Walls & Ceilings August 2011

A C O U S T I C S

I S S U E

Solve Your Acoustics Problem With

One Word Turn to page 13 for more info

August 2011 | Volume 74, Issue 8 | The Voice of the Industry Since 1938™ | www.wconline.com

WC08114CERTCEIL.indd 1

7/21/11 3:13 PM

U.S.A.

PRODUCTIVITY:

HIGH Get rid of the sand piles and take advantage of SPEC MIX preblended stucco and silo delivery systems for high productivity.

SPEC MIX FBC is available in 80 lb. bags and recyclable 3,000 lb. bulk bags.

SPEC MIX FIBER BASE COAT (FBC) will produce more wet stucco compared to traditional field-mix product every time. SPEC MIX FBC is specially formulated with 100% dry sand and cementitious materials that yield as much as 30% more stucco compared to damp, loose sand shoveled into a mixer. WWW.SPECMIX.COM

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© 2011 SPEC MIX, INC.

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INTRODUCING THE TOUGHEST SOUND DAMPING BOARD AVAILABLE. Knock out noise with a gypsum board that’s abuseresistant, mold-resistant and UL Classified Type X for fire-rated assemblies. Choose SoundBreak®XP® and you’ll see it can really take the hits.

1/2” version now available for residential applications.

Technical Info: 1-800-NATIONAL or visit soundbreakxp.info

The GREENGUARD Children & Schools Mark is a registered certification mark used under license through the GREENGUARD Environmental Institute.

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august columns 06

Up Front by Mark Fowler

44

Smart Business by Jim Olsztynski

46

Finish Line by Robert Thomas

48

All Things Gypsum by Michael Gardner

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On the Safe Side by Michael Rich

departments Trade News

16

Product Focus

56

Classified Marketplace

57

Advertiser Directory I S S U E

August 2011 | Volume 74, Issue 8 | The Voice of the Industry Since 1938™ | www.wconline.com

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Advances in medical technologies and practices have spurred new thinking about the construction of medical suites.

22 Effective Noiseproofing: Build Quiet Rooms, Don’t Make Rooms Quiet How one insulation expert is helping the architectural and construction communities understand the value of taking a systematic approach to soundproofing.

26 A Rose by Any Other Name Not everything that’s marked “plaster” is plaster and there’s a growing number of products which prove that’s a good thing.

This article discusses fire testing of air barrier materials and summarizes four fire test methods used to establish building code compliance of air barriers used in exterior wall assemblies.

36 Advances in Air Barriers and Air Leakage Control

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A C O U S T I C S

18 Prescribing a New Hospital

32 Fire Safety and the Importance of Testing Air Barriers

Straight Green by Chris Dixon

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features

VO L U M E 7 4 N U M B E R 8

Strategies for air leakage control and recent changes in air barrier code requirements.

on the cover o A Achieving good acoustics in a sterile environment requires detailed planning re aand careful construction as ddemonstrated in this Class C surgical suite in Advocate G Good Samaritan Hospital in D Downers Grove, Ill. Photo by B Ballogg Photography

| Walls & Ceilings | August 2011

40 Hard Work in the Big Easy Manufacturers and volunteers help bring families back to New Orleans.

ON THE WEB www.wconline.com Breaking News W&C Blogs Web-only Features Special Sections W&C Architect

W&C Digital Edition Media Kit Facebook White Papers/ Case Studies

Readers can download the mobile app to snap the mobile tag at http://gettag.mobi

Install drywall soffits faster and easier Now there is a better way to install drywall vertical drops. The newest Armstrong Installation Systems for drywall soffits are engineered to require less time and effort, while providing improved fit and alignment.

QUIKSTIX™ Knockouts at 6" and 8" centers reduce cutting time. Alignment holes make screw installation simple and form perfect 30-, 45-, 60-, 75-, and 90-degree angles. Offset flattened bulb allows true angles without interference, and bending crimp prevents misalignment. New rout holes accommodate drywall tees, allowing larger section spans. You’ll save installation time with fewer ribs to create.

INSTALLATION

LOCKING ANGLE MOLDING Features pre-engineered locking tabs punched 8" on center. Locking tabs eliminate measuring and marking every 16" or 24", while preventing lateral and upward movement. Eliminates the need for screws, pop rivets, or crimpers to attach tees to molding. ScrewStop™ reverse hem prevents spin off and provides safer handling.

SY STEMS Between us, ideas become reality™

FA S T E R . E A S I E R . B E T T E R . armstrong.com/soffits8wc

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FRONT BY MARK FOWLER

Misclassification According to the U.S. Department of Labor, 30 percent of companies misclassify employees. Misclassification is defined as employees being referred to as independent contractors and it is a violation of the law. The United States Accountability Office produced a report titled “Employee Misclassification,” which states that approximately 3.4 million employees are passed off as contractors who are in fact employees. The practice is done to avoid paying unemployment and payroll taxes as well as lowering insurance costs. The extensive use of this illegal practice is lost revenue for state and federal governments. They are finally getting sick of it and starting to take action. For us in the construction industry, we are all far too familiar with this practice and the rest of the world is finally waking up. It is particularly difficult to catch employees who are misclassified in construction as they tend to move around from one location to another. The recent recession has escalated the practice of misclassification and, with it, the fact that state governments are losing more revenue than ever. The perfect storm scenario has caused many states to escalate the efforts in catching misclassification violators. Colleen Gardner is New York’s labor commissioner and recently testified the state of New York identified more than 35,000 instances of “employee misclassification” in a period of just over 24 months. Gardner went on to explain that through misclassification, the state lost approximately $14 million in tax revenue. This prompted the “Construction Industry Fair Play Act” that was passed in August 2010 in an effort to curtail worker misclassification; other states are following suit. About 25 states have substantially increased their effort to catch the

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| Walls & Ceilings | August 2011

offenders, for both employees and employers. In California, a framing contractor was found guilty of employee misclassification and as the subcontractor filed for bankruptcy protection, the state went up the ladder to the general contractor and project owner for the lost tax revenues. The state attorney general was able to prove the general contractor and building owner had to know the bid submitted was “not reasonable” and as such were deemed complicit.

GOVERNMENT ACTION T he Obama ad m inistration has hired 100 more enforcement personnel and they plan to look closely at the construction industr y. The IRS began auditing an additional 6,000 companies for compliance. The Federal “Employee Misclassification Prevention Act” was introduced to the U.S. Senate, requiring every company to keep records of non-employee workers and to inform all new employees of their rights. The point is: If you are cheating by knowingly misclassifying as an employer or employee, you stand a higher chance than ever of being caught. For those that who want to play fair and be sure they are on solid ground if an auditor comes by, the following might help: • Know the rules and document your relationship with your independent contractor. • Keep documentation and review it annually. • Conduct a self audit to qualify employees and independent contractors.

• Verify that independent contractors have insurance and other customers; being a company’s sole customer is a red flag to an auditor. • The litmus test often used for employee to independent contractor is control. Does the worker have control? Is he/she allowed to work for other people at the same time? The problem for the construction industry are the piece workers, who are legal, but are really just employees. Employers should be wary of minimum wage and overtime laws as they would correspond to piece work rates. Some in our industry “misclassify” and pay employees the amount as if they were a “subcontractor” and then 1099 the “employee” at the end of the year. The confusion is some of these employees could have much of that “control” used to test the misclassification theory but they are not “real” independent contractors. They do not bid work, they do not have an office, they do not carry insurance and do not have a license. These are the ones the government is trying hard to clamp down on. It is tough. Misclassification hurts all those contractors who play strictly by the rules. Those that knowingly cheat the system beware: You are playing with fire and the penalties when caught are extreme. For those that say, “I cannot compete if I put them on the payroll and pay taxes,” how do you think the contractors who play by the rules feel? If the industry as a whole cleans up its act, we could all compete honestly and fairly. The firms with the best supervisors, best trained help should succeed—not those willing to cheat the system. The added bonus is the states would be in far less dire financial straits. W&C

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EDITORIAL ADVISORY BOARD Bob Drury — Executive Director, NWCB Michael Kwart — Executive Director, ICAA Michael Gardner — Executive Director, Gypsum Association Steve Pedracine — Executive Director, Minnesota Lath & Plaster Bureau Jon Mooney — President, Acoustics by J.W. Mooney Elizabeth Steiner — Executive Director, ICFA

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WALLS & CEILINGS (ISSN 0043-0161) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: WALLS & CEILINGS, P.O. Box 2147, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to WALLS & CEILINGS, P.O. Box 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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All kinds of insulation challenges

Rain, rain and more rain

Today’s heat wave: -10º It’s shiver and sweat

The 2-H club: hot & humid

©6/11 CertainTeed Corporation.

America’s biggest outdoor oven

All kinds of CertainTeed solutions At CertainTeed, we have an insulation product for every condition under the sun – or pouring rain, frigid cold or high humidity. We know how important it is to have products that fit your specific insulation challenges. At CertainTeed, our full line of innovative products, years of industry experience and technical support can help you find the perfect product for any corner of the country. Regardless of climate, your forecast is bright when you choose CertainTeed for your next project.

Learn more at certainteed.com/insulation or scan the QR code.

800-233-8990 • certainteed.com • http://blog.certainteed.com ROOFING • SIDING • TRIM • DECKING • RAILING • FENCE • FOUNDATIONS GYPSUM • CEILINGS • INSULATION • PIPE

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TRADENEWS CALENDAR SEPTEMBER 13-16 CONSTRUCT/TFM 2011 McCormick Place Chicago www.constructshow.com 22-24 ICAA ANNUAL CONVENTION & TRADE SHOW Contemporary Resort Orlando, Fla. www.insulate.org

OCTOBER 4-7 GREENBUILD 2011 Metro Toronto Convention Centre Toronto, Canada www.greenbuildexpo.org 11-13 METALCON Georgia World Congress Center Atlanta www.metalcon.com 12-15 THE REMODELING SHOW Lakeside Center McCormick Place Chicago www.remodelingshow.com

NOVEMBER 6-9 AWCI ANZ 66TH ANNUAL CONFERENCE Reef View Hotel Hamilton Island Queensland, Australia www.awci.org.au 13-15 STADFA Henry B. Gonzalez Convention Center, San Antonio www.stafda.org For additions or corrections to our Calendar, please call (248) 244-6404.

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| Walls & Ceilings | August 2011

LAFARGE GYPSUM ASSETS TO BE SOLD TO ETEX FOR $1.4 BILLION Belgian manufacturer of building products Etex Group is in exclusive talks to buy gypsum assets from Lafarge SA in a transaction valued at 1 billion Euros ($1.4 billion), as reported by the Bloomberg News. Lafarge will get cash proceeds of about 850 million Euros from the sale of the European and South American assets, the company said in a statement. It will retain a 20 percent stake in the combined business. Etex, which fended off competing interest from buyout firms, is building on an existing alliance with Lafarge in Latin America as builders there adopt gypsum-based wallboard as a faster alternative for interior walls and ceilings. The Brusselsbased company has turned to emerging markets to bolster profit, against a backdrop of sluggish demand for tiles, corrugated panels and other building products in European construction markets. “At first glance, positive news,” said Marc Nettelbeck, an analyst at DZ Bank with a “sell” rating on Lafarge. “The company found a smart solution” to excluding the underperforming U.S. business,” he said. The gypsum operations to be integrated into Etex generated sales of 895 million Euros and earnings before interest, taxes, depreciation and amortization of 115 million Euros last year. The price paid including debt is 8.7 times last year’s Ebitda, in line with the average multiple paid in building-material deals over the past two years, according to data compiled by Bloomberg. Lafarge shares gained as much as 2.2 percent to 40.50 Euros in Paris, and they traded at 40.16 Euros as of 9:11 a.m. The sale takes Lafarge a step closer to regaining an investment grade credit rating. Chief Executive Officer Bruno Lafont, who ran the unit from 1998 to 2003, has pledged to step up asset sales and cut spending to trim debt by

at least 2 billion Euros this year after Lafarge was relegated to junk status by Standard & Poor’s in March. The disposal will have a positive impact on Lafarge’s rating, spokeswoman Claire Mathieu said by phone. Etex is paying a “fair price,” said Levon Babalyan, an analyst at Cheuvreux with an “underperform rating” on the French company. Lafarge’s debt to Ebitda ratio stands to fall to 3.4 times as a result of the deal, he said. The deal will provide a “welcome but rather modest reduction” to Lafarge’s leverage, Babalyan said.

CPI ANNOUNCES NEW LEADERSHIP FOR SPRAY FOAM COALITION The Center for the Polyurethanes Industry of the American Chemistry Council announced the new leadership team of the Spray Foam Coalition, formerly called the Systems House Group. The coalition formally adopted its new name this month and elected Paul Duffy, vice president of engineering at Icynene, as chair and Peter Davis, president and CEO of Gaco Western, as vice chair. The Spray Foam Coalition chose its new name to better represent the group’s core mission of championing the use of spray polyurethane foam in U.S. building and construction applications. In addition to electing a chair and vice chair, the Spray Foam Coalition chose the following members to serve on the Leadership Committee: Lance Altizer of Johns Manville, Doug Kramer of LaPolla Industries, Dave Lall of DEMILEC USA, Jim Perkins of SWD Urethane and Mike Sievers of BASF. The new leadership team will serve for 18 months. “The Spray Foam Coalition is establishing itself as a leading voice in the spray foam insulation industry. With this new leadership team in place, the coalition can continue its growing work in product stewardship, industry research and advocacy efforts. I am pleased to work with Paul and Peter to help the Spray Foam Coalition meet our strategic

THE BUILDING LANDSCAPE IS

CHANGING

U N D E R Y O U R F E E T.

A N D B E F O R E Y O U R V E R Y E Y E S.

STRONGER T H A N S T E E L.

