Walls & Ceilings October 2011

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I S S U E Products you can look up to. Se ee page pa age ge 13 3..

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October 2011 | Volume 74, Issue 10 | The Voice of the Industry Since 1938™ | www.wconline.com

9/19/11

FOUR? SCORE. National Gypsum introduces e2XP Tile Backer, the final piece of the puzzle for extended exposure fiberglass-faced gypsum panels. T le Ti e Bac acke kerr ke

Designed for use as a substrate for interior tile applications in high moisture areas, e2XP Tile Backer is the perfect fit for interior residential and commercial applications. To learn more about our complete family of e2XP products, including Sheathing, Shaftliner, Interior Extreme and Tile Backer, visit purplechoice.info.

Technical Info: 1-800-NATIONAL or visit nationalgypsum.com

U.S.A.

PRODUCTIVITY:

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october columns 06 Up Front by Mark Fowler

34 On the Safe Side by Michael Rich

38 Finish Line by Robert Thomas

features

VO L U M E 7 4 N U M B E R 1 0

18 The Marriage of Form and Function Manufacturer helps create a symphony of curves at New World Center in Miami.

22 Window on the Future New thinking on fenestration products means a window doesn’t have to represent a gaping hole in the thermal envelope.

26 Mind the Gap Expansion joints can close the spaces between surfaces without compromising fire safety.

40 All Things Gypsum by Michael Gardner

30 Knock on Wood? Faux wood beams offer the look of rustic timbers without the weight and worry that comes with real wood.

42 Smart Business by Jim Olsztynski

44 Straight Green by Chris Dixon S

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46 Industry Voices

on the cover

by Phil Mancuso

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Trade News

Architect Frank Gehry’s vision for the New World Symphony called for curves in almost every space of the 106,350-square-foot building. Radius Track assisted with the project.

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Product Focus

Photo courtesy of Radius Track.

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Classified Marketplace

October 2011 | Volume 74, Issue 10 | The Voice of the Industry Since 1938™ | www.wconline.com

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Advertiser Directory

9/20/11 2:37 PM

ON THE WEB www.wconline.com

NWCB—May 10-12 The Fairmont Scottsdale Princess, Scottsdale, Ariz. FWCCA—July 18-22 Renaissance St. Augustine. St. Augustine, Fla.

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| Walls & Ceilings | October 2011

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

Easy, accurate ceiling transitions Our new transition molding is a simple solution to making clean transitions from a suspended ceiling – including mineral fiber, wood, and metal – to a drywall surround. It’s compatible with all Armstrong Suspension Systems and Drywall Grid Systems. And the hot dipped galvanized transition molding eliminates the need for a vertical drywall return at the transition, return framing to support drywall return, and corner bead and vertical taping. 1" INVERTED T MOLDING Allows a monolithic horizontal transition that works with Armstrong Suspension Systems. Pre-painted white integral acoustical flange eliminates the need for a separate acoustical molding.

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TRANSITION MOLDING WITH SHADOW REVEAL The easy-to-cut molding installs with all types of framing, including Armstrong Drywall Grid and ShortSpan™. Available with a 9/16" or 15/16" acoustical flange; 15/16" flange is compatible with our Seismic Rx® solutions.

up

FRONT BY MARK FOWLER

Fall

Forward As we now are into the fall, it is time to look forward. We may think of spring as the season that begins life for nature but many of us in the association world of the construction industry consider fall the beginning of the year. Association meetings, seminars and many industry events start back up after “going dark” in the summer. Along with the networking and educational opportunities, this is also a good time to re-evaluate your company, it’s goals, any objections and the direction you should be heading. Association executives around the country have been scrambling to bring you interesting, relevant and timely chapter meetings. I have been doing this for years and sometimes we hit the mark and sometimes we miss. In the never-ending attempt to find interesting topics and speakers, we try to be observant of what is going on, what our members need and should be hearing about. We also rely on our members for feedback on what they would like to hear about or concerns that may have an impact today on your business. By the time you read this, all the member meetings and speakers have probably been arranged for your local association. If you have an idea for a speaker or topic, let your local association know—they will be happy to arrange it and I know they will appreciate your interest and the suggestion. Early fall is typically very nice all around the country. It can be so pleasant that it lulls us into a false sense that winter won’t be so bad this year. However, we should be thinking about the impending colder and wetter weather that is fast

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| Walls & Ceilings | October 2011

approaching and about the adjustments our supervisors need to make. For example, most of our clients think that installing and finishing drywall is the same job all year long. After all, the work is indoors year round. What’s the difference when you’re inside? Experienced tapers know there is a difference. The warm fall days followed by nearfreezing nights can cause all kinds of problems for drywall finishers. Problems can range from nail pops, delayed shrinkage and joint cracking to joint ridging. The taper will surely be blamed—after all it didn’t happen in the last few months or on the last job. So it must be his fault! How could warm days and cold nights affect indoor joint taping or plastering?

PREPARE FOR THE CHILL When the weather changes, problems can start suddenly and at almost an epidemic rate. All materials expand and contract at different rates as they are exposed to temperature changes—some a lot, some a little—but the fact remains they all grow and shrink to some degree. What can be done? We can’t change the weather. First, educate your crew. Be the Paul Revere of your shop and warn the locals that the colder weather is coming. Review standards, follow ASTM and other industry guidelines for guidance. When a general

contractor or owner fails to assist you or dismisses your requests, send him a clear, concise, but friendly letter advising him of the standards recommended by the local trade association or bureau. Don’t wait until the first weather-related problems appear and the finger pointing starts. Get a jump on the problem and make your employees aware. Stucco and EIFS installers have issues too. In cold regions of the country, snow may be just around the corner and you should be prepared to inform the general contractor that tenting and heating may be the best recommended practice. Fall is always the tough season, as walls could be well over 90 degrees Fahrenheit at mid-afternoon and then drop below freezing just 12 hours later. This 60-degree temperature swing in less than 12 hours is powerful and something all parties involved should be aware of. Again, it’s best to talk to your crews in advance and not wait until you wake up to two feet of snow in the morning. The general contractor says it is the drywall subcontractor’s responsibility to tent, heat and provide the proper environment. Is it really? Do you control the weather? While the general contractor does not have control over the weather either, he does control the project and other trades. He can direct other subcontractors to close doors, keep tenting in place and back-charge violators; you have no such authority or control over other trades. In addition, who “benefits” from the accelerated schedule? The owner does, they want the project completed fast because they’ll benefit the most from early completion. It stands to reason they should bear the cost of tenting and heating in cold weather. Wall and ceiling contractors can provide language in their bids covering tenting and heating. Don’t be caught with your pants down, plan ahead. After all, fall means old man winter is not far away. 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

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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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TRADENEWS CALENDAR 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 STAFDA Henry B. Gonzalez Convention Center, San Antonio www.stafda.org

JANUARY 24-27 WORLD OF CONCRETE Las Vegas Convention Center Las Vegas www.worldofconcrete.com

FEBRUARY 8-11 INTERNATIONAL BUILDERS’ SHOW Orange County Convention Center Orlando, FL www.buildersshow.com International Builder For additions or corrections to our Calendar, please call (248) 244-6404.

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| Walls & Ceilings | October 2011

IP TO ACQUIRE TEMPLE-INLAND International Paper Co. said it agreed to acquire Temple-Inland Inc. for $3.7 billion, ending a three-month battle for control of the shipping-box manufacturer. International Paper increased its offer to $32 a share, the company said in a statement. Temple-Inland had previously rejected a June 6 allcash bid of $30.60 a share as too low. “The strategic benefits of this combination are clear and we are pleased to be able to move forward on terms that are financially attractive for both sets of shareholders,” International Paper Chief Executive Officer John Faraci said in the statement. Faraci said in June the deal would raise International Paper’s share of the North American corrugatedpackaging market to about 37 percent from 27 percent. To fend off the original bid, Temple-Inland had adopted a so-called poison pill takeover defense that limited any person or group from acquiring more than 10 percent of its stock. The company also has a staggered board, meaning it could have taken more than a year for International Paper to gain control through proxy fights.

CERTAINTEED GYPSUM PROVIDES SUSTAINABLITY TRAINING CertainTeed Gypsum has implemented a sustainability training program to nearly 1,000 employees in all of the company’s gypsum plants in the U.S. and Canada. Additionally, several of the company’s territory sales managers and marketing professionals have earned their LEED Green Associate credential. The training program implemented at the company’s plants focused heavily on water conservation, waste reduction and energy conservation. Employees were trained in best practices and encouraged to find creative solutions that increase efficiency, eliminate waste and enhance recycling efforts. As a result, the company has reduced waste by 20 percent over the course of two years.

To achieve the LEED Green Associate credential, the company’s sales and marketing associates tackled course work designed by U.S. Green Building Council and successfully completed a comprehensive exam. The LEED Green Associate credential demonstrates knowledge of green design, construction and operations. “We take a holistic approach to sustainability that includes product innovation, environmentally responsible manufacturing practices and a well-trained, knowledgeable team of employees,” said CertainTeed Gypsum President John Donaldson. “We are making significant contributions to the performance and longevity of homes and buildings, strengthening our position as the preferred supplier for innovative, sustainable building products and systems.” For more information on CertainTeed Gypsum’s sustainable offering, visit www.certainTeed.com/sustainable.

