-050 26. Screw LH 8-050 28. PE wall profile 29. Stiffening block
11. Structural connector in angle 22. Stiffener 23. PA Profile 24. PE load profile 25. Screw MM 10-050 26. Screw LH 8-050 27. PA wall profile 28. PE wall profile
DETALLE 6
DETAIL 5
Mezzanines with a galvanized steel structure Projecting of load profiles
1. Cement beam 4. Anchorage bolt 6. Connector in angle 22. Stiffener 23. PA Profile 24. PE load profile 25. Screw MM 10-050 26. Screw LH 8-050
Mezzanines with a galvanized steel structure Projecting perpendicular to the load beams
6. Connector in angle 11. Structural connector in angle 22. Stiffener 23. PA Profile 24. PE profile 25. Screw MM 10-050 26. Screw LH 8-050 28. PE wall profile
Plystone Mezzanines DETAIL 7
DETAIL 8
Mezzanines with a galvanized steel structure Union between concrete load profiles
Mezzanines with a galvanized steel structure Auxiliary support for the fixation of the Plystone sheet 26
27
1. Beam 4. Anchorage bolt 6. Connector in angle 11. Structural connector in angle 22. Stiffener 23. PA Profile 24. PE profile 25. Screw MM 10-050
24
24
OPTION 2
OPTION 1
24
25
6. Connector in angle 24. PE profile 25. Screw MM 10-050 26. Screw LH 8050 27. PA Profile
24
24
6
6
DETAIL 10
Mezzanines with a wooden structure Distribution of Plystone sheets DETAIL 9 14 4
3
8
3
Mezzanines with a galvanized steel structure Perpendicular encounter between load profiles and perimeter beams
5
7
9
2
7
7
6
6. Connector in angle 23. PA Profile 24. PE profile 25. Screw MM 10-050
d
7
3. Perimeter tie beam 7. Load tie beam 14. Auxiliary tie beam
d = 610 mm (24”) max 406 mm (16”) 305 mm (12”)
d
7
End sheets supported by three tie beams
1
d
d
7
The estimator must establish the space between the load tie beams according to the load conditions and the distance between the supports.
Plystone Mezzanines DETALLE 12 DETAIL 11
Mezzanines with a galvanized steel structure Location of fixations on the Plystone sheet
Mezzanines with a galvanized steel structure Fixation of Plystone sheets to profiles
17. Plycem screw PL 10-175 18. Antivibration tape 19. Multi-use adhesive for construction 20. Plycem-gel, Pegacem 24. PE load profile
Distance between centers
D15
Finishes â&#x20AC;&#x201C; Placement of light covers Index of details D16
D18 D17 D14
The application of high specific loads, transmitted through reduced area elements, may cause perforation of the material; in order to avoid this, it is necessary to previously place an auxiliary element that will expand the contact area.
Plystone Mezzanines DETAIL 14
Finishes Placement of vinyl and ceramic tiles
DETAIL 15
Finishes Placement of rugs
18. Anti-vibration tape 19. Multiuse adhesive for construction 32. Adhesive for the rug base 33. Rug base 34. Rug
18. Anti-vibration tape 19. Multiuse adhesive for construction 30. Plycem Adhesive 31. Vinyl floor NOTE: Avoid specific loads Do not submit the sheets to humidity
DETAIL 16
DETAIL 17
Finishes Installation of wood
Finishes Mezzanines – Metal Lath
10. 1 ½” Nail 18. Antivibration tape 19. Multiuse adhesive for construction 21. 3” x 1” wood 35. Floorboards
18. Antivibration tape 19. Multiuse adhesive for construction 38. Waterproof membrane 39. Contraction bar 40. Mortar layer 41. Adhesive mortar 42. Ceramic
NOTE: Do not adhere the sheets in a perimeter matter with regard to the wall.