SM

© 2011 Clarkwestern Dietrich Building SystemsLLC

If today’s buildings are going to meet tomorrow’s needs, they’ve got to stand on strong materials—and even stronger ideas. From online tools and BIM data that drive smarter designs, to design and engineering services, to a lineup of steel framing systems delivered nationwide, ClarkDietrich stands with you and is a proud member of SFIA (Steel Framing Industry Association). clarkdietrich.com Please Circle #154 On Reader Action Card

Interior Framing ∙ Exterior Framing ∙ Interior Finishing ∙ Clips/Connectors ∙ Metal Lath/Accessories∙ Engineering

TRADENEWS goals and expand our markets,” said Lee Salamone, senior director of CPI. “I am pleased to take on this new role as chair of the Spray Foam Coalition and to help our group establish itself as a strong actor and reliable resource for the industry and

SPACKLE BY DAVE COVERLY

for those who want to learn more about spray foam,” said Duffy. “The new name, the Spray Foam Coalition, better reflects our focus and activities and will help direct our work over the next 18 months. I look forward to working with Lee, Peter, and everyone in our coalition.”

DACHOWSKI RETIRES AS CERTAINTEED CEO CertainTeed Corp has announced the retirement of its president and CEO, Peter Dachowski, effective August 31, 2011. During his 35-year tenure with CertainTeed, and its parent company Saint-Gobain, Dachowski served in a long progression of executive roles in finance and global management. After Exxon Treasurers and the Boston Consulting Group, he joined CertainTeed in 1976 and was quickly promoted to vice president and treasurer and later, corporate comptroller. Through the late 80s, despite an economic downturn, he led significant growth in CertainTeed’s roofing, ventilation, siding and window businesses through

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| Walls & Ceilings | August 2011

new product innovations and acquisitions. In the early 90s, his responsibilities were expanded to include all of CertainTeed’s building materials manufacturing and wholesale distribution businesses. Dachowski currently serves on the board of directors of Ball Horticultural Company, International House of Philadelphia, Foreign Relations Policy Institute, Philadelphia Film Society, and the advisory council to the Joint Center for Housing Studies of Harvard University. He is an emeritus board director of the Philadelphia Orchestra Association. John Crowe, who is currently the president of Saint-Gobain’s global abrasives business, will succeed Dachowski as president and CEO of CertainTeed Corporation. Crowe has held numerous leadership positions within the SaintGobain group of companies over the past 30 years. As the president of SaintGobain Abrasives, he is responsible for 13,000 employees and approximately 75 manufacturing facilities in 24 countries.

AEC ANNOUNCES NATIONAL BIM CONFERENCE IN DECEMBER

WIND-LOCK EXPANDS DRYWALL LINE

BIM products and services will be on display during the two-day exhibit December 7-8. The exhibit also features: BIMStorm, presented by Onuma, will focus on Energy, BIM/GIS integration and Cloud Computing. BIMStorm will demonstrate full life-cycle use of BIM, including green product integration along with real-time energy data connected to BIM. Its interactive format invites teams of attendees to participate via smart phone or laptop in a live workshop charrette on the 3-D design of hospitals and federal facilities in real time. Demonstrations will include how BIM can support EcoDistricts and HighPerformance Buildings. The AEC Interoperability Center is a hands-on collaborative workplace, where design and construction professionals, building product manufacturers and commercial software companies can showcase current IT and BIM developments, BIM objects

After announcing entry into the drywall tool market late last year, Windlock has more than doubled its drywall tool offering. The company now carries more than 1,000 additional products not shown in its 2011 catalog. “It’s always a challenge with a new product line to get everything done at once,” said Carter Benjamin, executive vice president for Wind-lock. “We wanted to get a catalog out at the beginning of the year to let everyone know that we carried drywall tools, but we continued to bring in more products after that catalog was produced.” Drywall tools and accessories have been added from the following product lines: Ardell, Arrow, Bjorklund, Custom Leather Craft, Duo-Fast, Levelline, SurPro, Trimaco and many others. Wind-lock has compiled a product list addendum to help customers find what they need. This addendum is available on the Web site or by calling Wind-lock to get a copy.

Building information modeling standards, objects, software and more will be the focus of the National BIM Conference sponsored by the buildingSMART alliance and AEC Science and Technology. The National BIM Conference will be held December 5-9 in Washington, D.C. There will be a wealth of educational opportunities offered for government agencies, building owners, contractors, architects and all building industry professionals. Several types of BIM educational sessions, including case studies, standard updates, green BIM and more will be offered throughout BIM Week. Sessions and meeting at the December conference include: • Introduction to buildingSMART • Introduction to NBIMS-US • Building Smart BIMs • BIM in the DoD’s Military Health System to Improve Facility Life Cycle Management • Modeling the Future of Education: The Multi-disciplinary BIM Project at WIT • Going Lean with BIM • A Research Framework for Building Information Modeling and many more

Solve S olv ve Y Your our ur A Ac Acoustics co ous sttic cs s Pr Problem Pro ob ble em m

With W Wit th h One One On e Word Worrd Wo d Environmental nvv on onmen men e al A Acoustics co stic sti s st

45 hum-gurgle-whir as everyone fills up

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22 conversations catching up on the weekend gossip

+

800 thunks and clunks with day-to-day business

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Design Harder Working Environments with Adagio™ Ceilings. Add up all the distracting noise in the typical modern office. Factor in the proven harmful effects noise has on workers’ ability to concentrate. Your answer is Adagio Ceilings Systems from CertainTeed. Nobody takes environmental acoustics more seriously. Adagio has a NRC value of 0.80 and a CAC value of 42, the best in the industry. So for those spaces where creating productive work environments is vital, it’s Adagio.

You’re not just solving a design problem. You’re helping people be more productive.

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TRADENEWS PEOPLE Parex USA Inc. announced the addition of Karine Galla and Heidi Larsen to the marketing team as product managers. Dave Westerman, a former regional manager with Probuild Gypsum, has recently purchased The American Masons and Building Supply Company in Hartford, Conn.

Galla

Ames Taping Tools announced the appointment of Mark Wilson to the new corporate role of director of education with responsibilities for product education and industry stewardship. Larsen

Korpershoek

Dow Performance Materials has named Carlos Silva Lopes as strategic marketing director for the business, which includes the specialty companies ANGUS Chemical Company and Acima Specialty Chemicals. Ewout Korpershoek will join the Topcon Positioning Systems senior executive team as chief marketing officer responsible for all marketing and product management functions at TPS and TEP. He was also named chairman of the TEP board of directors. Tony Hirayama, currently CEO of Topcon Positioning Iberia/InlandGEO and a director of TEP, will become the new managing director of TEP. Hirayama will also remain in his current positions.

Hirayama

and the state of applications compatibility. Plug and play kiosks will be set-up for firms to rent and show their solutions. A wide variety of meetings will be held during the week, including the BSA Board of Directors Executive Committee Meeting, NBIMS Interest Groups and more.

ALLIED BUILDING ACQUIRES AUSTIN ACOUSTICAL MATERIALS Allied Building Products Corp., a division of Oldcastle Inc., announced in June 23 that it has completed its acquisition of Austin Acoustical Materials Inc., a privately held interior product building materials supplier based in Austin, Texas. Austin Acoustical Materials is a one-branch distributor of drywall, Armstrong ceiling tile and related products founded in 1985 and an important addition to Allied’s interests in central Texas. For more information about the company, visit its Web site at www.alliedbuilding.com. W&C

Would you do this with your steel framing? by

Of course you wouldn’t.

But if you had The EDGE™ from Super Stud, with its patent pending rolled edge to protect your hands, you wouldn’t have to worry. The EDGE EQ Drywall Framing System was designed with your safety in mind. It’s also made with the highest

quality, mill prime 40KSI steel, is UL® classified for use in one-, two-, three- and four-hour wall assemblies and meets or exceeds the criteria of ASTM C645 and C754. So, if you are ready for the new industry standard steel stud, let Super Stud give you The EDGE.

www.edgesteelframing.com

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For licensing opportunities at select locations across the US, call or visit our website. Please Circle #120 On Reader Action Card 14

| Walls & Ceilings | August 2011

WHAT AMERICA’S MADE OF™ .

We helped a timeless classic stay timeless. When the historic Miami Woman’s Club needed renovation, QUIKRETE® products helped restore the building to its original textured stucco facade. Over 50 bags of QUIKRETE® Fast Set Repair Mortar were used for structural repair. And over 1,700 bags of QUIKRETE Base Coat Stucco were used to match the original Mediterranean exterior. It’s further proof that no matter what you’re building, QUIKRETE® has everything you need to keep pouring. And with over 90 manufacturing plants, we can speed hundreds of high-performance products right to your jobsite. QUIKRETE even offers technical support. For a free construction product guide, visit QUIKRETE.COM or call 1-800-282-5828. Please Circle #268 On Reader Action Card

product

FOCUS

on

EIFS and Stucco EIFS weather resistant barrier pumps APLA-TECH INC. The company offers two weather resistant barrier pumps to spray liquid air and water resistant barrier products for the EIFS industry. These inexpensive, lightweight 10- and 15-gallon reservoir pumps come with a standard 50-foot material line, trigger gun and fan texture tip. Spraying the product results in tremendous labor savings compared to the alternative roller or trowel application methods. If you read this article, please circle number 320.

Advanced cavity wall system with waterproof air barrier EIFS, stucco and EPS decorative finish

STO CORP.

ARMOURCOAT SURFACE FINISHES INC.

Phillips J-Weep is a versatile product used in several applications. J-Weep is commonly used as a casing bead or plaster stop in stucco applications. The punched weep holes allow for use as a sill weep screed in exterior stucco applications. This product features a 3½-inch nailing flange meeting applicable code requirements. Perforated flanges aid attachment and plaster keying. This galvanized steel product is available in 3/8-, 1/2-, 7/8- and 13⁄8-inch grounds.

StoEnergy Guard is an integrated cavity wall solution that is used for protection under multiple cladding types, including stone, siding, stucco and more. It integrates a fluid applied waterproof air barrier, sheathing joint and rough opening protection, proven drainage technology and approved continuous insulation into a flexible system that can be designed to meet individual climate zone and building code requirements. Easy to install, the system offers a choice of compatible components for specific design and climate needs. Not only does it work under most cladding types but also in buildings that combine more than one cladding, such as stone and stucco. For increased safety and comfort, StoGuard reduces energy use in hot and cold climates and is comprised of Class A building materials tested for low flame spread and smoke development. Designed to protect the entire building, it offers improved air quality and thermal comfort as well as resistance to mold and mildew.

If you read this article, please circle number 322.

If you read this article, please circle number 323.

ArmourCast External is a custom-cast exterior grade architectural product comprised of 50 percent recycled marble, Portland cement and mineral oxides. The finished product has the durability and decorative finish of quarried stone. Usually cast over an EPS foam core, the product is lightweight and easy to install and its appearance makes it well-suited for a variety of ornamental architectural shapes such as window sills and door surrounds, column wraps, moldings, fireplace surrounds, keystones, crown molding and more. It is offered in a range of stock molds, finishes and colors. Custom colors and finishes are also available. Single use molds are created using EPS foam, which reduces lead time needed to create traditional molding and cast methods. If you read this article, please circle number 321.

Weep screed for stucco applications PHILLIPS MANUFACTURING INC.

Eco-friendly trowels for EIFS WIND-LOCK As an addition to its Comfort Soft trowel line, the company is offering leather and cork handles developed with the same German engineering. These handles made from natural materials are manufactured from renewable resources. Both the leather and the cork handles are open pored, shock absorbing and extremely comfortable in the hand. They also provide 100-percent blister-free work. If you read this article, please circle number 324.

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| Walls & Ceilings | August 2011

Add some speed at the tile backer position. When your team hits the showers—or the kitchen— Diamondback™ Tile Backer will add speed to your game. Diamondback’s unique textured pattern and coating help grip tiles to prevent slippage during installation X Lighter weight than traditional cement or glass-mat gypsum backer boards X No need to install additional vapor barrier X Scores and snaps like regular gypsum board X

800-233-8990 • www.certainteed.com ROOFING • SIDING • TRIM • DECKING • RAILING • FENCE • FOUNDATIONS GYPSUM • CEILINGS • INSULATION • PIPE

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PRESCRIBING A

NEW HOSPI A

relatively inexpensive hobby of mine is the collecting of old technology books. My collection includes books on rebuilding player pianos, blacksmithing and a mail order course on how to set up a vacuum tube radio repair shop (I will be set if my time machine leaves me stranded in the 1850s or 1950s). One of my favorite books was written in 1870 and describes the technology of the day and includes a prediction of the U.S. and technology in 1970. Although the future world it describes is interesting (including mass transportation through giant

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| Walls & Ceilings | August 2011

Advances in medical technologies and practices have spurred new thinking about the construction of medical suites. By Jon Mooney Photos by Ballogg Photography

wooden pneumatic tubes) the 100year prediction was too far a stretch to extrapolate the technology of this period. Today’s rate of technological advancement makes even a 10-year prediction questionable. Therefore, with that warning, I present the state of current hospital operating room technology and venture a prediction of the surgical suite in the year 2020.