AMM PROVIDES PRICE FORECASTS TO SFIA The Steel Framing Industry Association and the American Metal Market have entered into a joint marketing agreement to provide SFIA members access to AMM forecasting information via the SFIA Web site’s “Members Only” section. As part of the arrangement the AMM will also offer special discounts to SFIA members for AMM information products and services. “We are excited about our relationship with American Metal Market and the many benefits their products and services offer to the members of SFIA,” said organization President Bill Courtney. “This service will provide SFIA’s manufacturers, suppliers and contractors with valuable guidance regarding steel price forecasts. It is one of the many statistical tools to be offered by SFIA covering profile and trend information about the coldformed steel industry,” said the association’s Industry Statistics Committee Chairman Terry Westerman, who

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TRADENEWS led the development of the forecasting relationship with AMM.

KNAUF ANNOUNCES UL VALIDATION Knauf Insulation has announced that UL Environment and their Environmental Claims Validation service have validated post-consumer content of 55.7 percent. ULE’s conclusive and independent third-party validation process further supports Knauf Insulation’s value as a leader in sustainable product manufacturing. “As one of the first manufacturers in our industry to work with ULE on this type of initiative, we are proud to announce the validation of environmental and sustainability claims for our glass wool products,” said Knauf Insulation Director of Sustainability Scott Miller. “Independent, third-party validation provides our customers with confidence in the sustainable attributes of our insulation products. Knauf Insulation, as a company, will continually adapt to the constantly changing atmosphere of environmental sustainability and

PEOPLE Saint-Gobain has announced the appointment of John Crowe as president and CEO of both Saint-Gobain Corporation (Saint-Gobain’s North American holding company) and CertainTeed Corp. (SaintGobain’s largest North American subsidiary).

Eisenmann

Following Bob Drury’s retirement, Mark Eisenmann has been named the Northwest Wall and Ceiling Bureau’s executive director. Hacker Industries has named Nick Quercetti Jr. regional sales and marketing manager in the Northeast and Midwest.

stay in the forefront with our sustainability platform.” Knauf Insulation manufactures thermal and acoustical fiber glass insulations for residential, commercial, industrial, marine, OEM (original equipment manufacturer) and metal building applications. Postconsumer recycled bottle glass along with sand, one of the world’s most abundant and renewable resources, and Ecose technology are used to create the next generation of sustainable insulation.

Quercetti

“We applaud Knauf Insulation for their commitment to diverting waste to make insulation,” said Stephen Wenc, president of ULE. “Knauf Insulation is also committed to building confidence and trust in the marketplace by validating their claims with an independent, third party.” Knauf Insulation worked with ULE to validate their post-consumer content claim. “It just made sense to use ULE as our validation body. Knauf Insulation currently works with UL to classify the fire performance of most

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| Walls & Ceilings | October 2011

© 2011 CertainTeed Corporation

Products you can look up to.

EPDs you can look into. Many of CertainTeed’s Ceilings have Environmental Product Declarations (EPDs) – 3rd party certified life cycle assessments that tell their whole green story, from raw materials to reusability. That’s transparency you can see. View the EPDs at www.CertainTeed.com/CeilingsEPD

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 SPACKLE BY DAVE COVERLY

pass the tests to apply the ULE ECV service logo on product packaging and marketing materials. Results for the validation are available at www.ulenvironment.com.

L&W SUPPLY TO CLOSE NINE LOCATIONS

of its products, and has for many years. UL is recognized by architects, engineers in building specifications and is certainly recognized on consumer products as well,” said Knauf Insulation Director of Technical Marketing Glenn Brower. UL Environment applies a rigorous, independent process to the testing and auditing of environmental claims and allows manufacturers that successfully

USG Corp. said its L&W Supply distribution unit would shut eight distribution branches and its Nevada custom door and frames business by the end of the third quarter, as it continues to be hit by a weak U.S. housing and construction market. The company said it would take a charge of about $7 to $8 million in the current and future quarters. It also expects a cash expense of about $6 to $7 million in relation to the closures.

NWCB RELOCATES The Northwest Wall and Ceiling Bureau relocated to the Seattle Eastlake area at the end of September. The new address is: 2825 Eastlake Avenue East #350, Seattle, Wash., 98102. The telephone number remains the same at (206) 524-4243.

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| Walls & Ceilings | October 2011

SAFETY SERVICES RELEASES NEW MEMBERSHIP BASED SAFETY PROGRAM Tempe, Ariz-based Safety Services Co. has launched the Safety Services Network, a new membership-based program designed to help companies stay safe and compliant. Through the starter package, members receive a free federal labor law poster, an OSHA audit and compliance book, certificate of recognition, $100 safety voucher, subscription to a safety newsletter and more. In addition to the free membership that is currently available, Safety Services will launch a pro membership in the coming months. The pro membership will feature all the benefits of the starter membership, plus 12 safety meetings a year, access to the compliance expert tool and more. The pro membership will cost $10 a month. “This new membership program is a great way for both new and existing companies to get a greater handle on creating safe and compliant work-

places,” said Safety Services President Devon Dickinson. To learn more about the program, visit www.safetyservicescompany.com and click on the “sign up” button.

UNITED STEELWORKERS RATIFY CONTRACT WITH OMNOVA SOLUTIONS OMNOVA Solutions announced that members of United Steelworkers Local 22L have ratified a three-year labor agreement at the company’s Jeannette, Pa., decorative products plant. The vote of the membership was held in September. Details of the agreement were not disclosed. The Jeannette facility is part of OMNOVA’s Decorative Products business unit, with about 105 of its 138 employees represented by Local 22L. The plant produces performance and industrial films used in a number of products, including awnings, medical inflatables, commercial ceilings and flooring.

EMPIRE STATE AWARDED LEED GOLD The Empire State Building has been awarded LEED Gold for Existing Buildings certification as further recognition from the $550 million Empire State ReBuilding program. The Manhattan building is the tallest and most well-known structure in the U.S. to receive LEED certification. The 2.85 million-square-foot building is celebrating its 80th anniversary while nearing completion of its renewal and repurposing to meet the needs of 21st Century businesses. It is one of a small number of National Historic Landmarks to earn the designation, which was established by the U.S. Green Building Council and veri-

fied by the Green Building Certification Institute. The LEED Gold certification follows the ground-breaking creation and implementation of a new replicable, transparent, quantifiable process for economically justified energy efficient retrofits in the existing built environment created a team of the Clinton Climate Initiative, Johnson Controls, Jones Lang LaSalle and the Rocky Mountain Institute. The game-changing analytical model is non-proprietary and open-source and is being replicated at other properties around the world. There is a new focus by government and the real estate industry on investment and return in energy efficiency retrofits driven from the well-documented success of the Empire State Building. The retrofit conducted by Johnson Controls and Jones Lang LaSalle is guaranteed to reduce the building’s

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energy consumption by more than 38 percent and should save $4.4 million in energy costs annually. W&C

product

FOCUS

on

Safety and Ergonomics Dust control joint compound NATIONAL GYPSUM The ProForm XP Ready Mix Joint Compound with Dust-Tech is an all-purpose, low-dust joint treatment with enhanced mold resistance. The product is specially formulated to cause dust to fall straight to the floor, reducing airborne dust by more than 60 percent and improving indoor air quality during all phases and types of construction. In addition, the product features enhanced mold resistance to help prevent mold growth during and after the construction process. It has achieved the highest possible score for mold resistance on both the ASTM G 21 and ASTM D 3273 tests and achieved GreenGuard Children & Schools certification, the industry’s most stringent indoor air quality standard. If you read this article, please circle number 270.

Scaffolding toolbox RAS SPECIALTY TOOLBOX CO. The Sure Step Toolbox is a product that doubles as the top plank of a scaffold. It weighs less than 30 pounds empty. If workers need to get on the top step, the toolbox can be closed, locked and the toolbox becomes a plank with a non-skid surface that can easily support their weight. It has a locking mechanism that locks the toolbox shut and fastens it to the scaffold for safety. The product is designed to increase work efficiency by allowing workers a place for their tools and increase job site safety by eliminating dangerous tool-related debris from the planks of the scaffold. If you read this article, please circle number 271.

Portable scaffold system WERNER LADDER CO This lightweight portable scaffold sets up quickly, provides multiple working and has smooth gliding wheels allow it to easily haul heavy loads. With a highest standing level of 30⅛ inches and a width of 46⅛ inches it provides over a 6-foot reach, making it ideal for painting and many other projects. The 500-pound load capacity scaffold doubles as a workbench or multi-level storage and organization unit. Highgrade wheels lock in place for extra safety and security. The product meets or exceeds applicable OSHA and ANSI codes and standards for strength and structural integrity. If you read this article, please circle number 273.

Portable guardrail protection system CAPITAL SAFETY The Portable Guardrail System offers a practical fall protection solution that is designed to prevent personnel from reaching a fall hazard. The freestanding system can be erected in minutes, requires no permanent or penetrating surface attachments and seals off areas and edges that are unprotected, offering an ideal passive fall protection solution. The guardrails are offered in 6-, 8- and 10-foot sections to fit a site’s specific needs. The new and unique lightweight bases incorporate ergonomic handles, four rail receptacles and built-in toe-board brackets that allow infinite configurations with no additional components required. In addition, a rubber pad on the bottom of each base provides skid resistance and surface protection, while splice kit, roof hatch and swing gate accessories provide added versatility. Installation of the Portable Guardrail System is quick and easy with no special tools required. Simply position the bases, insert the guardrail sections into the bases and tighten the set screws to secure in place. If you read this article, please circle number 272.

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| Walls & Ceilings | October 2011

Dust level sensing unit ONEIDA AIR SYSTEMS INC. The Oneida Dust Sentry with adjustable infrared-sensing technology has a strobe light to alert the operator when the dust reaches a preset level, indicating when it’s time to empty the container. The operator will not have to unpack a filter full of chips again because someone forgot to empty the dust drum. The product will alert you when it’s time to dump the drum. If you read this article, please circle number 274.

