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Table of Contents
- What is the Monolite? How is it made? What is it made of?
- How is the Monolite used?
- What are Monolite panel's Basic Technical Data
- What choices of Monolite core density and steel mesh styles are available?
- How does Monolite compare in cost to other building systems?
- What code's do Monolite conform with?
- What is the insulation (R) Value factors for the Monolite?
- What about thermal value heat loss?
- What is the (S.T.C.) Sound Transmission Coefficient?
- What is the fire rating of Monolite?
- How is the Monolite panel secured into the slab?
- How is a bond beam made with Monolite?
- How is the electrical and plumbing installed?
- How are windows and doors installed?
- How do you build curved or radius walls with Monolite?
- How does Monolite hold up under adverse conditions such as hurricanes, tornadoes, earthquakes and fires?
- What is the wind load capacity of Monolite?
- What are the load bearing capabilities of Monolite?
- How are various Shotcrete or cements applied to the Monolite?
- Is the polystyrene waterproof? Is the foam waterproof?
1) What is the Monolite? How is it made? What is it made of?
Monolite is a prefabricated Three Dimensional Lightweight Structural panel consisting of a super-insulated polystyrene core sandwiched between two engineered layers of 10 ga Steel welded wire fabric mesh. To complete the panel form process a 10 ga Steel wire truss is pierced completely through the polystyrene core and welded to each of the outer layer sheets of 10 ga Steel welded wire fabric mesh. Once these three elements are joined by
Monolite's state of the art manufacturing equipment the panels are delivered to the job site, erected, plumed, wire-tied and The Shot-concrete is field applied to each side of the panels, you end up with what many have referred to as The wall of the future; a Super insulated Monolithic, Lightweight, Cast In Place Concrete wall system that due to its Characteristics makes it one of the strongest and most energy efficient wall system you can find.
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2) How is the Monolite used?
Monolite Systems is a Constructive system that is being used all over the world, in construction projects of virtually every type, projects such as; Office Buildings, Upscale Homes, Affordable Housing Condominiums, Shopping Centers, Schools, Assisted living quarters, High Rise Hotels, Churches, Fire Stations, Sound barrier walls etc. Quite often the Monolite panel is being used in all the elements of the building Structure including walls, floors, ceilings and roof structure. Monolite panels replace wood, metal, masonry block pre-cast panel and ICF block walls. Monolite is also extremely versatile and can be easily integrated with any of the above construction systems.
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3) What are Monolite basic technical data -- with 1 ˝” Shotcrete applied to each side
Characteristics
Mop-3”
Mop- 4”
Axial load
14025 kg/ml
16130 kg/ml
Flex Capacity
498 kg/ml
635
kg/ml
Lateral Load
5000 kg/ml
6000 kg/ml
Thermal Barrier
14-R Value
18-R Value
Sound Barrier
46 db
46 db
Fire Resistance
150 C- 60 min
150 C - 60 min
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4) What choices of EPS core density and steel mesh styles are available?
Dimensions of the Monolite panels are manufactured from a starting width of (4' x
8') length. The Monolite panels can be
prefabricated up to (40' in length) in (12” increments).
Truss wire gauges available are 11, 12 and 14.
EPS Core Outer Layer Wire Thickness [Mesh to Mesh] STANDARD MOP 2.0” MOP 3.0” MOP 4.0" Please request a
price list and information on custom made panels to meet special requirements.
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5) How does Monolite compare in cost to other building systems?
Our product is not price competitive with (2x4) stick framing. Monolite system is competitive with (2x6) stick framing, Metal-stud, Pre-cast walls and is more competitive than Masonry blocks or Insulated Concrete Blocks wall system (ICF). The price comparison below depicts an Approximation your actual cost may vary slightly. Monolite is extremely versatile and can be used with any of the above systems. For return on investment, Monolite beats stick framing as well most other building Systems. The Monolite panels account for a fraction of the structure's cost. The dollars you spend on The Monolite panels can be made up very quickly in energy savings alone. Over the life of the structure, the savings are quite staggering.