PAGING DR. DIFFICULT If you have ever helped construct a surgical suite, you will agree it is one of the more complicated and most inspected project types. Most inspected because surgical suites must comply with Department of Health regulations and Facilities Guideline Institute design practices before they are approved for use. More complicated since

ITAL

simple building component designs cannot generally meet one performance requirement without compromising another. Present surgical suite design is heavily influenced by the FGI which publishes “Guidelines for Design and Construction of Healthcare Facilities” once every four years. The FGI is a collaboration between the American Institute of Architects and the United States Department of Health & Human Services. To reduce the opportunity for organism growth within the surgical suite, the FGI guideline requires

surgical suite ceilings to be “monolithic” (a surface free of fissures, cracks and crevices). Today, this usually means hard, smooth surfaces of epoxy finished gypsum. Walls are typically ceramic tile or epoxy finished wallboard and floors are seamless sheet vinyl, linoleum or rubber. But, because completely hard room finishes result in a reverberant room, they add to the cacophony of mechanical and medical equipment noise and reduce the speech intelligibility within the room. To address this issue, surgical suites in Europe have begun using stretched plastic ceilings with fiberglass sound absorber panels placed above them. Noise passes easily through the stretched plastic ceiling where it is absorbed by the fiberglass panels. According to Pascal Gicquel, president of Newmat USA Ltd., “While Newmat (stretched PVC ceiling) would be perfect for this particular application because of its monolithic aspect, the fact that it can be sealed, the fact that it is washable and the fact that we have a specific membrane with a “bio-pruf” treatment (anti-bacterial), we have been unable to be specified and/or used for this type of application in the United States. I am not clear on the reasons for this failure, since we have done similar applications throughout Europe.” Presently, washable and demountable sound absorption is allowed on the walls of a U.S. surgical suite. Robert Marshall, Technical Services Engineer for CertainTeed recommends Hygiene Advance Wall or Hygiene Foodtec Wall. “Essentially removable acoustic panels (for cleaning the panel and cleaning behind the panel) … provide excellent absorption.”

TURN YOUR HEAD AND … Ventilation is another important regulated requirement of surgical suites. The ventilation system is arranged so that air drops down from the ceiling directly above the operating table and travels outward. In the ideal case, every air molecule travels along an airstream directly from inlet to return, passing the operating table only once and spending only about two or three min-

utes in the room. But, since most surgical suites are not aerodynamic but rather rectangular rooms filled with obstructions, airstreams tend to break up into less than ideal patterns. Also, replacing all of the air in the room every two or three minutes results in noise created by air rushing in and out of ventilation grilles through ductwork and control dampers and by the fans that supply the air. At this high rate of ventilation, even air rushing out the bottom and sides of doors can cause noise issues. Present FGI guidelines recommend quiet operating rooms but also point out, “… current ventilation system technologies and devices required for sanitary purposes often result in sound levels higher than these.” Also a function of ventilation is the control of room temperature. Preferred room temperature and temperature of air surrounding the patient depends on the type of operation and the needs of the surgeon. Surgeons and their staffs want to be cool because of gowning requirements and the amount of time they are in the OR but the type of surgery will dictate conditions in the room. Cardio procedures typically cool the patient while pediatric procedures may require a warm-up cycle.

BETTER OR WORSE? Lighting requirements are much more complicated than one might first suspect. Of course, the amount of light on the patient must be at least the required minimum. T he amount of infrared light is kept at a minimum to prevent drying of tissue and localized heating of the room. The amount of light on room surfaces should not be less than one third of that on the patient. This is to prevent the surgeon’s eyes from becoming fatigued as they periodically look up to monitor equipment. Surgeons may prefer certain colors of light for specific operations. A recent development is the replacement of incandescent surgical lights with focused LED lights. When I asked KJWW Engineering’s Senior Clinical Engineer, Tom Tod ro, what equ ipment shou ld

August 2011 | www.wconline.com |

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PRESCRIBING A

NEW HOSPITAL UTTERLY NEW AND NOT SO DIFFERENT

be included in our future surgical suite he replied, “You would want to include surgical robots and surgical navigation systems as well as video integration. Though not yet an industry standard term, the ‘wall of knowledge’ is gaining more interest. There are all kinds of data sources, alarms, patient data, etc., that are all discrete systems. The wall of knowledge seeks to integrate these systems displaying only the information that the surgeon needs and alarm information should conditions change from the normal operating range. The prevalence of surgical navigation and surgical robots is growing at a phenomenal rate. These systems allow the surgeon to view not only the actual patient but also a composite image from a CT (Cat Scan). The surgical robot is operated by the surgeon and both systems allow for truly minimal invasive surgery (smaller incision) which leads to faster recovery, reduced stress on the patient and reduced post-surgical complications from infection.”

STEADY AS SHE GOES Micro-vibrations in the floor and ceiling of the surgical suite, caused by mecha n ic a l equ ipment i n a distant part of the building, can cause blurry images in high resolution medical equipment such as the surgical microscopes used in

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brain surgery. The classic solution is to mount the equipment on a massive concrete pad which sits on springs. However, as medical equipment becomes more sensitive, the pads must be designed heavier and the springs must be made longer. Presently, equipment sensitivities require spring lengths and pad weights which are becoming unwieldy in construction. A relatively new type of isolator which doesn’t require excessive weight or spring lengths is the negative st i f f ne ss me cha n ism develop ed by Minus-K Technology. According to Jim McMahon, President of Zebra Communications and technical spokesman for Minus K, “I do understand, with the increased use of sensitive optical instrumentation in the OR, it is inevitable that non-intrusive vibration isolation would be required. For quite some time, Negative-Stiffness Mechanism vibration isolation has been used in laboratory environments, including sensitive medical research applications, not only because of its superior capability of canceling out vibrations that can negatively influence operation of sensitive optical instrumentation, but also because of its non-dependency on electricity or pneumatic requirements, making NSM an ideal system for critical environments such as Class 100 operating rooms.”

Starting with today’s state of the art, we have developed a concept of the surgical suite of 2020. Gypsu m b oa rd m a nu fac t u rer s a nd contractors will be happy to know the surgical suite of 2020 still has re c t a ng u la r g y p su m wa l l s a nd ceilings. In most cases, it just is not feasible to fit non-rectangular rooms within a building envelope. To isolate the surgical suite from building vibrations and noise from adjacent spaces, the entire room floats on several NSMs. Beneath the gypsum ceiling is a stretched plastic ceiling, supported by tubular framing and given the shape of an isentropic expansion nozzle to encourage ventilation air to remain laminar. Sound absorption, as well as indirect room lighting, is hidden bet ween the stretched plastic ceiling and the hard gypsum lid. Borrowing from James D yson’s bladeless fa n look, we have anticipated a major advance in ventilation design using concent ric ai rfoil ri ngs w it h separate injected flows and allowing detailed airflow and temperature adjustments with minimal noise. Surgical lights have been taken off the ceiling and placed at the incision site. To make su re the room stays well sealed, entry doors are Tanaka-type automatic slat doors, each pair of slats opening only about 2 inches wider than the person or object passing through. To allow the room to be thoroughly disinfected without damaging medical electronics, the wall of knowledge is now a 3-D, holographic display with all of the electronics housed safely in a separate room. And although no-one else mentioned the need, I have seen enough operating rooms to know that a great sound system, preloaded with the surgeon’s music librar y will definitely be part of the surgical suite of 2020. Take a tour and listen to the 2020 su r g ic a l su ite on my Web site w w w.jw mooney.com. (available August 2011). W&C If you read this article, please circle number 300.

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Effective

NOISEPR BUILD QUIET ROOMS, DON’T MAKE ROOMS QUIET

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n the world of acoustics and soundproofing, specialists abound. Coming in during the last stages of construction or renovation, these sound gurus bring their acoustical expertise to bear on what is essentially a finished room or building. The walls are framed, the floors are in place and most of the heavy lifting is done. At this point the specialist enters to advise on which soundproofing products the contractor should use. For Yan ky Drew, fou nder of TMSoundproofing, this approach is akin to closing the barn door after the horse has bolted. “The goal should always be to build a room that’s quiet—not to go into a finished structure and only then start thinking about reducing noise,” says Drew. “It’s vital to work with contractors at the very start of a project – the earlier in the process you use soundproofing technologies, the better result you can achieve.” Drew’s no-nonsense approach to noise reduction stems in large part from his industry background. Rather than coming from the specialty acoustics field, he started with a traditional insulation company in 2004. As he developed relationships with builders, contractors and customers, he found more and more requests to put in insulation to soundproof floors, walls, bathrooms and bedrooms come his way. “The problem was, it never really worked that well,” he remembers. “People kept asking us what else we had that we could put in to block off the noise.” This seemingly simple request led to nearly two years of research into

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How one insulation expert is helping the architectural and construction communities understand the value of taking a systematic approach to soundproofing. different soundproofing methods and technologies available on the market. Beginning his search on the Internet, Drew quickly realized that there was too much information out there that was dated, biased or just plain wrong. He decided to reach out to his associates in the construction industry, calling builders and contractors about specific products like soundboard or MLV, asking how they worked, and then visiting sites to see the technologies in action.

PRODUCT RESEARCH It was at around this time that Drew first began to see the Green Glue name featured in the media and online. Consisting of the company’s flagship viscoelastic compound, as well as other noiseproofing technologies such as the sealant, joist tape and clips, the product came together as a system to decrease noise transmission. In 2007, with his research complete, Drew was ready to open a separate company, TMSoundproofing, to consult and work solely on sound insulation projects. Drew’s first client for TMSoundproofing was the B eit Shvidler Conference Center, a small luxury hotel in Monsey, N.Y. With only 25 rooms, the hotel had built its reputation around quality, service and exclusivity and was now looking to soundproof its rooms to enhance guests’ experiences.

Drew decided to choose a simple approach: Each room was soundproofed with Resilient Sound Clips on one side and Green Glue Noiseproofing Compound on the other. Working with his crew, the rooms were completed in short order. “For hotels, guest experience is everything. TMSoundproofing and the Beit Shvidler Conference Center had essentially staked our reputations on Green Glue, so we were gratified and relieved to find it working so well,” Drew says. The real proof came later on when a foreman was contracted to take out an adjoining door between rooms in the same hotel and fill it in so that it was flush with the existing wall. Because Drew had used resilient sound clips (which decouple a wall from the frame) and and two layers of drywall to sandwich the Green Glue, it took five layers drywall to fill in the gap. One of the original ways to reduce sound is to add mass to a wall, but even this much drywall couldn’t compete with TMSoundproofing’s solution. When he went back to test the quality of noise reduction, he had to give Drew a call, “Despite those five layers of dr y wall, he could still hear music in the adjoining room when passing the filled-in door,” Drew remembers. “W hen he passed the walls we’d treated— he heard nothing.”

ROOFING

Effective

NOISEPROOFING HOW HO W SY SYSTEMS SYST STEM ST EMS EM S WO WORK RK Attention to detail, Drew explains, is critical. Underst a nd i ng how soundproofing products work as a complete system has enabled him to work through and offer solutions to problems that contractors face in construction and renovation. “When we were brought in to soundproof entire floors or buildings, we’d find that even if we treated the floors and ceilings, noise would still escape. It was a mys-

I started workte ry aatt first, tery firs fi rstt until u ing on the projects much earlier in the construction process. Then the problem became obvious to me— although we were soundproofing the floors, we weren’t doing anything to the floors that ran under the walls,” says Drew. “Those bits were completely u nt reated a nd the sound was traveling smoothly down between floors.” Drew realized at once that he needed to get in front of build-

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ers before they ever began framing the walls. At that point, he was able to have them install two layers of subfloor—with soundproofing in between—that ran across the whole building. Once the walls were framed, the noise was gone as sound would still travel down the wall but each time the subfloor stopped it from crossing over into the room above or below. “ T h i s i s re a l ly where I s e e TMSoundproofing adding value,” he says. “We’re not just selling the products. I’m on job sites every day, working with the Green Glue system, seeing how it behaves under varying construction conditions and coming up with ideas to improve the installation.” Drew’s idea of soundproofing the subfloor before framing the walls has been used on numerous projects and is one of the top solutions he promotes to builders. More importantly, it has led to a key lesson—in any construction project it is critical to get a dialogue on soundproofing started early so you have more options available for addressing noise problems. “If you’re brought in to soundproof a room that’s essentially already built, you’re very limited in what you can achieve. You need to get in front of the contractors—and ideally the architects—from the very beginning,” he adds. ”That way, you can recommend a solution from a wider breadth of soundproofing options and end up with a far better end result.” D re w ’s h a nd s - on ex p er ie nc e in the field has led him conclude that professional soundproofing shouldn’t be just about going into an existing room and finding ways to reduce the noise. “We need to be there at the start of construction to make sure we are building quiet rooms,” he notes. W&C

A Ro Any O

Application by Hugo Rivera using the products Epoca Spatolato over Antiqua I lime plaster from Merlex Stucco & Vero. 26

| Walls & Ceilings | August 2011

ose by Other Name “Italian finish” is the broad term given to a wide range of products that have been introduced into the market. Other names include faux finish, Venetian plaster, colored veneer plaster and I am sure there are more regional names out there in the marketplace. The lines have certainly become blurred between t hese produc t s. S ome produc t s are referred to as a plaster and are really no more than a thick paint. Not to demean these types of products, though, they can perform admirably and meet a need. It is understandable that manufacturers would want to capitalize on the history, legacy and marketing advantages of calling the product a plaster. The terms plaster and decorative finish, when referring to interior finishes, can be confusing.

Not everything that’s marked “plaster” is plaster and there’s a growing number of products which prove that’s a good thing By Mark Fowler WHAT’S IN A NAME? So what is the difference and why does it matter? The definitions of “plaster” from the online Wikipedia and Webster’s dictionaries both basically define plaster as a product that starts as a dry power and when mixed with water, is trowel applied and sets to a hard decorative coating. This could describe a setting type joint compound just as easily and setting type joint compound is not a plaster. It also comes up short on other products, such as lime-based putties, which would definitely be plasters. Why does this matter? If you live in a state with various subcontrac-

Chris Miller with Miller & Sons used Merlex’s Antiqua I product in this application.

tor license classifications, you need to be careful. A recent scenario had a subcontractor with a drywall license ask the state license board about his license being appropriate to apply a specific product which had the word “plaster” in it. The state responded as I thought they would: “You need a plastering license to install plaster.” When the inquiry was resubmitted and a more accurate description of the product was provided, the state reversed its position and allowed the drywall contractor to proceed. Remember, state employees do not know the product like you do

Variance’s Omnicoat is a surface leveler designed to be applied over rough textures to create a smooth finish.