The contractor’s new choice.

SCB

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Simpson Strong-Tie introduces slide-clip and fixed-clip connectors for cold-formed steel curtain-wall construction. Our new line of connectors for steel-stud framing is designed and field tested with the installer in mind. From field support and training to national product availability, we are here to make sure installation is as simple and quick as possible. As with all Simpson Strong-Tie ® products, our new connectors for steel-stud framing carry our promise of quality and performance, and are backed by prompt, technical support. Learn more by visiting www.strongtie.com/cfsclips or by calling (800) 999-5099.

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©2011 Simpson

Strong-Tie Company Inc. CFSCWC11-C

The Marriage of

Form&Fun F

rom t he out side , t he newly opened New World Center, the campus of the elite New World Symphony in Miami Beach, Fla., may not appear to be a celebration of curves. But visitors stepping inside the rectangular 80-foot high glass box are treated to a dynamic interior full of dramatic swoops, swirls and sails designed by Gehry Partners. Indeed, Gehry’s vision for the project called for curves in almost every space of the 106,350-squarefoot building. Radius Track, provider of cold formed steel framing and 3-D modeling for curved surfaces, was called in to transform Gehry’s architectural concepts into engineering reality.

TUNING UP New World Symphony, the noted orchestral academy, prepares highly gifted graduates of distinguished music programs for leadership roles in orchestras and ensembles around

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| Walls & Ceilings | October 2011

Radius Track creates a symphony of curves at New World Center in Miami. By Chuck Mears | Photos courtesy of Radius Track

the world. With the opening of the innovative New World Center campus, students now have access to some of the orchestral world’s premier performance spaces and learning environments. In eras past, a design with these curved surfaces and dramatic knife edges would have been nearly impossible to complete. There are simply too many complex curves and 3-D objects with no “plumb-bob-angle” surface to set as a work point. However, advances in curved cold formed steel framing and BIM 3-D modeling allowed the curves not only to be relatively quickly and easily built, but to be precise enough to acoustically tune the building’s world-class concert halls. The first glimpse of Gehry’s distinctive curved design comes in an overhanging portico that encom-

passes Gehry’s signature scalloped sails. Inside, a soaring 80-foot glass wall leads into an atrium featuring a high-tech box office, a public bar with an undulating canopy and a series of playful geometric practice and rehearsal rooms. These unique rooms are essentially a series of stacked forms, contorted, compressed and twisted to fit within the rectangular building structure. The centerpiece of the building is a 757-seat natural acoustic performance space featuring large, distinctive saillike acoustical surfaces designed for the ultimate orchestral experience. A director’s studio and penthouse garden sit atop the structure.

CREATING THE CURVES Radius Track worked closely with the project’s structural engineers, Haskel Mayer, PE (Mayer Structural Design in Miami) and Gilsanz, Murray, Steficek LLP (New York) to create the intricate framing necessary for the project. “This was one of the most challenging projects in company history due to the abstract and unbalanced nature of the forms that exist in the space,” says Radius Track President Bob Krebsbach. “Because many of the surfaces are angled, tipped or curved, traditional framing methods would not have been cost effective. The framing members had to be perfectly fabricated with incredible precision. When you are creating surfaces like these, every piece is different.”

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The architectural team created 3-D models of the surfaces themselves and handed them off to the curved steel framing fabricator (Radius Track). The curved framing team took the curved surfaces and began creating “framing solids” (the spaces assigned to the eventual built framing members) based on requirements set forth by the structural engineering team. Next, each curved surface was individually analyzed to optimize the curved surface and ensure that each one precisely matched the architect’s design intent. Then, the isoparms (the lines that define the surface) were positioned to optimize framing efficiency. These isoparms became the “wires” (the bent corners between flange and web on the outside of the framing solid surface) which served as

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the basis for calibrating the curvature and bend spacing of the framing members. Proprietary modeling software then compiled all of this information and organized it into bend spacing and bend angle settings for each unique piece of the framing system.

THE RIGHT TOOLS Each piece of the framing puzzle was then pre-bent to exacting standards (1/8 inch per 10 feet) at the fabrication facility using proprietary pneumatic and hydraulic benders. This is a drastically different method than was used even a few years ago. Prior to the advent of these new bending tools, many structural steel curves were created using a process called stretch forming. In this method, steel members are bent around cus-

tom-built forms using large-capacity hydraulic stretching equipment. Although effective, this method requires custom forms to be built for each curve in the framing system, significantly increasing costs while limiting the number of curves that are included in the project. In the late-1990s, Radius Track introduced proprietary bending tools. These tools use calibrated crimps (or bends) in the web and/or flange of standard steel tracks and steel studs to precisely curve members to match design intent. Because no molds are required to bend the members, this method is both more versatile and more affordable. Today, these tools have been integrated into complex computer systems, allowing even heavier gauge members to be bent into precise curves and even compound curves. This was certainly the case for the New World Center. As the curved members were created, each piece was double-checked for accuracy on a layout table to ensure complete precision.

KNIFE EDGES Interestingly, the curves did not end up being the biggest challenge on this job. Gehry’s design called for knife edges throughout the project. Knife edges come together at a sharp edge or acute angle. These have been among the most challenging profiles for drywall contractors to execute consistently and precisely. They can be difficult enough to execute when they are uniform from top to bottom. However, in New World Center, the angles were constantly changing as they went from floor to ceiling along the curved surfaces. In most cases, to create a knife edge, framing members are welded

to give the edge an added rigidity. However, the dynamic curves in this design meant that welding was not an option. Even a single weld bead would have warped the shape of the geometrically precise forms. The challenge for Radius Track was to devise a way to create the stiffness that drywall contractors would need in order to execute the knife edges flawlessly. The custom solution came in the form of diagonally-braced frames. A unique tie system holds the members together, allowing the creation of a smooth, sharp knife edge.

TRIAL RUN Due to the complexity of the curves and the knife edge support system, the construction contract required large mockups to be created of many of the complicated structural forms in a nearby Miami warehouse. The entire assembly was tested at the warehouse with all trades participating. The curved framing components, combined with the tie system, were able to effectively and accurately create the curves specified in Gehry’s original design. In all, Radius Track created an Erector Set-type kit of parts containing 259 different surfaces, for a total of 505,683 square feet installed and covered with drywall. The company created nearly 3,500 studs and more than 2,500 tracks, 94 percent of which are one-of-a-kind.

FINISHING TOUCHES Radius Track partnered with the Miami offices of specialty contractor Lotspeich Co. Inc. to finalize the wall surfaces. “This project was a completely new way of building for us,” recalls Lotspeich Senior Project Manager and Vice President Joaquin Riera. “We’d never worked on a project that had so many undulating, curved surfaces and the knife edges. Understanding complex 3-D modeling and using Rhino was new to some of our job site team, and they were a bit nervous at the beginning of the project. However, as time progressed they realized that these models actually made their job simpler. Radius Track fabricated the complicated knife edges in Minneapolis, and then shipped them to us in an incredibly organized way. Looking back on the project, it would have been impossible to do without Radius Track.” W it h t he f ra m i ng comple te , Lotspeich was able to complete the acoustic drywall quickly and efficiently. With geometrically precise surfaces, the drywall portion of the job was made easier and more efficient.

CLASSICAL MUSIC FOR THE MASSES Several months after the building’s opening, people who have never experienced classical music are flocking to the New World Center. The design of the building is the perfect marriage of form and function—a classical musical tradition set against an

arrestingly beautiful bevy of curves. The symphony extends itself to the public through live feed performances played on the side of the building for pedestrians to enjoy. During the day, when no performances are going on, visitors can peer into the rehearsal halls and wander through the symphony lobby. The new building also offers audience members the opportunity to observe performers from a balcony as they prepare to play. As a structural landscape based on fluid lines, the New World Center gestures toward a more accessible take on classical music in the modern era. It blends the lines between high-art aficionados and invigorates and those who see classical music as an antiquated genre. The brilliant, sweeping curves of the New World Symphony define classical music’s new home as a place where edge and elegance meet. With dynamic spaces that dive, loop and dance, Gehry’s curved masterpiece takes a bow before some of the loveliest sounds on earth. W&C Chuck Mears is founder of Minneapolisbased Radius Track. Through his expertise, architects such as Frank Gehry, Moshe Safdie and Douglas Cardinal have been able to push through the design barriers of creating curved surfaces. Mears’ work in BIM technology and fabrication allows his team to create steel structural systems to support any architectural form imaginable. If you read this article, please circle number 205.

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nergy codes and d standards stt an and d ard rds play a significant role in the United States construction market by influencing the design of commercial buildings. Once a code or standard is adopted by lawmakers, it becomes a legal requirement that protects our society from substandard building practices and ensures a minimum level of energy efficiency is achieved. Architects frequently turn to the International Energy Conservation Code and the American Society of Heating, Refrigerating and Air-Conditioning Engineers 90.1 standard to assist in creating project specifications. Complying with these codes and standards is a requirement to obtain building permits. However, many times the performance that results from these baseline codes is

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New N ew thinking thinking on n fenestration fe fenestrati tion prod products ductts means a wi window indow d doesn’t have to represent a gaping hole in the thermal envelope. By Michael Turner

not enough to meet the needs of the building’s owners. Current baseline codes do not meet the needs of green building practices. A recent trend has been to design buildings that achieve levels of energy efficiency above standard code. The trend has spawned the creation of alternative “green” codes and standards such as the ASHRAE 189.1 and the International Green Conservation Code (IgCC), which are more stringent and require higher levels of thermal performance. While these alternative standards are available to be specified on green

building projects, the baseline codes still influence the majority of commercial construction projects. Therefore, an effort to make baseline codes more stringent has recently gained momentum in order to reduce the energy demands of commercial buildings in the United States. To support increased energy efficiency in America’s built environment and help advance energy codes, the U. S. Department of Energy established a Building Energy Codes Program. This effort has influenced and driven recent changes in energy codes. For example, in 2004, the

 Advanced framing design incorporating a double polyurethane thermal barrier to significantly reduce heat transfer.