Attractive benefits of the Monolite System
- Fast High Quality Construction Time saved - 50% faster than standard construction Speed, occupancy - Saves money on construction loan dollars
- Enhanced resale and marketability value
- Reduces the need for heavy equipment on job fewer trades on job site.
- Strength Durability Greater Structural Integrity Virtually maintenance free wall System Save on long term replacement cost of structure Polystyrene panel or concrete will not decay
- Monolithic design for superior Strength, Safety and Security
- Excellent performance in seismic zones (Earthquake Resistance)
- Noncombustible structure Savings of 18% to 30% on fire Insurance
- Excellent Hurricane protection-up to 225mph wind load
- Insect Termite Rodent Resistant to Mildew and Mold growth, fungi resistant.
- Pro Environment Maximum Conservation of forestry products, Structure durability offers value for generations and saves many Earth resources Dramatically reduces consumption of fossil fuels
- Reduces the size and the cost of HVAC systems.
- Energy Efficient Save 50 to 80% of utility costs on heating and cooling the structure
- Quality Comfort Design flexibility Virtually eliminate outdoor noises Reduce drafts, Wind and temperature fluctuations you will enjoy air quality virtually free of dust, pollen and allergens with use of an air exchanger. Create an acoustical environment for full advantage of sophisticated sound systems and home theaters.
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6)
What code's do Monolite conform with?
- Monolite
Three Dimensional panel meets the CABO one and two-story family dwelling
codes (Compliance
Report No. NER-454, 1/01/1993) which satisfies all SBCCI, ICBO and
BOCA requirements for standard buildings.
- Monolite
Three Dimensional panel also
has HUD compliance covered under SEB#
1120.
- CABO- Council of American Building Officials
- ICBO
-
International Conference Building Officials
- SBCCI
-
Southern Building Code Congress International, Inc.
- BOCA
- Building
Officials and Code Administrators
- HUD
-
Housing Urban Development (SEB# 1120)
- NES
-
National Evaluation Service, Inc. (NEF 454) Miami-Dade County Building Code
Compliance Office American Society for Testing and Materials American
National Standards Institute copies of the above reports available upon
request.
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7)
What is the insulation (R) Value factor for Monolite?
R-Value
is a rating of the material resistance to thermal penetration. The higher the
number, the better the protection value. Many circumstances change the R-Value
rating. R-Values changes with different thickness and density of the polystyrene
panel core, as Well as various thickness of shotcrete applied to the interior
and exterior as well as fluctuation of ambient temperatures Chart shown below
shows the minimum R-Value Ratings you can expect using
Monolite. 2 lb. Polystyrene Core
2.5"
2.0 LB Polystyrene Core-R-Value
11.00
4.0" 2.0 LB Polystyrene Core-R-Value 18.004
5.0" 2.0 LB Polystyrene Core-R-Value 23.00
5.
Please
keep in mind that unlike “batt” Insulation once the Monolite panels are joined
they create a continuous Thermal
Brake thus
disallowing air filtration furthermore Monolite’s
R-Value rating is significantly higher than the R-Value attributed to the
Polystyrene core alone due to the Thermal Mass Effect of the concrete on each side of the panels.
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8) What about thermal value heat loss?
The Monolite System has been designed with maximum environmental comfort in mind. A wood structure simply cannot compare to the comfort level available and the outstanding energy savings created by using the Monolite System. The simple facts are that, Monolite will keep you cooler in summer and warmer in winter. The super-Insulating polystyrene core meets all VA, FHA and HUD thermal requirements.
- No
wood studs to transfer or conduct heat or cold through the exterior wall
- The
incorporation of minimum (3") density of shotcrete and variable
thickness of polystyrene ranging from 2" through 5" offers an
excellent thermal barrier.