August 2011 | www.wconline.com |

27

A Rose by Any Other Name

Merlex’s Antiqua I product used in a retail store. The application was done by John Moss of Moss Art Studio.

and must be fully informed to make the correct determination.

NEW PRODUCTS ALL THE TIME If these lines currently seem a little out of focus, they could get down-

ucts with a range of possibilities that would have been unimaginable only a few years ago. These “decorative coatings” and/or “plaster” products will be pushing the limits and changing perceptions of what wall finish-

Some products are referred to as a plaster and are really no more than a thick paint. Not to demean these types of products, though, they can perform admirably and meet a need. right fuzzy in the very near future. Not that that is a bad thing. Manufacturers have been discovering, testing, inventing and creating new formulations and compounds with the result being some very creative prod-

ing is. These new products are crossing the line in different directions. I recently saw three such products by three quality manufacturers. All are “decorative coatings,” some even use the word plaster in the product

description and they could not be further apart in performance, application and results. All are excellent and will fill particular market niches.

VELLA The first product I saw applied was by Vella and manufactured by Specialized Building Products. The newest product addition is a hybrid of a Level 5 gypsum wallboard skim coat and a veneer plaster (this is my personal definition). The product is primarily designed for spray application but can be trowel applied to a gypsum wallboard with treated joints or other properly prepared surfaces. While the product is approved for application over a Level 3 finish, existing painted orange peel or knockdown surfaces for optimum results, I would recommend it be applied over a Level

THEY COME IN THREES This story is unusual in that three competitors are featured in a single article. Each of the three companies were contacted—and in the spirit of fair play—they responded with enthusiasm. The desire to get honest and fair information out to Walls and Ceilings’ readers trumped all other issues. Variance, Vella and Vero-Rialto provided 100 percent support and with great respect and admiration to the competition. These three firms, and I am sure there are 28

| Walls & Ceilings | August 2011

others, are about to change the way we think about decorative finishes. Each company, in their own way, will reshape and challenge conventional practices. So much so that ASTM will likely have to deal with these new innovations. Companies like these are exciting to watch as we move into the future. Please verify any and all information in the article with the specific manufacturer before proceeding on your interior decorative or plaster project.

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A Rose by Any Other Name 4 fi fini finish. n i sh ni sh. h . I have h ave sseen ha een ee n it it d done onee bo on b both o th h wayss aand nd d tthe he application over the Level 4 was pretty amazing as it provided a smooth abuse-resistant Level 5 finish. The machine used at the test wall was an affordable airless type sprayer. The operation took two passes and was immediately wiped down with large 12-inch drywall knives. The tool blade lines were left and let set for a few minutes and then wiped down to leave a smooth, slick, blemish-free finish (water could be sprayed if needed). The product comes pre-blended in a bucket, sets slowly, can be lightly sanded but is not required, and when fully cured, gives you a hard and abuse-resistant finish that can be painted. The product can also be pre-tinted in a variety of colors. The folks at Vella seem to have the makings of a good product and are presently marketing it under a couple names as it is a blend between the traditional Level 5 finish for drywall and a veneer plaster. The product is being introduced

LEVELS OF DRYWALL SAMPLE

The East Coast marketed product Vella Venetian Plaster System’s Level Wall-5 (Vella Veneer Plaster as marketed in the West Coast) is seen on the far right. This product is a smooth wall system with zero sanding.

with two names, names Level Wall-5 Wall 5 and Vella Veneer Plaster—one for the East Coast and one for the West Coast. I would recommend that if you want an abuse resistant Level 5, you should check out the YouTube videos posted on the Vella Web site at www.vellaplaster.com.

VARIANCE Va r ia nce Acr yl ic Fi n ishe s is a unique product line with a full offering of affordable acrylic-based Venetian plasters that have proven to do some amazing things in their own right. The newest additions are A rmourtone and Omnicoat.

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| Walls & Ceilings | August 2011

Omnicoat (featured in both pictures) can be applied over a variety of properly prepared substrates and is also a basecoat for the Variance’s line of Venetian plasters.

Armourtone is a spray-applied product (unlike their more traditional line of trowel applied plasters) yet provides a very abuse resistant finish. Armourtone has a wide range of texture possibilities, from imperfect smooth, orange peel to a more conventional knockdown. The product line comes in 24 standard colors and sets in about two hours with a full cure in two weeks. Omnicoat is a high build surface leveler that was designed to be applied over those lovely rough textures that were so popular for decades to create a smooth finish with very little surface preparation. Omnicoat can be applied over a variety of properly prepared substrates, integrally colored or painted. Omnicoat is also a basecoat for the company’s line of Venetian plasters. Check out the Variance Web site for live product demonstrations in your area at www.variancefinishes.com.

VERO-RIALTO The last product line is by VeroR ia lto. Vero Venet ia n plasters were born in Italy from seasoned, slaked-lime kilns. While known as high quality, lime-based plasters,

the company is now offering some resin-based decorative coatings. The Vero Venetian products have broken new ground but in the complete opposite direction from the previous two products. They have made their product a true work of art and it is hard to call anyone working with this product a plasterer, unless you remember than Leonardo DiVinci was a plasterer, also. Now that I said that, if Leonardo were alive today, the Vero line is exactly what kind of plaster he would be proud to use. Some Venetian plasterers are true artists and this is their medium. More aptly put, your home is their canvas. Do yourself a favor, pull out a European baguette and check out the products featured on their Blog Spot: http://verorialto.blogspot.com. Featured are jobs using Vero’s lime products (Antiqua, Epoca Spatolato, and Epoca 800 lime paint) and resin-based products (Solution, Evolution, and metallics). Vero is also using a new medium of materials. Acoustical plaster is nothing new—we have been applying these plasters for years in auditoriums and concert halls to achieve highly

sought after Noise Reduction Coefficient ratings. Vero has a Venetian plaster that can do the same thing but made with cotton. Yes, cotton. Vero’s new US CottonWall Plaster is truly a “green” product that provides a nice looking plaster and can create a serene interior space by reducing noise and echoes. The product is perfect for in-home theatres. For more information, check out www.vero-rialto.com.

ALWAYS ROOM FOR MORE I was beginning to think that the market was saturated in decorative coatings and now was the time to see who survives, but I think I was wrong. Companies like these and others are on the move to re-shape our thoughts on interior wall coverings, decoration finishes, faux effects, Venetian plaster, Veneer plaster, Level 5 coatings or whatever you want to call them. The future looks pretty amazing and if you are not exploring this stuff, you are missing out. I strongly encourage you to visit, attend and seek out any demonstrations. This is not our father’s interior plaster. W&C If you read this article, please circle number 302.

August 2011 | www.wconline.com |

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FIRE SAFETY AND THE IMPORTANCE OF TESTING AIR BARRIERS

T

he renewed emphasis on energy conservation in building codes has led to increased awareness of the importance of controlling air leakage of buildings. One of the most effective ways to conserve energy is to provide an airtight building envelope. Various types of products— fluid applied, polymer based sheet wraps and asphaltic self-adhered membranes—are being used to provide air leakage resistance in wall assemblies. Sometimes, these products are used without consideration of their potential impact on fire performance of the wall assembly. Building codes are established to provide physical safety to the building occupants and fire protection is a significant component of the codes. Building construction is classified into types based on the use and occupancy of the building. Institutional and many commercial buildings are required to be of “non-combustible” construction (typically steel frame, concrete or masonry). One and two family dwellings and some commercial structures can be “combustible” construction (typically wood frame). Sometimes, combustible materials are used in the construction of buildings that are required to be noncombustible. This sounds like an oxymoron, but the codes allow for this provided certain testing is performed and the materials meet criteria established by the codes.

TEST METHODS Three fire tests are used to evaluate exterior wall materials and assemblies for use in noncombustible construction:

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| Walls & Ceilings | August 2011

Air barrier materials can be a vital part of a building’s defense against fire and four test methods are used to make sure wall assemblies are up to code. By Terry Viness, P.E. and Tom Remmele

• ASTM E84, Standard Test Method for Surface Burning Characteristics of Building Materials • NFPA 285, Method of Test for the Evaluation of Flam mability Characteristics of Exterior Non-bearing Wall A ssemblies Containing Combustible Components • N F PA 268 , Test Met hod for Determining Ignitibility of Exterior Wall Assemblies Using a Radiant Heat Energy Source A fourth test, ASTM E 119, Test Methods for Fire Tests of Building Construction and Materials, is sometimes required in addition to the above tests when walls are required to have an hourly fire-resistance rating. NFPA 285, NFPA 268 and ASTM E 119 are tests of the wall assembly. Alternate materials cannot necessarily be substituted for individual components of fire-tested assemblies without changing the fire performance. A qualified fire consultant should be involved if any substitutions are proposed. ( Note: comparable C an adi an fire testing standards and alternate Underwriters Laboratory versions of some of these tests may be acceptable depending on the applicable code requirements.)

ASTM E 84 ASTM E 84 characterizes the relative rate at which flame will spread as the subject material burns. This test method is often referred to as the “Tunnel Test” because the test chamber is a nominal 25-footlong by 20-inch wide chamber. A gas burner is lit at one end of the chamber and a draft is applied to facilitate flame propagation along the specimen. A photometer and light source is placed at the exhaust end of the chamber to measure the relative amount of smoke that is developed during the test. The test is run for 10 minutes and the distance that the f lame propagates during that time is measured and compared against a standard. The Flame Spread Index is a relative indication of the flammability of the test material with respect to a red oak standard. Both the distance of flame spread and the time-rate of flame spread are considered as part of calculating a Flame Spread Index. Overly simplified, a reported Flame Spread Index of 25 indicates that a material has approximately 25 percent of the standard material’s flame spread characteristics. The “smoke developed index” is calculated similarly. Section 803.1.1 of the International Building Code defines three classes of materials

based on ASTM E 84 test results (as shown in Chart 1). A combustible material is required to conform to the Class A requirements to be used in noncombustible exterior wall construction.

NFPA 285 NFPA 285 is commonly referred to as the “intermediate scale” or “ISMA” test. This test was developed to evaluate the fire performance of E I FS and other foam plastic-based wall systems. The test addresses the concern that fire could propagate through the combustible insulation and move from floor to floor, or laterally. The test involves constructing the test wall on one side of a two-story noncombustible (concrete block) chamber. The test wall has a window opening into the lower floor room. A burner in the bottom floor room is ignited and allowed to burn for five minutes. This part of the test is intended to simulate a real fire condition where the fire grows inside a room and then exits an opening, exposing the exterior wall cladding to fire. After five minutes a second gas burner, placed at the head of the window opening, is ignited and allowed to burn for 25 minutes. During the test numerous thermocouples embedded at different locations within the test wall are used to record temperature rise. Video is used to document conditions in the upper floor room (no window openings) to check for flame impingement or smoke entering the room. Visual observations of the height and lateral spread of flame that occurs on the exterior wall are also recorded. When the test is completed, if a visible failure does not occur, the thermocouple data is used to evaluate the amount of f lame spread within the wall assembly. Lateral and vertical flame propagation limits as well as thermocouple temperature limits must be met in order to meet building code criteria.

NFPA 268 NFPA 268 is designed to assess the potential of a fire in one building to ignite an adjacent building, for example, across a narrow street or alley. This test is useful to establish

minimum set-backs from property lines in urban areas for buildings with combustible cladding. The test is run by placing a gas-fired radiant heater a set distance from the exterior surface of the test wall assembly for 20 minutes. The heater and test configuration is calibrated to provide a heat flux of 12.5 kW/m². The radiant heat causes some materials to ignite, which is an indication of failure. An electric igniter (similar to that used to start a gas grill) is placed at the exterior surface of the test wall and is sparked repeatedly during the test to determine if ignitable gasses are being produced that might otherwise be

undetected. After the heat exposure the wall is allowed to cool and the test panel is dissected to check the conditions of materials that are not visible. In the case of air barrier materials that are behind cladding, this test both confirms the resistance to the conditions tested and provides information regarding whether the air barrier materials remain intact and in place in this type of fire exposure. Materials that soften at relatively low temperatures could become dislodged or melt, compromising the integrity of the air barrier in a wall that is otherwise unaffected by the fire.

August 2011 | www.wconline.com |

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FIRE SAFETY ASTM E 119 ASTM E 119 tests the hourly fire resistance rating for a wall assembly. An hourly fire rating is the time a wall assembly can be expected to contain a fire and, in the case of loadbearing walls, continue to provide some structural support. This test is not a requirement for a material to be used in noncombustible construction, but can be a requirement based on the construction and occupancy types for the building. Chapter 6 of the IBC identifies where hourly-rated wall assemblies are required and what the required hourly rating is for the respective building classifications. Chapter 7 of the IBC contains a list of typical rated wall assemblies. Combustible materials may be used in fire-rated assemblies, provided they do not change the fire rating. In other words, if a wall assembly is rated as a “two-hour” wall, adding a combustible element must not cause the fire endurance rating to be less than two hours. The air barrier material is more likely to have an

effect as its mass and combustibility increase. Both mass and combustibility contribute to the overall fuel load available to burn. Hourly ratings for assemblies can be established both by testing and analysis.