Plystone Mezzanines Installation of Ceramics – Laticrete system Requirements All the recommendations of the panel manufacturer must be followed in what refers to its specifications and correct installation: • Residential use (For commercial or industrial uses see Plycem Steel) • Panels for mezzanines are manufactured in 20 and 22mm PLYSTONE thicknesses. • The maximum distance between support structures must not be greater than 610 mm. • The panels must be installed in a perpendicular manner to the structure. • Panels of less than 1.22 x 1.22 meters must not be used. • The unions of panels must be of 3 mm (1/8”). • A specialized professional must determine the specifications and construction details of the support structure. • The maximum deflection of the support surface must be less than L/360 of the distance between supports for the case of ceramic tiles and of L/720 in the case of natural stones. • The support surface must be structurally solid, free of vibrations, clean, without residues of materials and any agent or sealing additive or curing. • Movement unions must be provided for the ceramic; in interiors they must be distanced at maximum each 6.10 x 11 meters and in exteriors 2.44 x 3.66 meters; movement unions must be considered throughout the entire perimeter. • Prior to the installation, dust must be removed with a humid sponge and the surface of the panel must be kept humid. • To guarantee the contact and the adherence of the finishing pieces with the substrate; trowels with the most adequate size and form of teeth must be used in accordance with the size of the finishing pieces. • In order to avoid cracking or detachment of the finishing placed over the panel unions, the use of anti-fracture membranes and adhesives developed with that purpose is necessary. • The installation of the ceramic or stone pieces must be carried out following the recommendations of the manufacturers of the adherence systems.
Installation of finishes The installation consists of three phases: • Treatment of the unions • Installation of the ceramics • Treatment of the unions between ceramics
“Premium” laticrete system for interior and exterior use The installation consists of three phases: • Treatment of the unions • Installation of the ceramics • Treatment of the unions between ceramics
Installation of Finishes Treatment of unions between panels Products: Anti-Fracture Membrane Laticrete Blue 92) • With a roller or brush apply a layer of waterproof coating over the unions, in a width of 20 cm. • Soak the 15 cm width membrane in the additive and apply a second layer of the waterproof coat. Let dry. • Once the previous treatment has dried, apply a layer of the waterproof coat with a roller or brush in a width such that will allow for a second layer of the Membrane of 97 cm in width. • Soak the membrane of 97 cm in width in the waterproofing liquid, pressing firmly with the roller or brush until the liquid soaks through the fabric. Apply an additional hand of the waterproofing liquid. When necessary join the fabric, overlap it 5 cm. • Let dry for three to four hours before installing the ceramics with the appropriate mortar unions.
Installation of the Ceramics Products: Laticrete Drybond 272 Premium + Latex Additive Laticrete 3701 • Do not humidify the ceramic or stone pieces. • In a clean and appropriate recipient, pour the latex additive 3701. (1.67 gallons for each 22.7 kg sack of Drybond 272 Premium). • Add the Drybond 272 mortar and mix until a uniform consistence of a plastic texture is obtained. • Never add water. • Adjust the consistency if necessary, mix again and let sit for 5-10 minutes. • With the smooth part of the trowel apply the mix on the substrate while pressing firmly on the substrate and with the adequate trowel scratch the applied product. Apply an area sufficient to work for 15 to 20 minutes. • Apply the mix on the back part of the ceramic pieces. • Apply the ceramic piece pressing and turning over the substrate to appropriately distribute the mix. • With a rubber mallet adjust the ceramic pieces until they are absorbed in the mix in a leveled manner.
• Make sure that the mortar covers the substrate completely, periodically remove a ceramic piece and check it. • Clean the tools while the mortar is fresh.
Treatment of Unions Between Ceramic Tiles Products: Union mortar: Laticrete mortar (Series 500 or Series 600) + Latex additive Laticrete 3701. • Start the treatment of the unions 24 hours after the ceramic pieces have been installed. • In a clean and appropriate recipient pour the Latex additive 3701 (1 liter of additive + 1 liter of water per 11.3 kg bag of mortar Series 500 or 2.4 liters of additive + 2.4 liters of water per 11.3 kg bag of mortar Series 600). • Add the Union Mortar and mix until a dense consistency is obtained. • Let sit for 5-10 minutes. • Humidify the ceramic’s surface before filling the unions. • Using the most appropriate techniques for this task, apply the mortar on the unions and with a rubber trowel distribute it diagonally. • Eliminate the excess of mortar from the ceramics immediately. • Let dry for 1 hour prior to cleaning the ceramic using a nylon sponge or a piece of carpet for the cleaning works. • Clean the tools while the mortar is fresh.
“Economic” laticrete system for interior and exterior use Treatment of unions between panels. Products: Anti-fracture membranes Lacticrete) • With a roller or brush apply a layer of waterproof coating over the unions, in a width of 45 cm. • Soak the 38 cm reinforcement fabric in the Liquid Rubber, pressing firmly with the roller or brush until the liquid soaks through the fabric. Apply an additional hand of additive. When necessary join the fabric, overlap it 5 cm. • Let dry for three to four hours before installing the ceramics with the appropriate mortar unions.