- Electrical
and plumbing is through the interior side of the Monolite,
so there are fewer wall penetrations, which keeps thermal loss at a minimum.
- Save
50% to 80% of heating and cooling costs.
- Reduces
size and cost of HVAC System.
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9) What is the (S.T.C.) Sound Transmission Coefficient?
The Sound attenuation is excellent. The double shell configuration of the
concrete plus polystyrene plus concrete sandwich minimizes sound transmissions.
Typical Sound barrier expected is as follows:
- 3"
Concrete (1.5" each side) = approximately
46db
- 4”
Concrete (2.0" each side) = approximately
46db
- Calculated
from the PCI Pre-cast Manual.
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10) What is the fire rating of Monolite?
Monolite has
the following fire-resistance ratings; Fire-rating is derived from the wire mesh
gauge in combination with concrete thickness. The E P S insulation core
demonstrated a flame - spread index of 25 or less and a smoke developed rating
of 450 or less when tested in accordance with ASTM -E84. The modified
polystyrene core does not contain ozone-damaging chlorofluorocarbons (CFC's) in
the manufacturing process or products. 2.5" EPS-Core with 1.50"
Shotcrete each side has the following data.
Fire
Resistance (MOP 2”, MOP 3”, MOP 4”) = 150C - 90min the fire rating
increases with greater quantities of cement applied to each side of the panel.
Polystyrene core will not burn.
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11) How is the Monolite secured into the slab?
The rebar is embedded within the concrete slab. The panel is placed over the
rebar, through the open space between the polystyrene core and the wire mesh.
Once set the rebar is fastened directly to the wire mesh by hand with tie wire.
It is critical the rebar be installed in a straight line so the rebar fits
easily into the cavity between the polystyrene and the wire mesh It is important
to make sure the rebar is completely exposed so it becomes monolithically enclosed
with the shotcrete or cement application. Should the building department or
engineer require additional tie downs, the polystyrene core can be removed from
the base of the panel The panel is then set in place over the required tie-down
and cemented in place. Another option for placing the rebar in the concrete slab
is to drill the concrete slab and pour epoxy in the cavity placing the rebar
within its confines. Typically,
the spacing of the rebar is (24") on center.
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12) How is a bond beam made with Monolite?
A bond beam is used to create large openings, or to strengthen large areas of
ceiling or to he support roof structures. All bond beams created should be pre
approved by a certified engineering firm. Removing
the polystyrene core and installing rebar creates the bond beam.
The best method for removing the polystyrene core is a high-pressure
water blaster; it takes only a matter of minutes. For further information please
see instruction manual.
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13) How is the electrical and plumbing installed?
The installation of electrical or plumbing is achieved by removing the
polystyrene core to create a cavity that electrical conduit or plumbing piping
may be installed into. The polystyrene is Typically1.5 ” off the wire mesh so
that you have a space to install these products. If this opening needs to Be
greater, the polystyrene core can be removed with a small keyhole saw or butane
torch. The polystyrene will not burn it will shrink or melt leaving a cavity.
The electrical or plumbing is then installed into the cavity. For further
information please see instruction manual.
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14) How are windows and doors installed?
The window and door openings may be cut out with the use of three primary tools,
a reciprocating saw, a set of 18" bolt cutters or pneumatic cutter, and a
small hand saw to remove the EPS core. It is recommended that a caulking sealant
compatible with the polystyrene core be used to seal the jamb to the polystyrene
core. For residential construction wood jambs of treated material are then
fitted into for commercial use, pre-finished concrete openings are created. The
windows and doors are then installed into the openings, as they would be into a
typical masonry block wall. For further information please refer to instruction
manual.
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15) How do you build curved or radius walls with Monolite?
You can build curved or radius walls by cutting the eleven gauge wires on one
side of the panel. This will allow
the panel to bend to the desired shape or radius. It is very important not to
cut through the heavier nine-gauge truss wire so that wall strength and
integrity remain intact.