IECC code was modified to require all operable windows to have a minimum U factor of 0.35. This was beyond the ability of readily available commercial products to satisfy and this version of the code was not widely adopted by jurisdictions. While later baseline codes relaxed the requirements for commercial products, the industry faced a call to action to design new products for future code cycles. Recent trends in baseline codes and standards have continued to require higher performance from fenestration products. The most recent version of the IECC took a big step in raising the minimum level of energy efficiency, as it mandates prescriptive performance requirements that are close to current green codes and standards (see Image 1). With DOE’s long-term vision of achieving net-zero commercial construction by 2025, it is very clear to the commercial fenestration industry that new designs are required to meet the market’s future thermal performance needs.

FENESTRATION: A KEY COMPONENT OF THE BUILDING AND THERMAL ENVELOPE A key component of the building envelope, fenestration provides natural light into the occupied space and allows occupants to connect with nature. Studies prove that increased natural light and increased vision area have a positive impact on mental health and productivity. So, maximizing the amount of fenestration on the building envelope is a key strategy. The concern is that fenestration has typically been a weak point in the thermal envelope. Many may recall when monolithic glazing and non-thermally-broken aluminum framing systems were widely used in commercial construction. The thermal attribute of these products was nearly equivalent to leaving gaping holes in the sides of buildings. Energy could easily pass through these products, placing a significant demand on HVAC equipment keeping the occupied space conditioned. Even if the equipment

Image 1: Advanced fenestration products establish a new baseline of performance for greater energy efficiency.

was robust enough to maintain a desired temperature, the areas adjacent to the windows remained undesirable because of the product’s interior surface temperatures, inability to control condensation and sensation of drafts. Due to its versatility and durability, aluminum is the preferred material for fenestration products used in commercial construction today. Aluminum systems can be easily manufactured to meet the architect’s aesthetic designs with affordable custom extrusions. In addition to delivering a high level of structural integrity at a low weight ratio, aluminum can be produced with superior finishes for durable, long lasting performance. It is also a good conductor of energy—an undesirable characteristic in framing materials. For this reason, thermal barrier technologies have been used for decades to minimize heat loss by interrupting energy flow. The primary products used today across America incorporate thermal barriers and accept standard oneinch insulating glass. Polyamide strips and polyurethane cavities are

commonly found in standard aluminum framing materials to help resist energy flow. These products have the ability to meet current codes with standard glazing. They also allow for more efficiency by incorporating high performance glazing to meet today’s green codes. However, they are not robust enough to meet upcoming baseline codes and future green building requirements.

ESTABLISHING A NEW BASELINE FOR FENESTRATION PRODUCTS Recently-introduced fenestration products significantly improve the thermal performance of the whole product and establish a new baseline of performance (see Image 2). Simulation tools such as Therm and Windows 5.0—developed with funding from DOE—allow manufacturers to simulate the thermal performance of various designs prior to production. Designers now have the capability to not only analyze the placement of thermal barriers, but also analyze the extrusion design to minimize heat flow through the profile assemblies. This process helps close the thermal per-

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Image 2: Prescriptive requirements of commercial fenestration products.

formance gap between the framing system and the glazing system and yields an overall product with sup er ior t her m a l p er for m a nc e. The result is a new generation of framing systems that have greatly improved thermal performance attributes and provide a more comfortable interior environment. Surface temperatures of the frame are raised and improve human comfort when in close proximity to the fenestration systems. This higher surface temperature also improves condensation resistance, which is an equally important performance metric in commercial construction. These advanced products incorporate multiple thermal barriers (see opening image). What’s more, they are capable of achieving current green building requirements and future baseline codes with readily available glazing infills. This concept is important because it lowers the overall price point in achieving this level of performance. Also, one can assume future green codes will also specify performance more stringent than the current code. By integrating high performance glazing with the advanced framing— and ultimately achieving the new baseline codes with standard glazing—architects can maintain their ability to achieve performance more stringent than code. So, how can architects ensure the correct product combination is specified to meet their requirements?

MAKE SURE PRODUCTS MEET CODE Along with the advancement of framing systems, the fenestration industry has developed tools to communicate the energy performance of whole products. The American Architectural Manufacturer’s Association released AAMA 507, a standard practice for determining the thermal performance of fenestration systems. By utilizing the same simulation standards defined by the National Fenestration Rating Council, AAMA 507 allows architects to quickly understand the whole product’s performance. It provides a fast and accurate analysis of how different insulating glass systems will perform within the framing system. AAMA 507 thermal certificates are

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Please Circle #104 On Reader Action Card | Walls & Ceilings | October 2011

readily available from fenestration manufacturers to demonstrate compliance to specifications and codes. NFRC , which is known for its residential window certification program, recently released a program to independently certify the thermal performance of commercial fenestration products, the Component Modeling Approach program. Similar to the concepts deployed in the AAMA 507 standard, the CMA program allows whole product energy performance ratings for commercial projects. The concept behind component modeling is performance data from the three primary components—frame, glass and spacer assemblies. These three systems are combined on a project-by-project basis to generate the overall product performance rating.

devices. By continuing to invest in research and new products, the commercial fenestration industry is in a strong position to meet future challenges and help reduce the energy demands of U.S. commercial buildings—ultimately creating healthier, more comfortable and energy-efficient buildings. W&C Michael Turner is vice president of marketing for YKK AP America Inc. If you read this article, please circle number 206.

CREATE HEALTHIER, MORE COMFORTABLE AND ENERGYEFFICIENT BUILDINGS Fenestration manufact u rers are answering the market’s call for i ncreased energ y ef f icienc y by launching advanced framing systems as standard products that meet and exceed future energy codes. Architects now have the ability to select advanced designs throughout all categories incorporated into the building envelope—entrance doors, storefronts, curtain walls, balcony doors, operable windows and sun control

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uilding ildi codes d are iincreasingly i l emphasizing requirements for fire protection and compartmentation within new structures as well as in renovation construction. Stopping the spread of smoke and fire is a critical element of today’s architectural and structural design. Wall and floor assemblies that were traditionally engineered to maintain thermal conditions, suppress the transmission of sound and seal out the intrusion of water and wind are now required to be fire-rated to contain the spread of fire. Expansion joint openings present a design challenge because they are literally a gap in the fire-rated wall or floor. The goal of compartmentation is to contain a fire in the area of its source on a particular story or even within a room. Compartmentation cannot be achieved when a fire is able to escape and spread through any gap—the expansion joint opening being the most prominent. However, when this gap is filled with a proper fire barrier, the fire-rated properties of the adjacent walls or floor assemblies can be restored.

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E Expansion i joints j i t can close l the th spaces b between t surfaces f without compromising fire safety. By Dennis Callahan

The challenge construction crews face is how to achieve a lasting, continuous fire barrier and still handle thermal, structural, sway and potential seismic movements expected at the expansion joint while also ensuring the expansion joint is not a gap in the acoustic, aesthetic, thermal or moisture protection performance of its adjacent wall and floor assemblies.

SINGLE UNIT FIRE-RATED EXPANSION JOINTS Traditional methods of joint treatment include the attachment of fire blankets (or mineral wool and sealant) into the joint gap in addition to separate expansion joint covers on one or both wall faces and a cover and moisture barrier in floor joints. T his multiple-product approach entails the combined costs of as many as four components in addition to the significant expense of money and time needed to install these separate products.

This outdated paradigm has been broken with the introduction of single-product expansion joint sealants with built-in fire ratings. In a single installation of a product, the fire protection is achieved while simultaneously handling movement, sound suppression, exposure to elements and thermal insulation. This singleunit fire-rated product approach simplifies design and trade coordination while providing easier and more cost-effective installation. Preformed, pre-compressed, ULcertified fire-rated expansion joints li ke t he E M SH I E L D fa m ily of products from EMSEAL meet these demands. The key to their ability as fire barriers is the base assembly of a fire-retardant-impregnated foam and intumescent coating. Designed for installation in gypsum or concrete walls, concrete f loors and decks (both solid and split-slab), these single-unit systems specifically address the need to maintain the life-

safety integrity of fire-rated walls and floors. They are manufactured to maintain the normal expectations of expansion joint assemblies while also acting as a fire barrier to contain the spread of smoke and fire travelling between compartments (rooms or stories) or through exterior walls where fire can wrap back into a building at the floor above or spread to higher-elevation adjacent additions or structures.