WATERPROOF AIR BARRIER MEMBRANES In the case of our company, the fire safety of StoGuard waterproof air barrier membranes has been tested either individually or as the air barrier component in wall assemblies using the four test methods described above by accredited laboratories in the U.S. and Canada. Part of the selection process for any air barrier material or air barrier system in the wall assembly must include verification of fire safety as evidenced by independent testing and evaluation, and an ICC ES or CCMC evaluation report. W&C Terry Viness, P.E. is senior technical service manager and Tom Remmele is director of technical services for Sto Corp. For

more information about the company, visit www.stocorp.com.

REFERENCES • 2009 International Building Code, International Code Council, 2009 • NFPA 285, Standard Fire Test Method for Evaluation of Fire Propagation Characteristics of Exterior Non-Load-Bearing Wall Assemblies Containing Combustible Components, National Fire Protection Association, Quincy, Mass. • NFPA 268, Standard Test Method for Determining Ignitibility of Exterior Wall Assemblies Using a Radiant Heat Energy Source, National Fire Protection Association, Quincy, Mass. • ASTM E 84, Standard Test Method for Surface Burning Characteristics of Building Materials, American Society for Testing and Materials, West Conshohocken, Pa. • ASTM E 119, Standard Test Methods for Fire Tests of Building Construction and Materials, American Society for Testing and Materials, West Conshohocken, Pa. If you read this article, please circle number 303.

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AIR BARRIERS and Air Leakage Control

A

ir leakage is the unplanned, unpredictable and unintentional airflow across the building enclosure. This makes air flow control important for several reasons: to avoid air transported moisture and moisture damage, to reduce energy losses and to ensure occupant comfort and health. Air leakage control is achieved with continuous air barriers and it is regulated through energy codes.

WHY WORRY ABOUT AIR LEAKAGE? Air leakage can impact energy efficiency, durability and indoor environmental quality. The direct impact of air leakage on building energy performance is the result of infiltration of unconditioned air or exfiltration of conditioned air, both requiring the HVAC mechanical system to

Strategies for air leakage control and recent changes in air barrier code requirements. Maria Spinu, PhD, LEED AP compensate for the losses. Energy simulations have shown that reducing air leakage can result in over 40 percent HVAC energy savings in certain climates. The indirect impact of air leakage on thermal enclosure performance is the result of loss of insulation R value due to air movement and moisture transported by air currents. These effects are more difficult to quantify. The impact of air leakage on building envelope durability is the result of air transported moisture that can be deposited on cooler interior surfaces leading to interstitial condensation. In heating climates, the main concern is exfiltration of interior

Figure 1. Typical Installation of Air & Water Barrier in a Framed Wall (Building Wrap installed over the exterior sheathing, behind exterior insulation board)

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| Walls & Ceilings | August 2011

moisture-laden air which can deposit excess moisture on cooler surfaces. In humid, cooling climates, infiltration of exterior moisture-laden air can lead to condensation on interior interstitial surfaces. Repeated condensation events coupled with slow drying rates can lead to significant moisture degradation of building materials (e.g. corrosion of metals, rotting of wood, etc.). Sometimes—if the focus is strictly on simple payback analysis based on energy cost savings—the air leakage impact on moisture damage can be overlooked. Air leakage control is important for indoor environmental quality and occupant comfort. Unfortunate-

Figure 2. Typical Installation of Air & Water Barrier on CMU back-up wall (Fluid Applied Air Barrier installed on the exterior side of CMU, behind exterior insulation board)

Figure 3. Treating of sheathing joints prior to FA application over exterior sheathing

ly, the impact of an airtight building enclosure is often misunderstood. Misleading statements such as “the more air tight our buildings are, the more polluted they may be inside” are unfortunately still being used. In fact, the opposite is true: Reducing the uncontrolled air leakage can improve IEQ and occupant comfort.

AIR LEAKAGE CONTROL In order for air leakage to occur, there must be a driving force (air pressure difference across the building enclosure) and a pathway. The main sources of air pressure difference include wind pressure, mechanical pressure and stack effect. Unintended openings and discontinuities in the building enclosure are potential air leakage pathways. Since the air pressure difference cannot be eliminated, the strategy for air leakage control is to minimize the airflow pathways. This is achieved with a continuous air barrier, which is a combination of air barrier materials and accessories that help achieve a continuous plane of airtightness. In addition to their primary function of air leakage control, air barriers are also water barriers in that they protect against bulk water intrusion. There are three main types of air barriers: mechanically fastened, fluid applied and self-adhered membranes. Some common building materials

such as OSB, closed-cell spray polyurethane foam insulation, and board insulation can be components of an air barrier system. However, achieving continuity and durability with these materials could be challenging. The choice of air barrier depends on the project type and location, wall design, installation preference, local expertise, technical support, etc. Mechanically fastened air barriers, which are more commonly known as building wraps, are prefabricated lightweight membranes installed with mechanical fasteners. In addition to fasteners, the most common accessories for building wraps include tapes, primers, flashing, through-wall flashing, caulks and sealants. Building wraps are the most common and cost-effective air barrier systems for light-weight framed construction, but they are not well suited for irregular surfaces, concrete or CMU walls. They are generally installed over exterior sheathing (OSB, gypsum board, etc.) as shown in the CAD detail in Figure 1. The key to proper installation of building wraps is Continuity, Overlap, Flashing and Fastening. Fastener type and spacing are critical for structural integrity of building wraps over the service life. Fluid applied air barriers are oneor two-component formulations in organic solvents or a water base and are applied on site by brush, spray or

roller. The two-component formulations are mixed at the site prior to application, while single-component formulations do not require site mixing. The most common continuity accessories for FA barriers include self-adhesive mesh, flexible joint compound, flashing, caulks and sealants. Fluid-applied air barriers are best suited for CMU, concrete or complex irregular surfaces, even though they can also be applied over exterior sheathing. A typical application over CMU is illustrated in the CAD detail in Figure 2. When applied over exterior sheathing, additional surface preparation is needed (e.g. sealing of joints, see Figure 3), which is not required for building wraps. FA application must be performed within the recommended temperature range for proper adhesion and curing. Some newer FA formulations allow for low temperature application. The FA air barrier performance is highly dependent on film thickness and continuity, both of which depend on contractor training and quality of workmanship. The film thickness must be checked during the application, using a thickness gauge as shown in Figure 4. The surface coverage for fluid-applied membranes varies with manufacturers, application technique and type of substrate. Many FA membranes require twocoat application to achieve proper

August 2011 | www.wconline.com |

37

AIR BARRIERS and Air Leakage Control

Figure 4. Using thickness gages during field application of FA membrane

thickness. Newer compositions with excellent coverage and single coat application are available. Some fluid applied membranes undergo shrinkage and cracking on curing. Newer compositions are available with superior elasticity, flexibility and extremely low shrinkage qualities. Self-adhered membranes consist of prefabricated sheets of rubberized asphalt bonded to a substrate (e.g. cross-laminated PE film). They are self-adhered on a clean, dry and primed surface and require surface preparation for proper adhesion. SA membranes are two to three times more expensive than building wraps and are generally vapor impermeable. Is there an ideal choice of air barrier for a particular project? Each air barrier type has advantages and limitations, and some are best suited for a particular application than others. For example,

mechanically fastened membranes are the most cost effective solution for light framed construction, even though other types can be used in this application. Fluid applied membranes are the best suited for concrete masonry walls, especially CMU with embedded ties, even though FA membranes are often used in other applications. Selfadhered membranes are perceived as providing limited self-sealing capabilities and are sometimes preferred. All air barrier types must be properly installed in order to deliver the ultimate benefits. Proper detailing for continuity at penetrations, transitions and intersections is critical for performance and must be included in the design documents. Integration at transitions between dissimilar surfaces and materials is essential for continuity and durability of the air barrier system. Figure 5 shows an example of integra-

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| Walls & Ceilings | August 2011

tion of mechanically fastened membranes with fluid applied air barriers. Vapor permeability—a material’s ability to allow moisture vapor to pass through—is an important consideration when choosing an air barrier. Vapor permeable air barriers do not interfere with drying potential. They can be installed at any location in the building enclosure and have no climate specific limitations. By contrast, vapor impermeable air barriers can interfere with diffusion drying potential; their placement within the building enclosure is climate-specific and special consideration must be given in order to avoid vapor traps and persistent condensation within wall assemblies.

RECENT CHANGES IN AIR BARRIER CODES Air barrier codes and standards include requirements for air barrier

materials, assemblies or whole buildings. National Building Code of Canada, the first air barrier code in North America, has included an air barrier material requirement since the mid90s. In 2001, Massachusetts became the first state in the U.S. to adopt an air barrier code which includes materials requirements similar to those of the NBC. Since then, many other states have adopted similar air barrier standards (Minnesota, New Hampshire, Georgia, Rhode Island, Oregon, Washington, etc.) and the list is growing. ASHRAE 90.1-2010, and ASHRAE 189.1 include a mandatory requirement for air barrier materials and air barrier assemblies. IECC 2012 will also mandate air barriers. Whole building airtightness is the ultimate goal of a continuous air barrier system. The first whole building airtightness measurement and verification standard has been introduced by the U.S. Army Corps of Engineers. USACE mandates that the building enclosure must be designed, constructed and tested to demonstrate that air leakage does not exceed a certain leakage rate (e.g. 0.25 cubic feet per minute per square feet–cfm/ feet², at a pressure differential of 75 Pa). This is the first performance measurement and verification program for building enclosure air tightness implemented by a government agency in the United States. A similar program was recently introduced by the General Services Administration in January 2011. The International Green Construction Code now under development also includes a whole building airtightness requirement. W&C

BEC, CSI, ABAA, and other professional and trade organizations. If you read this article, please circle number 304.

Detailing of interior corner for integration of building wraps with fluid-applied air barriers Maria Spinu, Ph.D., LEED AP joined DuPont Central Research & Development in 1990 as a research chemist. She was promoted to CR&D research manager, and in 2000 she joined DuPont Building Innovations where she currently leads Building Science and Sustainability initiatives for commercial markets. She is a member of the 90.1 ASHRAE Committee and Envelope subc ommit te e, BEC ( Building Envelope C ouncil) , AIA /

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Hard Work in

The Big Easy H

urricane Katrina made landfall in Louisiana in the last days of August 2005, carving a gouge into the Gulf Coast which, nearly six years on, still hasn’t been healed. Thousands of New Orleans residents are still living in Federal Emergency Management Agency trailers both inside and outside the state. While the tracks of that mammoth storm are still visible, and as long as there are Americans unable to return to their homes, there are people from all over the country ready to lend their time, strength, money and expertise to rebuilding one of the oldest communities in North America. The St. Bernard Project was started in March 2006 by Zack Rosen-

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One of the oldest cities in North America is still reeling from Hurricane Katrina and the Koenig family is helping bring New Orleans families back to their homes By Alex Lundberg

burg and Liz McCartney after the couple volunteered in St. Bernard Parish just one month previous. During that first month, they met people who were willing to look right at the devastation the hurricane wrought on their community and get to work. So far they have completed 380 homes.

FOLLOWING HER LEAD Joe Koenig, owner and president of Trim-Tex of Lincolnwood, Ill., fol-

lowed his daughter’s example and has been giving his money and time to help the still-beleaguered city get back on its feet. Koenig’s daughter, Lindsey, and members of her high school class volunteered to take part in the St. Bernard Project. Almost two dozen students and a handful of teachers from North Shore Illinois Country Day School headed down to New Orleans to pitch in back in 2009. She liked the experience so much

that she and a smaller group of friends went down again after the end of her senior year to do it again as part of her senior community service project. She went down again during her winter break from Kalamazoo College, in Michigan. Around the same time, the Koenig Family Charitable Foundation got involved and made a sizeable donation. The Koenig family itself, Joe and his wife Deb, are also taking part. Koenig says he’d like to see people in the industry do more to help out the people in St. Bernard— Trim-Tex is an official sponsor of the project. He’s used what contacts he has to bring more of them down to Louisiana. “I’ve got friends and peers that I’ve known for years from trade and industry shows. You meet a lot of people after 41 years,” he says.

CONSTRUCTION PROJECT NEEDS CONSTRUCTION EXPERTS “I want the drywall industry to do more, to get more people involved i n t h e e f f o r t t o r e b u i ld N e w Orleans,” Koenig says. “If we get

more people involved, we’ll get more people back into their homes. It’s six years on (af ter Katrina) and there are still people living in FEMA trailers.” H e s ay s f r ie nd s a nd f a m i ly are planning to go down to New Orleans again this fall to take another whack at the problem. This time, he’d like to hit the problem with some numbers. “I’d like to go down there with a bunch of drywall experts,” Koenig says. “Hopefully, we can knock out five or six houses at once.” So far, Koenig has managed to rope a few of his industry friends into helping the charity out. Freeman Products and Blue Line Taping Tools, both of Broken Arrow, Okla., have signed on to pitch in as well as Interior/Exterior Building Supply of New Orleans and TNT Drywall Supplies Inc. of Kenner, La. “The drywall phase of the Contractors Build month is the week of September 25th,” Koenig said. “Any professional hangers or finishers that are willing to donate a week of their time to help knock out several homes, please contact Kate

Schuman, Development Coordinator at (504) 261-0345” The mission of the St. Bernard Project is to create housing opportunities so that Hurricane Katrina survivors can return to their homes and communities. The St. Bernard Project, a nonprofit, community-based organization carries out its mission through programs for rebuilding, housing placement and community mental health. Development Coordinator Kate Schuman said the original organizers of the program started out wanting to help in February of 2006. They saw the level of devastation and were doubly impressed by the spirit of community and strong sense of family that pervaded the area and decided to stay. By Christmas 2006, they had worked on 10 houses. The surface has been scratched but that’s it. “There are 27,000 homes in St. Bernard’s that were destroyed,” Schuman said. “[The Department of Housing and Urban Development] estimates there are 10,000 people in temporary housing who want to return but can’t.”