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16) How does Monolite hold up under adverse conditions such as hurricanes, tornadoes, earthquakes and fires?
Monolite excelled in rigorous test given by Mother Nature. For the last ten years, numerous homes have been constructed with the Monolite System on the East Coast, Caribbean and Gulf areas of Mexico and the United States. The homes were built to withstand hurricane fore winds. In Laboratory testing, the Monolite have been tested for up to wind loads 0f 226 miles per hour. In the southwestern are of the United States, a two-story research complex jointly funded by the National Science Foundation, Southern California Edison, Inc., and the University of California built with 3-d panel withstood California's worst earthquake in forty years. The area was struck twice with a (6.5) and (6.9) Richter Scale. According to Dr. Philippe Cohen who resides at the site in the Mojave Desert, the area at one point was subjected to a continuous shake lasting over a full minute. The structure went through the quakes with zero structural effects. Complete (Earthquake) structural testing report from certified engineering firm available on above upon request.
Monolite has become the construction product of choice in
Pakistan, Israel, Saudi Arabia, Brazil, Indonesia, Mexico, and Central America
among others. Monolite
is an ideal building product for structures in dry adverse climates where fire
is always a constant. Monolite
is a non- combustible product and has a minimum 1.5-hour fire rating and higher
rating can easily be attained. Structures
built with Monolite
are virtually fire resistant. Full test report from certified engineering firm
available upon request along with photos.
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17) What is the wind load capacity of Monolite?
The brief synopsis, which follows, is from the test results report dated 1994
from Dade County Miami Florida pertaining to the wind load capacity of Monolite.
Three typical Monolite panels
4’ wide and 10' tall with 1" of field applied shotcrete on each face were installed vertically, side-by-side
on a concrete slab, several inches in front of a rigid backup wall with space
between the panels and the backup wall. The panels were tested per static-wind
load test (PA202-94 manner of testing). Summary: The specimens were
tested in accordance with the Dade County Building Code Compliance Office
Protocols PA 201-94,PA 202-94 and PA 203-94. No failures occurred to the
specimens or their fastenings or anchorage. The products describe in this report comply with SFBC
Sections 2309 and 2315. The panels tested at 126 lbs. per
Sq Ft. pressure, which represents over 225 mph-wind load
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18) What are the load bearing capabilities of Monolite?
The load bearing weights that a typical Monolite wall will support is amazing. The typical wood frame and metal frame wall cannot compare to Monolite strength. A typical Monolite Panel with 2.5" polystyrene core using eleven-gauge wire, 8' in height has been tested at a structure load of over 78,000 Ibs. full load bearing chart available upon request.
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19) How are various shotcrete or cements applied to the Monolite?
The shotcrete is field applied either by hand or machine application on both sides of the panel. This part of the operation is very specialized. We recommend a reputable Stucco Contractor or a combination of both Contractors for this part of the operation depending upon the desired finish. For architects with a special finish in mind we would like to mention that the architectural molds or metal trim could be incorporated into your design to achieve the desired finish. A few of the above-mentioned might be fry “reglets”, point-to-point reveals, parting screed etc. The versatility of numerous types of plaster finishes or stucco finishes will work on interior and/or exterior walls all of the newly created EIFS systems will also work. Additional products you may apply are brick, mini-brick, stone, stone facing, tile almost any type of finish your imagination can conceive will work.
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20) Is the polystyrene waterproof? Is the foam waterproof?
The polystyrene (E P S foam) core is water-resistant. The ASTM test proved maximum water absorption of (2.5%) for (2 lb density E P S). E.P.S. is an inert, organic material. E.P.S. provides no nutritive value to plants, animals, or microorganisms. E.P.S. will not rot and is highly resistant to mildew. Aging has no effect upon the performance of the polystyrene E.P.S. is able to withstand the abuse of temperature cycling 180 assuring long term performance.