THE IMPORTANCE OF UL AND ULC CERTIFICATION It is in the owner’s, designer’s and installer’s interest for life and safety—not to mention liability—to demand, specify and install fire rated expansion joint assemblies that not only meet UL standards but are also tested by UL (U.S.) and/or ULC (Canada) and certified by UL to have passed these standards. Why demand materials tested at UL and not just a lab capable of testing to the UL standards? When a manufacturer commits to having their products tested in a UL lab and then certified under UL’s Follow-Up service, the manufacturer opens its doors to UL before, during and after manufacture of the specific material submitted for testing. This means that at any time in the future, UL can make unannounced visits to the manufacturer to inspect production of UL listed products. Other labs can run tests to UL standards, but there is no inspection of the build of the sample submitted for testing nor is there any follow up inspection to ensure that what is being shipped to your project meets the same build requirement as the part that was tested. Manufacturers can substitute components or build off-shore production and reduce the bulk of the build to lower costs and the owner, designer and installer would have no way to know How do you know a product is U L listed and m anufactured under the UL Follow-Up Service? Only products that are tested in a UL lab can carry the UL and/or ULC symbol. Only products that carry the symbol(s) and are listed in UL’s online certification directory can be trusted to be manufactured under the UL Follow-Up service.

How does UL verify that a manufacturer is still producing a product in accordance with the requirements after UL Listing is obtained? UL has a Follow-Up Service program designed to check and verify that the manufacturer continues to produce products in compliance with the requirements of UL. UL’s field representatives make periodic tests and/ or examinations at the factory and may, from time to time, select samples from the factory, the open market or elsewhere for further determination of compliance. In addition, if a problem with a UL listed or classified product is reported to UL, UL typically opens up a field investigation. It is of utmost importance that any expansion joint product used in a fire and life-safety situation be certified by UL/ULC specifically to the UL 2079 standard. UL/ULC certification is especially important for expansion joints because of their susceptibility to the stresses of structural movement and the demand that they be able to maintain their ability to be a fire barrier while handling cycling and other expansion joint requirements. U L 2079 incorporates a rigorous process which tests the product to the demands of joint cycling and fire-resistance and (in the case of wall expansion joints) a high pressure hose-stream. If ASTM standards are your criteria for performance, it is worth noting that UL 2079 testing encompasses the burn requirements of ASTM E119 and the joint cycling requirements of ASTM E1399 in the same way that ASTM E1966 does. Additionally it tests the same specific expansion joint for both tests in the same compact test period which better replicates real world conditions. Products tested to UL 2079 therefore meet or exceed all of these ASTM requirements. T he U L 2079 testing process begins with a two-part cycling test. 400 cycles at 10 cycles per minute simulates thermal and wind-sway cycling. This is followed with an additional rapid 100 cycles at 30 cycles per minute to simulate seismic movement. Any failure of these tests will expose the inability to maintain an adequate build necessary to keep an expansion gap closed and therefore work effectively in stopping fire.

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Within 96 hours of the cycling test, the product then undergoes a rigorous fire test. A two-hour fire rating involves subjecting the same installed and cycled product to temperatures approaching 1,650 degrees Fahrenheit (899 degrees Celsius) in about 30 minutes. The internal temperature of the test oven gradually reaches its maximum of 1,850 degrees Fahrenheit (1,010 degrees Celsius). To pass this test, no thermocouple attached to the surface of the non-fire side can reach 248 degrees Fahrenheit (120 degrees Celsius). Final UL/ULC 2079 certification for fire-rated expansion joints, with its rigid test and ongoing monitoring of product manufacturing and standards, is the absolute gold standard for fire safety. Any fire-rated expansion joint considered for specification should be UL 2079 tested and certified before it is accepted for use in life safety situations.

NON-INVASIVE INSTALLATION The way a fire-rated expansion joint system is installed has everything to do with the system’s ability to block the spread of fire. Traditionally, separate fire barrier materials or fire blankets have been installed from below or behind the expansion joint. This method often hinders successful placement of the fire barrier due to limited access and structural obstructions. By incorporating the fire barrier into the construction of the single-unit expansion joint, the seamless fire barrier is in place when the expansion joint is installed and no secondary installation is required. Because it is installed from above, the installation avoids many of the obstructions typically found

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beneath a floor or wall. Installation and continuity of the fire barrier is therefore not compromised by restraints created by HVAC, electrical, plumbing or mechanical equipment. Additionally, the installation in floor joints is accomplished entirely from above the deck or floor, eliminating any need for utility lifts. Previous methods of installing or anchoring can cause the substrate to be marred or damaged and therefore the integrity of the seal and the ability to properly block flames can be compromised. Traditional expansion joints, whether mechanical or plated systems, are usually anchored in place through intrusion into the substrate by screws or drilling— both of which damage the surfaces and can damage the overall seal. pre-compressed impregnated expansion joints offer a simpler solution— they are held in place by the stored strain energy of compression (back pressure) of the foam and an epoxy adhesive applied to the substrates. In addition to easier installation, this non-invasive anchoring eliminates damage to the joint surfaces or the adjacent wall or floor while also eliminating any thermal breaks in the form of metal screws, anchors or other fasteners. It also allows the expansion joint to form and shape itself around minor substrate irregularities. This method further permits the joints to be installed in inside corners and at changes in plane and direction that are impossible to access with screws.

CONTINUITY OF SEAL AND FIRE PROTECTION In any fire-rated system, the joining of the vertical and horizontal joints

and fire-barriers presents a potential break in the system. Such a break can allow flame to spread at that junction. Preformed, pre-compressed impregnated foam fire-rated expansion joints can eliminate this break because they are designed to operate as a single system continuing through any change in the horizontal to vertical plane. This continuity of seal is what makes it different from other fire barriers which typically terminate at the end of a run. There are two methods that allow fire-rated preformed sealants to maintain their seal. One is the availability from one manufacturer of factory-fabricated single unit 90-degree turns which are a single undivided piece with the upward/downward turn. These are manufactured without a break in the turn of the expansion joint. The other option is to join the horizontal and vertical sticks in the field with a fire-retardant intumescent caulk which seals the join from any gaps or openings. Both the watertight seal and the established fire barrier are maintained using either of these innovative methods.

EXPANSION JOINT PERFORMANCE AND FEATURES T here a re many advantages to choosing a fi re-rated pre- compressed, impregnated expansion joint over multi-product alternatives. Expansion joints are structurally necessary because they are designed to handle the movement of walls or floors. A proper fire-rated expansion joint will also be waterproof thereby sealing out water and weather. When the product includes published independent laboratory certification for ASTM E-330, E-331

and E-283, they can be expected to exhibit no water leakage at pressures equal to winds above hurricane force as well as no deflection at positive or negative pressures of up to 4,950 Pascals (equal to 200 miles-per-hour wind loads). The expansion joint will also contribute significantly to a wall’s sound attenuation as displayed in published STC and OITC ratings.

FLOORS AND CEILINGS Horizontal expansion joints often have additional performance requirements due to the increased joint gap size needed to accommodate larger structural design or seismic movement, split slab construction requiring the incorporation of waterproofing membranes and/or the ability to handle heavy pedestrian and vehicular traffic. In all of these applications, single-system fire-rated expansion joints are available that combine pre-compressed, fire-rated watertight expansion joints with the additional factory-assembled components necessary to meet the requirements

of floors and decks. These expansion joints can be manufactured in greater widths (up to 10-inches in seismic applications), assembled as necessary with integrated sidesheets to tie into waterproofing membrane systems of split-slab deck design and/or available with trafficable cover plates.

SEALANT FINISHES T here a re ma ny sea la nt f i n ish options of fire-rated pre-compressed, impregnated expansion joints. Many products are available to accommodate applicable environmental needs. There is often a wide range of colors available to blend the expansion joint to the surrounding environment. There are also sealant finishes which are pick-resistant, making them an ideal choice for prisons, hospitals, detention centers, schools or anywhere where vandalism or tampering are a concern. For floor and deck applications, certain trafficable finishes which are resistant to vehicular chemicals such as oils and gasoline are also available.

SUMMARY A fire barrier installed in an expansion gap should have the ability to be that gap’s expansion joint filler in all other respects. In creating this multipurpose system, there is no longer a need to build a system composed of numerous separate products with each performing a single purpose. Singleunit, fire-rated expansion joints for interior and exterior walls are now the best option for a fire-rated expansion joint product. Strong, certified performance as a fire barrier as well as other performance features, make the modern, fire-rated, pre-compressed, impregnated expansion joints the best choice in life safety applications. W&C Dennis Callahan is the director of business development at EMSEAL Joint Systems Ltd. The company has been manufacturing and supplying innovative and high-quality expansion joint systems to the architectural and construction industries since 1979. If you read this article, please circle number 207.

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Knock on Wo F

or the most part, houses are largely made of wood and have been since life in caves fell out of style. It’s a versatile, reliable and plentiful construction material. But even though it’s been a very long time since Americans felled their ow n timbers to construct their homes, we still like the look of wood beams. They give a room a warm and natural ambiance that harkens back to a dimly-remembered , even my t holog i z ed past reflected in countless frontier stories. Somewhere between “Bonanza” and Paul Bunyan, exposed wood timbers stir memories of a rugged and pioneering history.

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Superior Building Products offers a line of faux wood beams that offer the look of rustic timbers without the weight and worry that comes with real wood. By Alex Lundberg

Like all mythologies, big exposed beams have quite a few less-than-ideal characteristics when viewed in the stark light of reality. They’re clunky, vulnerable to infestation by any number of insects and are even heavier than they look. What people often find out is that the idea of those rough timbers is much more attractive than the timbers themselves.

What about having the look of wood without all of the inconvenient realities that come with them? Superior Building Supplies of Ft. Lauderdale, Fla., is a producer and distributor of decorative polyurethane building accents. They make faux beams, architectural accents and other items out of rubber and polystyrene as well. General Manager Jeff Bloom said the company is

ood? making a name for itself providing a product almost no one else does. “There aren’t many people producing this kind of product,” he says. “We’re the largest or secondlargest producer of this kind of product in North America.”