August 2011 | www.wconline.com |

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Hard Work in

The Bigg Easyy

BIG HANDS, BIG HEARTS, BIG JOB Schuman said the project has been aided by construction companies and suppliers who have made what they do possible. Toolmaker DeWalt has contributed more than 150,000 tools used at jobsites, American Standard has provided interior bath-

room fixtures for 120 homes this year and the energy provider Entergy has clocked in the most financial support with $500,000 in donations so far and another $350,000 promised for the near future. T he f e d e ra l gover n m e nt h a s also stepped up. Aside from pro-

viding technical help via Americorps, they’re also bringing in the Department of Energy to make the homes in the new St. Bernard Parish a model for energy efficiency. It’s the donations, of cash, supplies and expertise that make the project successful. “We do everything we can inhouse,” Schuman says. “That keeps the cost of the homes down to $15,000 to $25,000 for materials.” The project will soon launch the “Good Work, Good Pay” program wh ich w ill h i re vetera ns to do labor on the project sites. Veterans have a higher unemployment rate than other sectors of the society and the program will give them a place to work and develop the kinds of skills that will pay them well in the future. I n terms of the future of the project, there’s still a lot of work to be done. Schuman said the various non-profit groups working in Katrina-affected areas did a study last summer to find out how much work there is yet to do. If the groups can keep up the level of activity at which they’re currently producing, they will still be working for the next 15 years. Those wanting and willing to lend a hand can find out more about individual and group support for the St. Bernard Project at www.stbernardproject.org. W&C If you read this article, please circle number 306.

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BUSINESS BY JIM OLSZTYNSKI

Kudos to

Southwest Airlines I wrote this a few days after the scary incident in early April when a 5-foot long gash ripped open atop the fuselage of a Southwest Airlines jet while the aircraft was cruising more than six miles up in the air. Fortunately, nobody was badly hurt as the pilot never lost control and descended to a safe emergency landing at a nearby military base. Nonetheless, the widely publicized incident sent a shiver down the spines of millions of frequent air travelers like me. The incident was later traced to a bad riveting job, although it raised fears of metal fatigue stemming from numerous short flights imbedded in SWA’s business model. A similar but worse tear on a 1988 Aloha Airlines flight resulted in scores of injuries and the death of a flight attendant who was sucked out of the airplane while aloft. Aloha specialized in short hops between the Hawaiian Islands and that accident revealed the until then unknown peril of metal fatigue resulting from frequent cabin pressurization. Both accidents occurred with relatively old Boeing 737 planes.

LESSONS TO BE LEARNED An important business lesson can be lea r ned f rom t he way S WA responded to this crisis. Without being ordered to, SWA immediately grounded all 79 planes it operated of the same class as the afflicted jet. That was about 15 percent of its fleet and resulted in the cancellation of hundreds of flights and thousands of delays. The economic hit to SWA and future bookings is

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unknown at this point but likely to be substantial. Since SWA flies nothing except Boeing 737 aircraft, questions arise about the longterm consequences for our nation’s heretofore most successful airline company. Nonetheless, the company emphasized passenger safety above all else and deserves hearty applause for that. SWA’s plight calls to mind the infamous 1982 episode when seven people in the Chicago area died after taking extra-strength Tylenol capsules that had been filled with cyanide by a still unconvicted killer. All of us live with the legacy of that crime, which led to a federal law mandating tamper-proof containers for all ingestible products. The Tylenol tampering clearly was done af ter the products hit the shelves, so even the sleaziest ambulance chaser would’ve had trouble squeezing money out of the drug’s maker, Johnson & Johnson. Yet instead of dithering and pointing fingers, Johnson & Johnson conducted an immediate product recall spanning the entire country—even though no case of poisoning showed up anywhere except the Chicago area. T he recall tot a led 31 m i l l ion bot t le s a nd cost the company more than $100 million dollars. They spent millions more running sensitive T V

commercials featuring Johnson & Johnson’s somber CEO explaining their action and expressing sorrow for the victims, even though the company had done absolutely nothing wrong. It remains a textbook example of crisis management taught in business schools throughout the country.

RESPONSIBILITY TO CUSTOMERS How do you react when one of your jobs goes wrong? Whether or not it’s your fault is almost beside the point. In most cases it takes days, weeks or months of forensic investigation to figure out the ultimate cause of a mechanical or management failure. In the here and now, you are held responsible in the eyes of your customer. How a contractor reacts even before knowing all the facts reveals a lot about that contractor’s personal character. It also has a lot to do with the longterm health of the business. Dithering and finger pointing is the default position for most business owners when something gets botched. Nobody likes to admit to mistakes and, as noted, it’s not always clear who’s to blame, especially at first. Yet it’s never good to be perceived as shirking responsibility. My column of August 2010, “Prepare For Disaster Now,” covered advice from a crisis management expert of what to do in case of a PR emergency. It was geared to dealing with the news media, but most of the recommendations fit equally well in reacting to customers and other interested parties. Here’s a repeat of some of that advice. • The first step is to organize an emergency management team to deal with any potential crisis. In big companies typically this would include people such as a project superintendent, safet y manager, project manager, HR manager, legal counsel and, of course, a high-ranking executive, preferably the CEO. Select one of these to be the team leader charged with responsibility for quick reaction and damage con-

How a contractor reacts even before knowing all the facts reveals a lot about that contractor’s personal character. It also has a lot to do with the longterm health of the business.

•

•

•

•

trol. The team leader will be the targeted recipient of all information leading to the emergency and responsible for disseminating that information to all other emergency team members. Talk to the media. Saying something, no matter how little, is better than saying nothing. Explaining why you can’t talk more (don’t know all the facts yet, advice of counsel, etc.) is better than stonewalling. “If you want your side of the story told, you must tell it,” said crisis management author Janine Reid. “If you don’t, reporters will get a version elsewhere, such as from the disgruntled employee who was laid off, or the worker who just witnessed his best friend getting killed or injured.” Avoid “no comment.” Anyone using this statement looks guilty as sin. If you don’t know the answer, tell the reporter that you don’t know but will try to find out. Avoid excuses and explain how you are planning to make things right. Designate one person as the sole spokesperson. In many cases the spokesperson would be the compa ny ow ner/C EO, t houg h i n some situations it might be good to insulate the CEO from media attention. Some CEOs may be too gruff, inexperienced or for any other reason not the best person to be the public face of the company, or may be too engaged behind the scenes to devote time to this important function. Make sure everyone knows who the spokesperson is. The designated spokesperson should be the only one authorized to disseminate information to the outside world and every other member of the crisis management team

should clam up and refer all media inquiries to the spokesperson. No information should be released without being approved by upper management. • Don’t cover up. If you find out bad news, bring it up quickly before someone else does and makes it sound worse than it is. However, first make sure your information is accurate. • Tell the truth. This does not mean you have to provide every little detail or admit to wrongdoing, but lying always comes back to haunt you.

• Don’t say a ny t h i ng “of f t he record.” Assume that anything you say will be made public. • Emphasize the positive. Point out all the remedial measures t a ken a nd what you r tea m is doing to make things right. Talk up any awards or positive recognitions your company has re c eived for profe ssiona l ism , c om mu n it y work , ch a r it able contributions, etc. Here’s hoping your problems are magnitudes smaller than the ones that afflicted SWA and Johnson & Johnson. W&C Jim Olsztynski (pronounced Ol-stin-skee) is Editorial Director of Plumbing & Mechanical and Editor of Supply House Times magazines. He can be reached at 847405-4006, [email protected] If you read this article, please circle number 314.

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FINISH LINE BY ROBERT THOMAS

Design

Features There are lots of small details and design features about EIFS that can help create a better-completed EIFS project. This month’s column is a list of many known—and not-sowell-known—design features that you should be aware of. HEIGHT ABOVE GRADE It’s not uncommon for designers to want to extend EIFS down into the ground at the bottom of a wall. This looks fine but it is not a good idea. EIFS is not a below grade insulation and waterproofing system, and will slowly disintegrate if used this way. But there are other factors. The codes, in many areas, require the bottom of EIFS to be at least 6 inches (or more) above grade. This is especially an issue in areas where termites are rampant, such as in the southern states. One compromise is to use the EIFS coatings alone—with no insulation— applied directly to the concrete foundation wall. At least this retains somewhat the appearance of the continuity of the EIFS wall directly above.

CREDIT CARD TRICK One of the keys to a crack-free EIFS coating system is to tightly abutt the edge of the insulation boards. If this is not done, the EIFS lamina may crack at the board joints. One easy way to inspect the fit of the EIFS insulation layer—as it is being installed—is to use a credit card. If a card will not fit between the edges of the insulation board, then the board joint is tight enough.

getting mangled by maintenance people. One solution is to make the cap from thin cast concrete or cast stone and cover it with EIFS finish. It looks nice and can take a beating from ladders and swing stages, etc.

RESIN PERCENT The glue that allows a good bond of EIFS to the foam and the wall comes from plastic resins, usually acrylics. The percentage of resin is not the same for all EIFS. Since resin is expensive, the minimum amount helps keep the cost down but there is a price to pay. Diagram 1 shows the concept. When only a little resin is used in the product, the effect on performance is small. But when a lot is added the benefits do not make up for the cost. So the well-formulated product would have a resin percentage somewhere near line “A.” A less expensive product would be near line “B.” The problem with resin percentage “B” is that it does not allow for a lot of tolerance for mixing errors. The moral: If the mixing or watering-down is too much, the performance suffers. With a higher resin percentage, the product is more tolerant of mixing errors. Don’t add extra sand, water or cement.

and fire escapes. Heavy objects need to be attached through the EIFS and into the supporting structural wall system. But you can attach some very lightweight objects to EIFS. Very light objects can be attached to the EIFS using a structural adhesive. This includes light objects like small plastic address numerals on homes. Using an adhesive is faster and less expensive and bypasses the problem of drilling holes through the EIFS, possible water intrusion and fastener corrosion stains.

ACRYLIC SEALANTS: BOND VS. STRETCHINESS Many EIFS coatings, including the basecoat and finish, use acrylic resins. Naturally, acrylic-based adhesives and sealants adhere well to these EIFS materials. By acrylic, I mean sealants that are mostly acrylic and not a blend with some other sealant material. Acrylics get stiff when they get cold and when a sealant joint opens up (when the temperature goes down), the movement can exert enough force on the EIFS coatings to pull apart the surface of the EIFS. This can lead to leaks. Thus, acrylics are best suited for small joints that are not subjected to a lot of movement, such as around small windows in homes. For large joints, such as between prefab EIFS panels, a softer grade of sealant is needed, such as a low modulus silicone.

BARBEQUE GRILLS I’ve been on a number of condo projects where the owners were griping about the EIFS being “dented” or “weak” on their deck. It takes 30 seconds to note that they have their BBQ grill pushed up against the wall where the dent was. The problem is that the heat from the grill gets transmitted through the EIFS coatings and melts the foam insulation. The EIFS coatings are then unsupported and sag.

WOODPECKERS PARAPET CAPS USING CONCRETE OR CAST STONE A number of my clients are sick to death of the following: the top of EIFS walls (that use EIFS as the parapet cap without any flashing)

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GLUE-ON SIGNAGE EIFS is a nonstructural cladding. It supports its own weight and resists wind forces. EIFS is not intended to have objects attached to it—especially heavy objects, such as flag poles

These cute but frisky little buggers can be a real hassle if you live in an area like I do (in the southeast U.S.). Why EIFS? They seem to like the sound of bashing their beaks against EIFS (sounds like a decaying tree, may-

B

A

PERFORMANCE

be?). Once through the EIFS lamina, they find soft foam insulation. They auger out the foam and create an insulated nest. Then you have even more of them. You can hear them indoors at night. What to do about this? Many woodpeckers are endangered, protected species, so you just can’t shoot them. Some species migrate, and once you think you’ve scared them away, they come back next year. Fake owls and snakes don’t fool them either. Firearms and other forms of death are illegal in most area. There is no easy solution to this problem other than harsh language and prayer.

➁

➀

➂ RESIN PERCENTAGE

Diagram 1

Diagram 2

PAINTING EIFS If painting EIFS (to change the color or generally improve the appearance), be careful what kind of paint you use. Water-based paints work best and EIFS producers make paint versions of their own finish coatings. Also, some EIFS finishes have water repellant materials in them that make the adhesion of additional layers, like paint, difficult. Also, if you use a highly water repellant paint, it can seal the outside of the EIFS from water vapor flowing outward from indoors. EIFS coatings are breathable and if the vapor flow is stopped by a hard, impermeable paint, condensation may occur within the wall.

RUST IN EIFS FINISH Once in a while, the rough “texture particles” in an EIFS finish become contaminated with iron. The iron is a tiny ferrous inclusion in the sand texture particle. After being on the wall, rust spots can develop in the form of streaks. This is especially common in hot, humid, salty environments like the Gulf Coast. These particles can be removed by picking out the offending particle and then removing the stain with a commercial rust remover. This is a lot of work. If the wall is full of rust spots, sometimes painting is tried as a quick cover-up. Often this does not work, as the rust “blooms” through the thin paint layer again anyway. By applying a new basecoat and finish over the existing EIFS lamina, the rust can be permanently buried.

V-SHAPED AESTHETIC REVEALS: CRACKING, WATER FLOW AND STAINING V-shaped aesthetic reveals (joints) are a convenient way for designers to give a modular panel effect to a façade. However, they also present problems (see Diagram 2), a vertical section through a horizontal V-shaped aesthetic reveal. First, water flowing down the wall is diverted into the joint area via Area 2 to Area 1. The resultant dirt in the water then stays in the joint and then—the next time it rains—flows out through Area 3 and deposits the dirt as a stain on the façade. That’s not all. The constant movement of the vertical face of the EIFS coatings makes the bottom of the V-groove at Area 1 act like a hinge. This can cause cracking. Then the water that is running down ends up being directed into the crack, leading to leaks. Further, the use of a flat sharp-edge metal trowel—when used to push the mesh into the groove— tends to sever the reinforcing mesh, making it extra vulnerable to cracking. The moral is to use rounded aesthetic reveals and to use a profiled trowel to press the mesh into the aesthetic reveal.