Treatment of Unions Between Ceramic Tiles Products: Laticrete Union mortar Drybond 272 Premium + Latex Additive Laticrete 73. • Do not humidify the ceramic or stone pieces. • In a clean and appropriate recipient, pour the latex additive 73. (1.67 gallons for each 22.7 kg sack of Drybond 272 Premium). • Add the Drybond 272 mortar and mix until a uniform consistence of a plastic texture is obtained. • Never add water. • Adjust the consistency if necessary, mix again and let sit for 5-10 minutes. • With the smooth part of the trowel apply the mix on the substrate while pressing firmly on the substrate and with the adequate trowel scratch the applied product. Apply an area sufficient to work for 15 to 20 minutes. • Apply the mix on the back part of the ceramic pieces. • Apply the ceramic piece pressing and turning over the substrate to appropriately distribute the mix. • With a rubber mallet adjust the ceramic pieces until they are absorbed in the mix in a leveled manner. • Make sure that the mortar covers the substrate completely, periodically remove a ceramic piece and check it. • Clean the tools while the mortar is fresh.
Treatment of Unions Between Ceramic Tiles Products: Union mortar: Laticrete mortar (Series 500 or Series 600) + Latex additive Laticrete 3701. • Start the treatment of the unions 24 hours after the ceramic pieces have been installed. • In a clean and appropriate recipient pour the Latex additive 3701 diluted (1 liter of additive + 1 liter of water per 11.3 kg bag of mortar Series 500 or 2.4 liters of additive + 2.4 liters of water per 11.3 kg bag of mortar Series 600). • Add the Union Mortar and mix until a dense consistency is obtained. • Let sit for 5-10 minutes. • Humidify the ceramic’s surface before filling the unions. • Using the most appropriate techniques for this task, apply the mortar on the unions and with a rubber trowel distribute it diagonally. • Eliminate the excess of mortar from the ceramics immediately. • Let dry for 1 hour prior to cleaning the ceramic using a nylon sponge or a piece of carpet for the cleaning works.
• Clean the tools while the mortar is fresh.
NOTES: The latex additives used as moisturizers in the mortars for the installation and unions seek to: • Provide greater elasticity • Improve adherence • Reduce water absorption • Increase resistance to cuts • Increase the resistance to physical and thermal crashes and impacts • Increase the work time of the mortars • A slower and more homogenous curing process For works during the night or that require a faster curing, the latex additives Laticrete 3701 and Laticrete 73 must be substituted with the latex additive Quick Laticrete 101. In shower areas or areas subject to humidity the use of the waterproofing membrane Laticrete 9237 is recommended. Said membrane consists of an additive and a fabric that when used between the panels acts as an Anti-Fracture Membrane.
Plystone Mezzanines DETAIL 18
Finishes â&#x20AC;&#x201C; Mezzanines â&#x20AC;&#x201C; Direct ceramic union, Laticrete system
18. Antivibration tape 19. Multiuse adhesive 41. Laticrete System mortar 42. Ceramic 43. First Laticrete System 44. Laticrete System Membrane
All unions must be treated with the Lacticrete system; the instructions of the corresponding annex must be followed for their installation. NOTE: Verify the need for peripheral dilations when required.
Fibercement Advanced Technology
Impact testing
Lightweight and Strong
Termite Resistant
Water Repellent
Moisture Resistant
Non-combustible Easy installation
For more information contact us: Costa Rica: (506) 2575-4300 • Guatemala: (506) 8707-4602 • El Salvador: (503) 2251-9300 Honduras: (504) 612-5001 ó 670-0444 / Tegucigalpa: (504) 239-7954 • Nicaragua: (505) 2255-5250 ó (506) 8707-4602 Panamá: (507) 6747-8700 • Puerto Rico, República Dominicana, Cuba, Jamaica, Belice: (506) 8707-4602 Venezuela: (58) 212271-3256 • Perú, Ecuador, Barbados, Trinidad & Tobago: (593) 9 8002877 México: 01 (55) 1114 1321 y 01 (55) 1114 1359, Nextel: 01 (55) 4616 3014 y 01 (55) 4616 3065 USA: +1 210 5457310
servicioalcliente@plycem.com
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