BENEFITS OF THE PRODUCTS There are a few benefits to using the faux beams and other accents available. The big selling point for contractors and homeowners is that the beams aren’t hard to work with. Because they’re virtually weightless—roughly a pound of weight per linear foot—the Superior faux wood beam installs for a fraction of the

cost of real wood of the same dimensions. The light weight of the product is a huge selling point. “General contractors to do-ityourselfers can install these fairly easily,” Bloom says. “The beams give you the chance to get the look without the headaches that go with it. A guy and a friend can install them by themselves. You need two decent ladders, a screw or nail gun and you’re in good shape.” The beams are also designerfriendly. Unlike a real wood crossbeam, the faux beams can be added as an absolute afterthought like drapes and furniture. They look like real wood (they also come in a variety of colors and grains) but the fact that they don’t have any structural “responsibilities” allow them to be added to a room without any architectural considerations. It’s probably important to mention that the beams aren’t woodbeam sturdy. Just as they don’t have to be part of an architect’s pla ns i n ter ms of load-bea ri ng

structures and the like, they cannot be used to support anything of any real hef t. Being made of polyurethane and light enough for a single person to carry unaided, they won’t support any real weight. T hat’s not to say, thoug h, that they’re entirely ornamental. “They’re main purpose is aesthetic, they’re not for anything heavy,” Bloom says. “But you can run lighting along them; you can hide wiring or ducts within them. “The rustic design looks like it’s been out in the barn for years and years,” he continues. “Jay Leno has them in his classic car garage, which was featured in the DIY Network show ‘Garage Mahal.’”

RUSTIC BEAUTY The product the talk show host bought, the rustic, weathered-looking design, is the company’s most popular seller. For those who aren’t looking for a log cabin effect, the company also makes a contemporary design with none of the dents and other “beauty

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marks” in the rustic. There are a number of textures, from the barn boards of the T-Series to the STB-Series, which has sharp edges and a grain that rises slightly from the beam. The latter comes in dark walnut, finished or completely unfinished hues. The unfinished, raw beams are yellow. Bloom’s people put a gel stain on the raw beams to create a grain which brings out “natural” color differences from low and high points. After that, the sky—or Glidden—is the limit. “If you want to you can cover them in an off-the-shelf primer and then paint them whatever color you want,” Bloom says. The company also makes halfround logs for the log cabin effect. The accents the company offers, the Superior Architectural line, come in moldings, medallions, corbels and rosettes. The medallions can be ordered either unfinished, painted or in gold paint or foil finish. W&C If you read this article, please circle number 208.

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SAFE SIDE BY MICHAEL RICH

Drill Down

Safely Portable power drills are some of the most useful tools in the construction industry, but without taking the proper safety precautions they can quickly become some of the most dangerous. According to a study released by the U.S. Consumer Product Safety Commission, more than 2,500 people receive hospital treatment a year due to power drill injuries. Causes of these injuries include b ei ng st r uck by f ly i ng d ri l l i ng material, bit punctures, trips and electric shock. While most of these injuries are minor, requiring only a few days away from work, the potential for a much greater tragedy is always present. To prevent injuries associated with power drills, OSHA makes employers responsible for the safe condition of tools and equipment used by employees, including tools and equipment which may be furnished by employees.

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| Walls & Ceilings | October 2011

I n addition to meeting these requirements, it is important to train employees on proper maintenance and safe handling of power drills. Here is a quick look at steps employees can take to prevent some of the most common power drill injuries.

PREVENTING ELECTRIC SHOCK The energy source for portable power drills either comes from a wall socket or a battery. When a drill is treated roughly, dropped or hit against things, or comes into contact with moisture, the insulation can weaken. This weakened insulation can cause a drill to become “live.” A live drill, if exposed to moisture, can cause an electrical shock. To prevent electric shock employees need to:

• Look for breaks, exposed wires or looseness at the plug or housing connections. Unless the drill is double insulated, be sure there is a ground wire and the third prong has not been cut off. • Only use extension cords that are free of splices, taps, bare wires or frayed and deteriorated insulation. Use three-prong adaptors. • Check that the electrical circuit to be used is of the proper rating and that cords, plugs, and fittings are intact and secure. • Never carry a tool by the cord. • Never yank the cord to disconnect it from an outlet. • Keep cords away from heat, oil and sharp edges (including the cutting surface of a power saw or drill). • Do not use electric tools in damp or wet locations unless they are approved for that purpose. • Use double-insulated tools.

PREVENTING FACE AND HAND INJURIES The most common types of injuries involving drills are to the hands, fingers, eyes and face. These injuries on average involve four to seven days away from work. To prevent these type of injuries follow these simple tips: • Examine your drill to make sure that it is clean. If the drill is dirty or rusty, tag it and return it to supply for maintenance. • Make sure the drill speed is proper for the job. Pull the trigger to be sure it doesn’t work too easily, too hard and to make sure that power cuts off when the trigger is released. • Be sure drill bits are set straight in the jaws. Hold up the drill and turn it on for a moment. The bit should spin without any wobble. If it wobbles, either the bit isn’t straight or it’s set in the jaws crookedly. A sharp bit will take hold without much pressure. • To start the drilling at the right angle and keep it straight takes steadiness and care. If a drill isn’t held just right, the bit may bend or break, sending metal flying. Use a pointed metal punch to start your drill right.

on the

SAFE SIDE • W hen drilling into metal, be aware of the material’s hardness. Soft metals like copper or aluminum cut with little pressure. Hard steel needs a different bit. More pressure must be applied, but care is necessary because too much will make the drill overheat and bind. • Do not allow anyone to use an electric drill that has not been properly trained in the processes of safe portable drilling operations.

• Be familiar with the power drill being used. When using a new or unfamiliar tool, take time to “test-run” it and get a feel for its performance. • Eye protection is extremely important and must always be worn when doing overhead operations. When operations present potential eye injuries, appropriate protection must be used. Depending on the task, use a face shield, protective goggles or approved safety glasses.

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• Wear clothing appropriate for drilling or boring; avoid long, loose shirtsleeves, neckwear, or untied long hair. These types of hazards can be caught in the drill. • When possible, always secure your work on a stable platform using clamps or vices. A secured work piece will help ensure straight drilling. • Prior to beginning drilling operations, inspect each work piece for nails, knots or flaws that could cause the tool to buck or jump. • Use gloves and appropriate safety footwear when using electric tools. • If any operational problems are noted, remove the drill from service and get it repaired immediately.

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When employees finish drilling, they need to have a safe place to put the drill. If tools are kept in the workplace it is good practice to have designated places for your tools. A great way to do this is by installing hangers in the workplace that allow the drills to remain out of the way but still within easy reach. In addition to properly storing tools employees should never leave a drill plugged in while not in active use. When returning the drill to the tool room or carrying it to a jobsite, it is vital to remove the bit. This eliminates the chance of your stabbing yourself or a co-worker. Even a dull bit can dig into flesh quickly. To su m up, u nsafe prac tices and inadequate housekeeping create potentially dangerous workzones; keep the work area free of trip hazards such as tangled power cords, cluttered material, scraps, stones, bricks or other obstacles and obstructions. Also when repairing ensure tools are tagged and the source of power is removed. If you are interested in receiving free guidelines on tool safety, e-mail [email protected] W&C Michael Rich is a writer researcher at Safety Services Company, a supplier of safety training and compliance products in North America. For more information on the products they offer visit www.safetyservicescompany.com If you read this article, please circle number 209.

BEFORE OUR STEEL EVEN

R E A C H E S T H E J O B S I T E, IT ALREADY STANDS FOR SOMETHING

S T R O N G E R. STRONGER T H A N S T E E L.

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FINISH LINE BY ROBERT THOMAS

Building Walls in the

Land Down Under Every American I know wants to visit Australia. It’s sometimes called “The Land of Milk and Honey” and it is. Next to Canada, Australia is more like the U.S. than any other country I can think of. From an EIFS construction standpoint, there are some big similarities and some important differences. Although they drive on the wrong side of the road, doing business there is easy and fun and they speak English, mate.

AUSTRALIA, COMPARED TO THE U.S. Australia is a big place. The flight from the country’s largest city, Sydney, to Perth (the only major city on the west coast) is only one hour shorter than the flight from Perth to Singapore which is on the Equator, near Borneo and Indonesia (see map). To put things into perspective, the land area of Australia is approximately 3 million square miles and the population is about 23 million. The land area of the U.S. is about 3.8 million square miles (including Alaska) with a population of about 309 million. By comparison, California’s population is about 37 million. Almost everyone in Australia lives on the East Coast. The center of the country is dry, flat and uninhabited. Most construction is on the East Coast with some on the West Coast (Perth).

CONSTRUCTION IN AUSTRALIA From a global perspective, both Australia and the U.S. are young countries. Australia and the U.S. also share a common heritage in their English roots, thus construction techniques are similar in both countries. Australia’s construction practices, like those in England, are more conservative than they are in the U.S. Parts of Australia, especially the sprawling Sydney metro area, will remind you of California, especially the San Francisco Bay Area.

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There’s another similarity to the U.S.—the country has the dry climate that California does. This creates fire risks which affect the building codes and the way buildings are constructed. More on materials later. Unlike California, yet near the western edge of the Pacific tectonic plate, serious earthquakes are rare. Australia, like the U.S., has a “melting pot” culture of people from many countries around the world. This cultural mix has its influence on Australia’s construction labor force. Both countries are progressive, modern, Anglo-oriented nations and have similar lifestyles. This is why Yanks feel right at home when visiting.