RECESSING SEALANT BEADS Replacing failed sealant joint in EIFS— especially with EIFS prefab panels— can be a meticulous process and expensive. One way to lessen this cost is to initially design the joint where the sealant is not at the face of the joint but

rather is recessed back in the joint. This does change the appearance of the joint but does do two key things: • It protects the sealant more from sun and weather. • It allows replacing the old sealant without removing it. The new sealant can be applied over the old one.

HUMID INDOOR SPACES VS. INSULATION JOINTS Beware of EIFS applications where the indoor space is very humid. The moisture indoors will naturally try to work its way toward the outdoors by flowing through the EIFS. If the joints between the EIFS insulation board joints are not tight, the moisture will come through to the surface, darkening the areas at the edges of the boards. I’ve seen this numerous times, and the worst example was a mushroom growing factory with a closed humid indoor environment. You could see every insulation board in the EIFS— it looked like a checkerboard. Next month’s column will present a whole range of other “goodto-know” aspects of EIFS that will help you to create better performing EIFS buildings. W&C Robert Thomas is a nationally recognized EIFS consultant, based in Jacksonville, Fla. He was the manager of technical services for a major EIFS producer, is the author of several books about EIFS and chairs the ASTM committee on EIFS. If you read this article, please circle number 310.

August 2011 | www.wconline.com |

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all things

GYPSUM BY MICHAEL GARDNER

Joints in Gypsum Panel Systems

When constructing a fire-rated partition, the prescribed gypsum panels must be applied to comply with the information provided in the corresponding fire test. To do otherwise is to risk compromising the integrity of the fire-rated system. The application process includes properly laying out the panels so that panel edges and end joints are placed to conform to the fire test. Every fire test report or listing contains specific language describing how the panels were installed during the test program. The language also describes exactly how the joints between panels were spaced during the test. Why then, despite the presence of specific language, do so many rated system post- const r uc t ion dilemmas derive from an incorrect layout that places joints in conflict with the requirements of the test report? Likely, the primary root causes of the problem are two separate, but related, concepts: Lack of applicator knowledge of the basic application requirements for any system—rated or non-rated—and misinterpretation of the fire-test language describing joint placement.

GENERAL JOINT SPACING CONCEPTS Correct joint placement is a basic requirement of any assembly constructed with gypsum panels. When constructing a partition, there are two primary joint spacing requirements that must be acknowledged: 1) Don’t install a joint on both sides of the same stud, and 2) Don’t create a continuous line of end joints on a stud.

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Joints are among the weakest structural points in a wall. They create obvious breaks in the planar surface of the finished assembly and provide a natural relief point for stress. Installing a joint on both sides of the same st ud is asking for trouble because any force that impacts one side of a st ud is goi ng to be t ra nsferred transversely through the assembly. If the force is significant it can cause the joint centered on the stud on the opposite side of the stud to crack. End joints on st uds are also required to be staggered between alternate panel courses when panels are installed with their bound edge perpendicular to the studs. You need to create a “running bond” pattern to prevent continuous joints from running up the face of a single stud. Joints are weak points; lining them up on one face of a stud is asking for trouble. Both concepts apply, with some modifications, to both single layer and multi-layer systems. For additional information, reference Section 4.6 of GA-216-2010, Application and Finishing of Gypsum Panel Products.

JOINTS IN A FIRE-RATED PARTITION SYSTEM For a fire test assembly, gypsum panels are installed in a defined

pat ter n to m it igate t he i nt r i nsic characteristics of the joints bet ween individual panels and, where necessary, to limit the installation of directly aligned throughsystem joints. The heat of a fire impinging upon the interior of a system at an opened joint will initially impact the area immediately across from the opening. If the area of impact incorporates a joint, the heat will be directly attacking a weak point in the assembly. Unless permitted by the fire test, the joints on opposite faces of a partition should not be installed in close proximity. C lo s ely ex a m i n i n g t he joi nt language for system W P 1072 as listed in GA-600, Fire Resistance Design M anu al, helps illustrate some basic panel lay-out requirements. The joint application language is quite straightforward and states: “joints staggered 24 inches on each side and on opposite sides.” In this instance joints are to be separated a minimum of 24 inches from each other: 1) on the same side of the partition, and 2) on opposite faces of the partition. While the language is applicable to WP 1072 it is also referenced in numerous other systems. It’s important to understand— and this is occasionally m isu nder s to o d — t h at t he appl ic at ion la ng u age appl ie s to joi nt s t h at run in the same direction on the same or opposite faces of the partition. It does not say that horiz ont a l a nd ver t ic a l joi nt s c a nnot i nter s e c t . W h at t he l ist i ng says is that the panels must be applied so that all of the horizontal joints (those pa rallel to the f loor or ceiling) are at least 24 inches apart and all of the vertic a l (p er p end ic u la r to t he f loor or ceiling) joints are at least 24 inches apart when the joints are on the same face of the partition. It also states that joints that run in the same direction on opposite faces of the par tition are to be offset by at least 24 inches. A diagram is instructive:

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(Note: WP 1072 permits either a parallel or perpendicular panel application orientation. For discussion purposes, we’ll assume a perpendicular—bound edges at right angles to the studs—application.) The solid lines show the panel edges on the visible face of a standard eight foot high partition with studs spaced at 24 inches on center. The dashed lines show the panel edges as they are installed on the opposite face of the same partition. Note that while the solid and dashed lines intersect when viewed through the partition they do not occur on the same stud and there is a minimum of 24 inches of separation between joints that run in the same direction. Line A-A is on the visible face of the partition. Line B-B is on the opposite side. The two lines are set 24 inches apart as prescribed by the fire test. It’s also worth noting that it may be necessary to split full panels to accommodate the joint spacing requirements. In the diagram above, the top and bottom panels on the obscured face of the partition are only 2 feet wide. To accommodate the joint spacing requirements an extra horizontal joint has to be installed in the face of one side of the partition. While this does create additional finishing work, it is unavoidable from a fire-protection standpoint. Other language in GA-600 initially appears somewhat less restrictive but, when taken in full context, is not so liberal. An example is the language describing joints for system WP 1070: “Joints staggered 24 inches on opposite sides.” In this instance, the listing addresses only the joints

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on opposite sides of the partition and does not provide specific guidance for the horizontal and vertical joints on the same side of the partition. What keeps the system from becoming joints amuck is: 1) With any installation you must first abide by the general spacing language that prohibits opposite side joints on the same stud, and 2) The specific fire test permits only a parallel application of panels. As a consequence, because all the installed panels “stand up” and must be applied with bound edges on successive studs, the vertical joints are adequately separated. In addition, the horizontal joints are addressed by the separation language in the fire test. It all points out that to create a properly constructed system, you often have to combine general joint language concepts with fire test requirements. As noted above, some proprietary systems listed in GA-600 do permit joints that occur on opposite sides of a partition to line up: “(h)orizontal joints on opposite sides need not be staggered or backed.” In this instance the horizontal joints, but not the vertical joints, on opposite faces of the partition are able to be installed in close proximity. The basic application requirements and the specific fire test define how the panels in a rated assembly are to be laid out and installed. While a correct interpretation of the relevant fire test is of paramount importance when constructing a fire-resistive assembly, the application requirements that are applicable to any installation of gypsum panels cannot be ignored during the application process. It is worth taking the time to review the fire test or listing before you begin panel lay out so that your installed system doesn’t compromise the intent of the fire test. W&C

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49

straight

GREEN BY CHRIS DIXON

Green Building

Legislation: An Unstoppable Freight Train I have long been bothered by the fact that legislative bodies have been broadly requiring that buildings be certified by nongovernmental private organizations such as the USGBC and its LEED green building rating systems (also included on the list is the GBI’s Green Globes rating system). Even more troubling to me is that the building industry, by and large, has tacitly accepted this without much concern or objection. Sure, there have been a few individuals that have raised issues about problems with these green building rating systems beginning, perhaps, with the paper by Auden Schendler and Randy Udall “LEED is Broken … Let’s Fix It” and peaking with Henry Gifford’s white hot lawsuit against the USGBC and LEED for false advertising and deceptive trade practices, but nothing has come from the industry as a whole. Green building legislation is being adopted rapidly across the United States. A 2009 American Institute of Architects study found that 138 of 661 US cities with a population of 50,000 or more had established green building programs. The study defi nes a “green building program” as a law or regulation that mandates or incentivizes construction of green buildings within a community. Professional organizations like the American Institute of Architects, Design Build Institute of America and the Associated General Con-

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trac tors of A merica have f ully embraced LEED and have produced documents and training materials to help industry professionals successfully implement the LEED program (LEED being by far the most cited) partly in response to this green building legislation.

QUESTIONING THE WISDOM OF GREEN BUILDING LEGISLATION In a recent Architecture Boston article titled “The Shadow Government: With little public oversight, the organization that invented the LEED system is remaking an industry,” author Michael Liu raises several concerns about the fact that LEED has been adopted as a requirement or a programmatic goal by a number of governmental agencies. One of his main concerns is, unlike the federal government’s adoption and use of standards by organizations such as ASTM, ANSI, NFPA and UL, “...the difference between these institutions and the USGBC is that while government regulators rely on the standards, regulations and research such organizations produce, the USGBC has become, in effect, a regulator itself.” Liu concludes, “… although the USGBC’s

LEED system has done more to bring the cause of sustainability into the public consciousness than any other, perhaps the time has come to revisit that assumption in the case of a private regulatory body that is not answerable to governmental authority.” At torney Stephen Del Percio, Green Real Estate Law Journal blogger, further explains “the difference is that those other standards are just that—standards. They’ve been accredited by ANSI or ISO or UL. There’s a mechanism in place within the state or local legislation to address any compliance disputes. There’s a body of law that addresses non-delegation in that context. Rating systems where a designation is conferred by a third party is a separate scenario.” He wrote that Liu’s argument is “… not necessarily a novel one, [but] it is significant that a major architectural publication has openly asked the question.” Del Percio sums up his blog post on the subject with the observation, “shining a spotlight on these issues as green building regulatory activity continues is critical, particularly as construction starts increase in an improving real estate climate.”

GREEN BUILDING LEGISLATION: UNCONSTITUTIONAL? Hofstra University J.D. candidate Frank David Ditta makes the case (in meticulous detail) that green building legislation is unconstitutional. In his Law Review article “Leading the Way in Unconstitutional Delegations of Legislative Power: Statutory Incorporation of the LEED Rating System,” Ditta points out “… the fervor surrounding the green building movement has left many of the usual safeguards of democratic accountability behind, resulting in an unconstitutional delegation of legislative power to the USGBC through the incorporation of the LEED rating system in law.” He goes on to explain that the U.S. Supreme Court and the supreme courts of several states have reaffirmed the premise that legislatures are limited in their ability to delegate the

authority to make law and that industry groups cannot be given this authority simply because they are familiar with their enterprises. Such a delegation of legislative power, he explains, is “unknown to our law” and “utterly inconsistent with the constitutional prerogatives and duties of Congress” and by extension state legislatures. Ditta provides several examples of states and cities that he said have unconstitutionally delegated lawmaking authority to the USGBC and says “codification of LEED standards into law at any level of government is an unconstitutional delegation of power to a nongovernmental organization— the USGBC—over which the government and public at large can exercise no direct control.” In a concluding statement, he insists “… government cannot dictate that the green building standards imposed on our building industry originate in a closed-off and interest-based nonprofit that has been unconstitutionally delegated authority to determine, on a nationwide scale, green building policy.”

tion of how to succinctly establish new sustainable design duties and responsibilities among the parties. The American Institute of Architects has sent out a rescue boat in its recently released Document D503—Guide for Sustainable Projects, which is much welcomed and long overdue. Freely downloadable, AIA Document D503 provides background information about sustainable design and construction practices and model language that can be incorporated into the AIA family of documents including A201 General Conditions of the Contract for Construction as well as Owner/Architect and Owner/Contractor agreements. For the owner, D503 prov ide s su g ge s t e d language in establ i sh i ng a m i n i-

WHAT’S A DESIGNER/OWNER/ CONTRACTOR TO DO? To owners, architects, and contractors that are legislatively and contractually obligated to deliver a green building meeting green legislation requirements, constitutionality matters very little. Owners, architects a nd c ont rac tor s h ave been struggling with these requirements and specifically w it h t he ques-

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mum level of performance required by t he a rch it e c t i n designing the building to

straight

GREEN meet established sustainable design goals. This may include a requirement that the architect perform certification services such as registering the project for certification, collecting sustainable building data and transmitting this data to the certification authority. A sustainability plan is defi ned and can be required to be developed by the architect in helping to outline steps in achieving owner-identified sustainable measures. The document also established minimum duties and responsibilities of the contractor including confirmation that substitution requests will identify any potential impact such requests may have on the project’s ability to meet its stated Sustainable Measures. Model language is also included requiring the contractor to prepare and complete documentation for certification as required in the contract documents. For the architect, D503 provides model language that certification is dependent on factors beyond the architect’s control such as owner’s

Contact Jon Mooney, author of this month’s article “Building the Surgical Suite of the Future” at (309) 793-3332 www.kjww.com 52

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use and operation of the project; the work provided by the contractor or the work or services provided by the owner’s other contractors or consultants; or interpretation of credit requirements by (certifying authority). The document also defines architect services exceeding the limits of basic sustainable design services and a mechanism to be compensated for them. For the contractor, D503 provides model language that establishes that sustainable objective achievement (certifi cation) shall not be a condition precedent to issuance of a Certificate of Substantial Completion.

