SHT-01 · COMMERCIAL ROOFING · TECHNICAL REFERENCE

Lightweight insulating concrete roofs, explained by the contractor who builds them.

INSULATE · DRAIN · ANCHOR — ONE CAST DECK

LWIC decks insulate, drain, and anchor commercial roofs — and they are chronically misunderstood, usually about water. Nine plain-English guides cover how the system actually works, from the material itself to what to do when the first membrane wears out.

TECHNICAL
REFERENCE
NINE GUIDES · SET LW
start with the section cut on SHT-03 ↘
LICENSED
FL roofing & general contractor · CCC1329972
3 US PATENTS
Co-inventor, incl. LWIC fastening US 7,299,598 B2
9 GUIDES
Material, drainage, wind, reroofing, moisture
FORT LAUDERDALE
President & CEO, Apex Roofing, LLC
2
A-2
SHT-02 · THE SYSTEM

What LWIC Is

Lightweight insulating concrete is a cast-in-place insulation systemPortland cement + water + preformed foam or lightweight aggregate. Cast at roughly 20–40 PCF instead of 140–150 PCF for structural mixes. placed as a fluid slurry over the structural deck, usually with EPS insulation boardExpanded polystyrene board embedded between slurry lifts — it carries most of the R-value; the concrete provides the surface, the slope, and the fastening substrate. embedded between lifts. It cures into a monolithic, sloped, insulating substrate ready to receive the roof membrane.

It is not structural concrete — it does not hold the building up. It sits on top of the structural deck and does three jobs at once: it insulates, it builds true slope to drainSlope is screeded in during the pour — crickets, saddles, and compound slopes shaped in place, no taper package to cut and puzzle together., and it provides a continuous, mechanically fastenable substrate for the membrane above it.

The result is a non-combustible deck surface with strong fire classifications and decades of commercial service history — on schools, hospitals, warehouses, and every building type between. The nine guides below cover the rest.

GENERAL NOTES — TYPICAL RANGES
1. DENSITY (CAST)~20–40 PCF
2. COMPRESSIVE STR. (ASTM C495)~125–300 PSI
3. SYSTEM R-VALUECODE R VIA HYBRID W/ EPS
4. FIRENON-COMBUSTIBLE
5. DESIGN SLOPE (NEW CONST.)1/4″ / FT MIN, SCREEDED
hover the dashed terms — notes pop up ↖
3
A-3
SHT-03 · TYPICAL ROOF ASSEMBLY · SCALE: NTS

Section Cut — Tap a Layer

membrane side up ↓
DETAIL 4/6 — CALLOUT
4

EPS INSULBOARD

CARRIES THE BULK OF THE SYSTEM R-VALUE

Expanded polystyrene board embedded between slurry lifts. The EPS carries most of the R-value; where the fill thickens toward high points, stepped layers thicken with it — R climbs with the slope.

GUIDE 08 · THERMAL DESIGN
4
A-4
SHT-04 · GUIDE REGISTER · READ IN ORDER OR BY NEED

The Nine Guides

01 → 09 is the intended reading order
01FUNDAMENTALSWhat Is Lightweight Insulating Concrete?A plain-English introduction to lightweight insulating concrete (LWIC) roof decks: what the material is, how it differs from structural concrete, and where it is used.READ →02SYSTEM SELECTIONLWIC vs. Tapered Board Insulation: An Honest ComparisonHow lightweight insulating concrete compares to tapered polyiso and other rigid board systems: slope control, joints, fire, wind, weight, schedule, and cost over the life of the roof.READ →03DESIGNSlope and Drainage: Designing Water Off the RoofWhy positive drainage is the highest-leverage decision on a low-slope roof, what codes require, and how cast LWIC creates slope, crickets, and saddles on flat structural decks.READ →04PERFORMANCEWind Uplift and Fastening: How LWIC Roofs Hold OnHow membrane systems anchor into lightweight insulating concrete decks: base sheet fasteners, field withdrawal testing, tested assemblies, and what high-wind and HVHZ approvals actually mean.READ →05REROOFINGReroofing Over LWIC: Reuse the Deck, Not the HabitWhat happens when a roof over lightweight insulating concrete reaches end of life: evaluating the existing LWIC, repair and re-fastening, when tear-off is actually required, and the economics of deck reuse.READ →06BUILDING SCIENCEMoisture and Venting in LWIC SystemsWhere the water in a lightweight insulating concrete system comes from, how vented decks and one-way drying paths manage it, and how to read moisture findings without panic.READ →07MATERIALSNot All Lightweight Concrete Is the SameCellular concrete, perlite and vermiculite insulating concrete, structural lightweight concrete, and AAC are different materials for different jobs. How to tell them apart — and why specifying the wrong one goes badly.READ →08THERMAL DESIGNDensity, Strength, and R-Value: How Insulating Concrete WorksDensity is the master variable in lightweight insulating concrete — it sets weight, compressive strength, and how well the material insulates. What the numbers mean, and how hybrid LWIC/EPS assemblies meet modern energy codes.READ →09DIAGNOSTICSLWIC, Gypsum, or Vermiculite? Identifying an Existing DeckOlder low-slope roofs hide several look-alike poured decks — lightweight insulating concrete, poured gypsum, and vermiculite fill. How to identify each before reroofing, and why the answer changes fasteners, moisture strategy, and cost.READ →
5
A-5
SHT-05 · ABOUT THE AUTHOR

David Gembala

David Gembala, President & CEO of Apex Roofing, Fort Lauderdale
FIG. 5.1DAVID GEMBALA — AUTHOR

David Gembala is President & CEO of Apex Roofing, LLC, a commercial roofing contractor in Fort Lauderdale, Florida. A licensed roofing and general contractor, he is a co-inventor on three US patents and a specialist in lightweight insulating concrete systems.

These nine guides are his working explanations of LWIC — the questions owners, architects, and roofing professionals ask most, answered the way he answers them in the field. Written by a contractor, not a content team.

“most roof failures are decision failures” — D.G.
PROJECT
LWIC ROOF SYSTEMS — DAVID GEMBALA
LOCATION
FORT LAUDERDALE, FL
CONTACT
SHEET
01 · © 2026 DAVID GEMBALA