Italy, Greece and all over Asia. This diversity brings new skills to the construction market. T hese skills include those used to working with plaster, stucco and EIFS. Unions can be strong in the Australian construction industry, including the plastering trades. Getting an EIFS project done often involves some specialized training, including working with the unions.

MATERIALS Australia has vast mineral deposits, but few forests. This affects construction techniques. Because of the danger of fire, Australian buildings tend to use fewer combustible materials like wood. The popular James Hardie product line of HardiBoard (Hardi is an Australia-based multinational company) was developed partly in response to the need for fire resistive walls, especially in homes. There is also an extensive use of ceramic tile for roofing. As a result, many homes look like those in southern California where there is often the risk of fast-moving brush fires during the windy, dry time of the year. Because the building codes in Australia are very much like those in England, the use of EIFS is not common.

CLIMATE There’s no such thing as a brutal cold season in Australia. Although there are a few areas that have mountains, even the coolest part of the country (in the south near Victoria) is hardly cold. The northern end is close to the equator and is hot (like in the film “Crocodile Dundee”) and sparsely inhabited. The point is that for most of the country there isn’t a need for insulation. Thus, highly insulated wall systems— like EIFS—are not in huge demand. The good news is that the stucco look is popular there, so EIFS fits into the market aesthetically.

LABOR Australia was founded as a penal colony where criminals could be housed as far away from England as possible. Many Aussies are still of English descent. This has changed quite a bit since World War II. Now there are lots of people who hail from Scotland, Ireland, Germany,

NEW ZEALAND It’s hard to talk about Australia without talking about its neighbor, New Zealand. It is arguably the most beautiful small country in the world with a wide-ranging climate and fabulous scenery. It’s modern and they use EIFS in construction. New Zealand’s culture is much more like England’s than is Australia’s. Kiwis (the term New Zealanders call themselves—after the odd flightless bird that lives only there) are more reserved and soft-spoken than Australians. With more than four million people and nine million sheep, lamb is popular and inexpensive. New Zealand is right on the edge of the Ring of Fire—a horseshoeshaped seam between tectonic plates that runs up one side of Asia and down the Americas—and earthquakes are com mon. Most are imperceptible, but once in a while a big one hits as it did last year. Much

of the devastation from the recent major earthquake in the Christchurch area (on the southern island) was to older masonry buildings (see Photo 1). These buildings, although sturdy, did not fare well in the extreme shaking of the recent quake and toppled. New Zealand’s modern and progressive building codes are very specific about dealing with this sort of problem and the chances of such destruction taking place in newer buildings are slim. New Zealand’s construction practices are much like those in the U.S. New Zealand has a major forest industry and the construction industry takes advantage of that fact. Timber construction is widespread, especially in homes and even in mid-rise commercial buildings. In New Zealand, it’s possible to find timber framing studs instead of metal studs in the exterior walls of commercial buildings as is common in the U.S. and Canada.

flexibility of EIFS is desired for its ability to take the bending motion impar ted onto a building by a quake. It doesn’t crack or delaminate as easily as more brittle, traditional materials.

CONCLUSION Last year, disaster hits in Christchurch, New Zealand.

Gypsum is not mined there, so traditional gypsum-based drywall is different than what we know of it here in North America. They mix their gypsum with volcanic dust (there’s no lack of that), creating a gray-colored core. The core is harder than plain gypsum, so it is a bit different to install than the drywall American contractors are used to. The volcanic dust-mix drywall is more brittle, so cutting and fastening it requires different tools and touch. New Zealand uses EIFS. Because of the prevalence of earthquakes, the

The gloves are off.

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 210.

by

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all things

GYPSUM BY MICHAEL GARDNER

between the edge of the stud and the edge of the wallboard, thus preventing the board edges from being crushed. Their use also permits placement of the shank of the nail or screw in the meat of the stud. A less obvious reason for the prescriptive dimension for wood framing members relates to the shrinkage characteristic of lumber. Lumber is sized by two different methods. Nominal lumber dimensions apply to “wet” or “green” lumber; material that has not been dried or finish cut. Actual lumber dimensions are used to define the size of a dried and cut member. Because lumber shrinks, a stick of actual-sized lumber is narrower in each dimension than a stick of nominal lumber. A nominal 2x4, for example, is 1½ by 3½ inches in actual dimension.

How Big is a

2x4? For many decades, consensus wallboard application standards have mandated that the surface for the attachment of wallboard be at least “1½ inches wide for wood members.” A similar but slightly

narrower dimension has historically been specified for the attachment surface for metal studs. The primary reasons for establishing minimum framing member attachment surface dimensions are reasonably obvious. Using studs that are too narrow tends to create situations where the fasteners used to install the wallboard are not properly seated in the framing member. In addition, narrow studs create the potential for

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| Walls & Ceilings | October 2011

board edge damage when an applicator tries to compensate for a slender stud by installing a fastener immediately on the edge of the board. Application standards, such as GA-216, Application and Finishing of Gypsum Panel Products, mandate that fasteners must be installed at least 3/8ths of an inch from the edge or end of a board. When wood studs with the proper dimension are used, the fasteners can be centered

PROBLEMS WITH GREEN LUMBER Prior to 1961, some consensus standards permitted producers to sell lumber that was sized and graded wet and sold dry. In such an environment, a lumber producer could cut green lumber to a nominal size, grade it and sell it based on its wet dimensions. Because varieties of wood shrink at different rates, this created all types of problems for consumers and builders. Frustrated by such activities, the gypsum industry established minimum attachment surface requirements. In their eyes, it didn’t matter what the dimensions of the wet stud were, what mattered were the dimensions of the dry stud. The stud had to be correctly dimensioned to support the attachment of the wallboard. In 1961, according to the “History of Yard Lumber Size Standards” (1964, U.S. Forest Products Laboratory), a lumber industry Committee on Grade Simplification and Standardization decreed that the standard dry thickness of 2-inch dimensional lumber “be reduced from 1⅝- to 1½-inches.” After that date, all lumber was to be sized and graded based on its standard dry (actual) dimensions. I can attest to this size difference. About 12 years ago, I demol-

ished a portion of a bearing wall in my home. The studs I removed from the wall were beautiful. They were straight like arrows with perfect, knife-like edges. I could have used one to filet a trout. What really caught me, however, were the finished dimensions of the studs. They were at least an eighth of an inch wider and deeper than anything I could obtain from a local retailer. When I investigated the issue I discovered the 1961 industry agreement. On the basis of that agreement and because my house was built in 1960, it made sense that the studs used in its construction were wider than those sold today. What I couldn’t figure out, however, was why they were more than 3½ inches deep. I originally thought it was because they were specifically hand-cut for use in a bearing wall. However, after closer examination, I found production grading stamps on some of the studs and some subsequent planned demolition in a different part of the house exposed identical studs in non-structural walls. In addition, I’ve never been able to find any reference to a 1950s-era discussion about a change in the greater dimension of studs. My ultimate conclusion? The deeper dimension related to the kind of wood used to make the studs and their primary use in bearing walls. For structural reasons the studs needed to be a bit deeper than

they are now and the builder wisely bought only one size of stud for the entire project to avoid putting the wrong stud in the wrong wall. Wallboard application standards, as noted above, also incorporate minimum dimensions for the application surface of metal and gypsum framing members. Interestingly, skinny metal studs must have been in vogue in the 1960s because the 1965 edition of a predecessor document to GA-216 mandated only a 3/4-inch attachment surface for wallboard applied to metal framing members. That dimension has increased to 1¼ inch, which is identical to the minimum flange width prescribed in the manufacturing standard for nonstructural metal studs, ASTM C 645. Structural studs manufactured to ASTM C 955 are subject to the same requirement.

GYPSUM STUDS Gypsum studs, rare as they might be, require a 6-inch-wide attachment surface. Gypsum studs are generally field fabricated using cut pieces of wallboard that are laminated together with adhesive or joint compound. The wider dimension provides an adequate surface for adhesive bonding. The 6 inch minimum also helps compensate for potential irregularities in the dimensions of a field-fabricated item. Even rarer than gypsum studs are plastic or fiberglass studs. Used

primarily in institutional construction, they seem to attempt a comeback every decade or so. Because of their limited use to date, wallboard application standards don’t contain minimum application surface dimensional requirements. The requirements contained in wallboard application standards help prevent substandard installations through the establishment of common minimum thresholds. In the instance of bearing surface requirements, the minimum language helps assure that an applicator will have an adequate surface for the installation of the fasteners or adhesive used in the application process. Because the drywall application requirements dovetail with the manufacturing and production requirements for steel and wood studs, compliance for an applicator is rarely a problem. However, damaged or poor quality studs do occasionally make their way to a jobsite. Installed framing members that are not of proper quality should be identified, removed and replaced prior to the application of wallboard. W&C Michael Gardner is the executive director of the Gypsum Association, an international trade association representing gypsum board manufacturers in the United States and Canada. If you read this article, please circle number 211.

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41

smart

BUSINESS BY JIM OLSZTYNSKI

16 Tips to Save Time and Money That old “penny saved” saying may be ancient and corny but it’s never outdated. Save enough pennies and they add up to dimes, dimes to dollars, and dollars eventually can add up to enough money to boost your company’s profitability and your personal lifestyle. And, since time equals money in the business world, saving time amounts to saving money. So without further ado, let’s review some ways to save penniesdimes-dollars-time in your business and personal life. Take early lunches. When eating lunch at restaurants, you’ll find service a lot better at 11:00-11:30 than during the rush starting around noon. Servers will take and deliver your order quicker, and you’ll reliably trim 15 minutes or more off the time it takes to eat. Construction people typically start work earlier than the typical 8:30 to 9:00 starts for most businesses, so your stomach ought to be growling well before noon anyway.