CONCLUSION Federal, state and city governments have been enacting legislation mandating that buildings be green with a sense of urgency so great that reason and common sense have been kicked to the curb. Unwittingly, perhaps, government has enacted this legislation unconstitutionally, delegating legislative authority to

third party organizations such as the USGBC. Instead of complaining or even questioning the wisdom of this legislation, the building and construction industry has more or less gone along with it and in most cases has enthusiastically supported it. If challenged in court and found to be unconstitutional, as Ditta presents in his Law Review article, will it be the end of green building legislation delegating authority to organizations like the USGBC? Will the legislation simply be modified to adopt green building standards such as ASHRAE’s Standard 189.1 or will governments simply fold the new IGCC requirements into building codes? Time will tell. W&C Chris Dixon is a registered architect, Certified Construction Specifier, and LEED AP. He serves on GBI’s Green Globes Technical Committee and is a former USGBC Materials and Resources Technical Advisory Group member. If you read this article, please circle number 312.

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on the

SAFE SIDE BY MICHAEL RICH

Protect

Employees With a PPE Maintenance Program Every day in the United States, more than 10,000 workers are injured on the job with 14 of those injuries resulting in death. While the sheer number of those injuries is staggering, the financial impact to employers is crippling. An annual study conducted by the Liberty Mutual Research Institute for Safety in 2010, revealed the direct cost to employers from injuries in 2008 was $53.42 billion and indirect costs were between $80 billion to $200 billion annually. A key component to protecting both the safety of your employees and the profitability of your company is the creation of a personal protection equipment maintenance program. A personal protection equipment maintenance plan is a method of periodically checking safety protection equipment to ensure its functionality.

to have the employee monitor his or her equipment. If all your PPE is turned into a central location at the end of the day, then it is best to have one person in charge of the maintenance. If your company features a combination of these policies, I would suggest the creation of a policy that combines the t wo management processes. For this discussion we will assume the workplace involves a joint maintenance program. If your workplace wants to institute only one side of the program, simply strip out the portion that does not apply.

SELECTING A PPE MANAGER The first step in the creation of a plan is to identify how you would like to manage your PPE maintenance program. Three models that exist for management are: 1. Employees monitoring their own equipment. 2. A central person maintaining all the equipment. 3. A combination of the two. In determining which of these management plans is most effective for your company, it is necessary to determine how PPE is currently treated in your company. If your employees are assigned a set of PPE and that equipment stays in their possession, it is best

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TRAINING Now that we have chosen the maintenance it is necessary to craft a training program for the upkeep of equipment. To create this program, first let me provide you with the maintenance for each type of PPE. Eye Protection: • Regularly clean safety glasses and goggles regularly with mild soap and water. • When lenses are dirtied on the job rinse with water before wiping to prevent scratching. • Store eye protection in a clean, dust-proof case or in a safe place such as the top shelf of a locker where it won’t get scratched or otherwise damaged.

• Replace safety glasses (if frames are bent) and replace goggles if headbands are loose, twisted, knotted or worn. Replace any kind of eye protection if lenses are scratched or pitted and impair vision. • Replace headbands that no longer contain elasticity, are sweatsoaked, broken or twisted. • Repair or throw away protection that that does not properly hold face guards in place. Hearing Protection: • Wipe earmuffs with a damp cloth after use, store in a safe place and replace cushions when they lose their resilience. • Wash reusable earplugs every day, store in a clean case and replace if plugs are hard or discolored. • Wipe canal caps (headband plugs) with a damp cloth after each use, store them in a safe place so the headband won’t get bent or twisted and replace if the band is damaged and no longer fits comfortably. Head protection: • Clean hard hats regularly with warm water and soap and allow to air dry. • Store head protection away from extreme temperatures, out of the sun and keep them in a safe place where it cannot get damaged. • Check the headband daily to ensure it is not stretched or worn. It should fit comfortably on the head. • Replace all hard hats that show cracks, dents or other signs of damage. Respirators: • Clean and disinfect your respirator daily according to manufacturer’s instructions. • Check seals for cracks, holes, deterioration and any other problems that could interfere with the effectiveness of protection. • Store in a location, protected from light, heat, cold, moisture, dust and chemicals. • Store the respirator in a way that rubber and plastic parts hold their shape.

Gloves: • Keep gloves clean and dry. • Always have two sets of gloves per employee in case one pair gets wet and needs to dry. • Inspect gloves for rips, fraying, cracks or other damage before using • Discard damaged gloves immediately. Footwear: • Clean soiled or wet shoes immediately. • Air out work shoes after work. • Check shoes regularly for signs of damage and wear. • Replace all worn and damaged shoes. • Ensure socks are free of holes and dry throughout a shift. If employee has sweaty feet have them bring an extra pair of socks and change at lunch. Now that we have laid out the basic details of maintaining your company’s PPE equipment, it is time to create a training program. To do this, create a list of equipment that is specific to your organization and show your employees how to perform each maintenance task in a group training meeting. After the meetings have employees sign off on a training log showing they understand the training. If you want a form, please email me at mrich@ safetyservicescompany.com and I will gladly provide it free of charge. In addition to this large group meeting, I recommend including with paychecks once every month or two a training refresher on a specific topic. This refresher training should have a place for a signature so they can be returned and documented.

When an employee starts each day, he or she will be responsible for checking the condition of their equipment, performing any required routine maintenance and signing off in the appropriate date box. For ease of use I recommend keeping this book near employee lockers or the time clock. By having a log book you are able to log the maintenance of your equipment, have a record showing your company was not at fault in case of equipment failure and constantly remind your employees to properly use this equipment. The second log book we will create is for equipment that employees share or equipment that is not used often. The easiest way to complete this book is to number each piece of PPE with a permanent marker and place the corresponding number in the vertical rows of an excel file or log book. The horizontal rows will represent dates.

After creating the log book, the person in charge of maintenance will sign off on the maintenance of the equipment each day. You can purchase log books at most office supply stores or you can print off blank Excel sheets, pu nch t hem w it h a t h re e hole punch and place the sheets in a three-ring binder. If you want to take the green route create an electronic log book using Excel or any other data base system. By implementing this simple policy you can both prevent failure of PPE and extend the equipment’s life. W&C Michael Rich is a safety writer and researcher for Safety Ser vices Co. To learn more about the safety solutions the company offers, visit www.safetyservicescompany.com. He can be reached at [email protected]. If you read this article, please circle number 313.

CREATING A TRACKING POLICY Now that we have crafted our training for our PPE maintenance program, we must create a method of tracking to ensure the proper maintenance of equipment. Since we are going with a twopronged approach we will create two separate log books for tracking. The first log book we will design is for our employees with a vertical row featuring each employee’s name and a horizontal row of dates. Please Circle #174 On Reader Action Card August 2011 | www.wconline.com |

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(800) 458-7895 | www.drywalltools.com Please Circle #366 On Reader Action Card CLEAR SEAS RESEARCH. Making the Complex Clear.

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ADVERTISERS’

This index is provided as an additional service. The publisher does not assume any liability for errors or omissions. Advertisers appearing in bold are new advertisers.

index

ADVERTISER

RAC#

PG#

WEB ADDRESS

PHONE

Adapa, Inc.

209

8

www.adapausa.com

(800) 255-2302

Al’s Taping Tools & Spray Equipment

366

56

www.drywalltools.com

(800) 458-7895

Allied Building Products

170

58

www.alliedbuilding.com

(800) 4-ALLIED

Armstrong World Industries

103

5

www.armstrong.com/contractorsonly

(877) ARMSTRONG

CertainTeed Ceilings

308

13

www.certainteed.com

(800) 233-8990

CertainTeed Gypsum

153

17

www.certainteed.com

(800) 233-8990

CertainTeed Insulation

139

9

www.certainteed.com

(800) 233-8990

ClarkDietrich Building Systems

154

11

www.clarkdietrich.com

(800) 543-7140

CONSTRUCT 2011/CSI Annual Convention

176

43

www.constructshow.com

(866) 920-0207

Dupont Tyvek Fluid Applied

140

21

www.fluidapplied.tyvek.com

Fiberweb

328

29

www.typar.com/metrowrap

(800) 281-2780

129, 174

42, 55

www.flexabilityconcepts.com

(866) 443-3539

Hy-Flex Corp.

323

38

www.hyflexcorp.com

(866) 849-6246

KJWW Engineering Consultants

207

52

www.kjww.com

(309) 793-3332

Lafarge North America/Gypsum

106

BC

www.lafarge-na.com

(800) 237-5505

MBCI

171

30

www.mbci.com

(877) 713-6224

METALCON International

199

35

www.metalcon.com

(800) 537-7765

3

www.nationalgypsum.com

(800) NATIONAL

www.nilesbldg.com

(800) 323-3329

www.oncenter.com/WallsAndCeilings

(866) 627-6246

56

www.outsourcesestimator.com

(804) 684-5613

Flex-Ability Concepts

National Gypsum Niles Building Products On Center Software

172

34

244, 245

39, 51

Outsource Estimating PDquipment

355

56

www.pdquipment.com

(888) 383-7274

Peters & Sons

173

52

www.ldpeters.com

(800) 221-9933

Plastic Components, Inc.

159

49

www.plasticomponents.com

(800) 327-7077

56

www.prosquareceilings.com/wc

(215) 775-0904

Prosquare Ceilings The Quikrete Companies

268

15

www.quikrete.com

(800) 282-5828

SPEC MIX, Inc.

342

IFC

www.specmix.com

(888) SPECMIX

Specialized Building Products

260

7

www.specializedbuildingproducts.com

(714) 279-1042

Structus Building Technologies

112

24

www.hydrotrimcorner.com

(888) 662-6281

Super Stud Building Products, Inc.

120

14

www.edgesteelframing.com

(800) 477-7883

Total Wall, Inc.

198

IBC

www.totalwall.com

(888) 702-9915

Trim-Tex, Inc.

118

45

www.trim-tex.com

(800) 874-2333

25

www.theweighthasbeenlifted.com

(888) USG-4YOU

USG Corporation

August 2011 | www.wconline.com |

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Sponsored by Allied Building Products Corporation

CONTRACTOR PROFILE cient in doing the task at hand. We’re a high-quality, best price operation.”

PROJECTS OF ALL KINDS

H. CARR & SONS INC. H. Carr & Sons is a true American company serving all New England for four generations and still counting. H. Carr & Sons Inc. is well into the 21st century and has no plans of going away anytime soon. The company, founded by Harry Carr in 1930, is now a fourth-generation company. When the company was founded, just a year after the stock market crash of 1929, H. Carr was strictly a plastering contractor. From there, James Carr (Jamo’s dad) took over and grew the business. Today, the company still plasters but in addition to drywall the company does ceilings, fireproofing, carpentry, metal framing, masonry, painting and more. “We are a general trades contractor,” says James “Jamo” L. Carr Jr., the company’s CEO, owner and president. “We do it down to the finish.” A very proud New England contractor, the company cu rrently serves Rhode Island (where it’s headquartered), with additional offices in Massachusetts, Connecticut and New Hampshire (serving that state, Maine and Vermont).

WHAT THEY DO “The primary goal of H. Carr & Sons has been to provide a quality product and service to the construction industry on a competitive basis,” says Jamo. “This concept is one of the directives that has not changed to this day. We have witnessed the rapid

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| Walls & Ceilings | August 2011

changes and cycles in this industry over the years and have maintained a high degree of management flexibility to meet the challenges that constantly confront us in this regard. Our sustained growth can be attributed to the keen understanding and the ability to adapt to market changes, as well as to the devotion and loyalty of our employees … .”

HAPPY WORKERS And the employees do stick around. According to Jamo, the union staff of the company is currently around 500 employees. Jamo says that figure is down from three years ago when its staff was a whopping 800. But as everyone else was impacted by the recession, the company wisely stayed small, collected money from projects and “hunkered down,” Jamo says. The company has several projects in the works right now that will last them well into the next year. “We have about 80 projects going on right now,” Jamo says. “And we have the staff to do it and more. We have everything from in-house engineers to accountants plus the tradesmen. A lot of people think we have a lot of overhead—but we don’t. Our overhead is a third less (by percentage) than the national average right now, actually. We run everything ourselves. That makes us much more effi-

The company does very large commercial and public projects, such as stadiums, casinos, office space, hospitals and more. Given that it’s New England, the company does a fair amount of work at the Ivy League schools as well. “We are always looking for work,” says Jamo. “Our volume is still down by at least 40 percent but there is work. When things were moving, we were a $100 million [a year] company. It’s down now about 60 percent, at $60 million. “This problem that we’re in isn’t going away anytime soon,” he adds. “I think it will be at least 2014 when we see the market rebound to normalcy.” Part of the company’s success stems from decade-long relationships with various builders, architects and distributors. As an example, H. Carr has been doing business with Allied Building Products since the 1970s. “It’s a very strong relationship,” says Jamo. “It’s a multi-generational company like ours. We know the family well. They’ve followed our career and we have followed theirs. They receive the vast share of our business.” Jamo says he works 14-hour days and frequently travels to all the New England sites as required. Tom Purcell (Jamo’s nephew) is COO and takes care of the jobs day-to-day. With a life-partner Mary Anne (BC-83, H. Carr CFO) they raised their six kids aged 18 to 24—some of which are scattered abroad so Jamo’s a busy guy. His true passion is football and he can be frequently found in the fall at all New England Patriot games and Boston College football games. When his son Jesse (BC-09), who is in the Marine reserves about to spend time in Afghanistan, returns next year, he’ll rejoin the H. Carr crew to prep as he carries the company into future generations. Well done. W&C If you read this article, please circle number 170.

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