1

Shop with promotional cycles. Study the flyers put out by office supply stores, Home Depot/Lowe’s and your supply houses. You’ll start noticing patterns to their product discounting and that’s the time to stock up. Bargains are available on many things after the holidays and January typically offers many clearance sales by retailers. Learn these rhythms and capitalize on them.

2

Buy private labels. Big office and construction supply stores typically carry a slew of private label

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merchandise that functions just as well as the brand names they carry but at a much cheaper price. Does it really matter whose name is on the scotch tape and paper clips or hammers and nails? Buy used tools and equipment. Used tools don’t necessarily mean broken-down tools. Many contractors have gone out of business in recent times and are selling off assets to pay bills and keep a roof over their head. You can find great bargains on eBay and from other secondary markets for tools, equipment and other merchandise still in good condition.

4

Stop buying stuff you don’t need. This is a discipline that needs to be enforced in conjunction with items #2, #3 and #4. By all means shop for bargains, but just because something is on sale doesn’t mean you need to buy it, or buy it in greater quantity than you can use in a reasonable time frame. Paying $90 for 10 widgets gets a better unit price than $10 for a single widget but isn’t worth doing if you only use one widget a year.

5

Get the best banking deals. Most successful businesses have longstanding banking relationships and there’s something to be said for that. At the same time it also makes sense to shop around for the best rates on

6

CDs and savings accounts. Banks frequently come out with new financial offerings and introductory rates that aren’t always publicized to existing clients. Tell your account rep that if s/ he values your business, you wish to be informed of all new offerings and be given the chance to take advantage of them even if they are aimed at new customers. Park as little money as possible in checking accounts, a lot more in accounts that earn more interest but whose funds could be swept into your checking account when needed. More ema il, less telephone. Routine information can be exchanged much more quickly via email than telephone. It’s also more precise and provides ready-made documentation. Where phone contact is important, set up conversations in advance via email, telling what you want to talk about, whatever information is required and decision deadlines, then nail down an appointment time for the call. This will avoid a lot of phone tag.

7

Exert “reply to all” discipline. Encourage everyone on staff to minimize “reply to all” responses. It’s hard to set precise guidelines because this is a judgment call, but so much time gets wasted copying everyone on messages relevant mainly to one or two recipients. Simple “thank you” or “you’re welcome” courtesy replies in particular don’t need to extend across the board.

8

Photograph job mishaps. I used to advise contractors to supply cheap cameras to their work crews to document jobsite damages, accidents or other conditions leading to disputes. Nowadays most people have cell phones with photo capabilities, so you don’t even need to issue cameras in most cases. Simply instruct your crews to use their cell phones to document situations where visual evidence could prove helpful.

9

Eliminate paper wherever possible. Printouts waste time, ink, paper and wear out equipment,

10

so minimize them. Get in the habit of keeping electronic files (with automatic backups—very important) for routine business tasks. Set the fax machine to print out reports only for transmissions that don’t go through. Get the best gas prices. A station near my office almost always sells gas for at least 10 cents a gallon cheaper than anywhere else around, so I do almost all of my fillups there. This seems a no-brainer, but I’m astounded by the number of people who don’t look around for the best gas prices. This is often the case with construction crews driving company vehicles. Warehouse stores like Costco offer member discounts on gas prices and you can often negotiate discounts if you operate a sizable fleet.

11

Organize batch work. Henry Ford revolutionized industry by coming up with the assembly line to boost productivity and the same principle applies to many tasks in both the field and office. Let certain kinds of tasks accumulate until your people can group them into a single kind of work, such as billing, mailings, filing, etc. Shop prefabrication can save a lot of time and material compared to assembling things on a jobsite where weather and other conditions may hamper productivity.

12

13

Strive for productive meetings. Few business activi-

ties waste more time than pointless meetings where everything gets discussed but nothing resolved. Don’t hold a meeting without a preprinted agenda and then stick to it. Establish times for both beginning and end of the meeting and what is to be accomplished. The person in charge of the meeting takes responsibility for moving it along, even if that means curtailing discussion and stopping digressions. Take detailed notes and record who is expected to do what with deadlines. The follow up to make sure everyone performs as expected or can explain why not.

15

Be an energy miser. Even small offices can save thousands of dollars a year in electricity and fuel bills by eliminating bad habits. Turn off all lights, computers and copiers for the night, unplug chargers, replace incandescent lights with fluorescent bulbs or the new LEDs. Consider timers if appropriate. Use programmable t her most at s a nd consider cei ling fans to help reduce a/c costs in summer. Humidifiers in winter can make the surroundings feel warmer and enable you to turn the heat down 2 to 3 degrees with no loss of comfort. Reduce water temperature settings, change furnace filters regularly and wash full loads. Individually all of these things contribute rather trivial savings, but when done together as a matter of habit they add up to big bucks.

16

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Buy bundled telecommunications. Fierce competitive battles are taking place by telecommunications providers and the best buys are for their bundled services— phone, Internet and TV for a single price. Cell phones can be added to the plan in some cases. Just like banks, the telecoms often offer steeply discounted specials to new customers. Existing customers often can get the same deal by simply calling the customer service department and ask for it (I tried this with my cable provider for a getaway home I own and got the newcomer deal without an argument). “Measure twice, cut once.” This old construction adage applies not only to field work but also to drive time. Every time you’re tempted to run out to a jobsite or visit a business contact in person, think of any other stops you might make in the same direction. If the activity can be postponed, wait until you can make several appointments along the way to save time, fuel and vehicle wear and tear. Speaking of which, be sure to have all work vehicles on a maintenance schedule. This does not cost money, it saves a bundle in the long run. W&C

Jim Olsztynski (pronounced Ol-stin-skee) was Editorial Director of Plumbing & Mechanical and Editor of Supply House Times magazines. If you read this article, please circle number 212.

Custom Stud is a light gauge steel framing manufacturer covering the US since 2001. Custom Stud continues a high standard of integrity, value and commitment in product and to our customers. Thank you for 10 years.

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straight

GREEN BY CHRIS DIXON

Drafted LEED 2012 was released for a second round of public comment August 1. The comment period will be open until September 14, which will have come and gone by the time this goes to press. Thousands of comments have been submitted to the USGBC in advance of the fi rst public comment period (which opens in November), resulting in major changes to the draft, especially with regard to Materials and Resources. Thousands more will likely be made during round two, because instead of simply fixing problems in the first draft, the second draft throws out large parts of the first draft and replaces it with brand new content— some of it half-baked. It is encouraging that so many comments are being submitted by people evidently now fully cognizant of the consequences in remaining silent.

WHAT’S DIFFERENT? A su m m a r y of ch a n ge s m ad e between draft version 1 and version 2 can be found on the USGBC Web site for each rating system. I will focus on the Building Design and Construction rating system in this article. A few highlights of some of the most significant changes, outside of Materials and Resources, include: • Integrative Process: This credit has been substantially reworked and renamed. It’s all about discovery now and requires the design team to conduct analyses on energy load reduction, water systems and site assessment. It’s much skimpier and simpler. • Low-Emitting and Fuel-Effi cient Vehicles: This credit has been removed from New Construction, Core and Shell, Data Centers, and Hospitality rating systems. • Fundamental Refrigerant Management (Prerequisite): This pre-

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requisite was removed from draft 1 and has been reintroduced in draft 2. • Enhanced Indoor Air Quality Strategies: This is a new credit created for draft 2 which combines the former Outdoor Air Delivery Monitoring, Increased Ventilation, Indoor Chemical and Pollutant Source Control credits. • Low-Emitting Materials: All former low-emitting materials credits have been combined into a new Low-Emitting Materials credit that requires emission testing for everything in the interior of the building. In the new credit, points are awarded for meeting minimum percentages. • Occupant Experience Sur vey: This credit has been deleted. T he m ajor it y of t he M a t e r i al s and Resources section has been completely rewritten and is unrecognizable when compared to the current rating system and formerly proposed revisions in draft 1. Previous credits Building Reuse, Materials Reuse, Recycled Content, Regional Materials and BioBased Materials have been rolled into a new credit called Environmentally Preferable Products and Materials. Previous credit Certified Wood has been incorporated into a new credit called Extraction of Raw Materials. Additional credits Nonstructural M aterials Transparency and Avoidance of Chemicals of Concern in Building Materials have been introduced in draft 2.

HUH? The USGBC’s Senior Vice President, Scot Horst, explains these radical changes as “a transition from where we think the market needs to get to be upto-date with the rest of the world and where it is right now.” Horst describes the changes made to the Materials and Resources section as “bold” and establishes the USGBC as a leader. Perhaps the best example of what I consider to be half-baked in this draft is the new proposed credit Avoidance of Chemicals of Concern in Building Materials. To get the available point for this credit, 20 percent of all building materials (by cost) must have an available list of ingredients and must not contain any substances listed in the State of California’s Proposition 65—Safe Drinking Water and Toxic Enforcement Act. On the surface, this may seem like a pretty good idea. The drafters of the credit, however, either do not understand the purpose of CA Prop 65 or do not care that it has nothing to do with materials avoidance. Indeed, this credit is in direct opposition to the USGBC’s own conclusion on material avoidance which was succinctly stated in its exhaustive study on PVC called Assessment of the Technical Basis for a PVC-Related Materials Credit for LEED issued February 2007. The report concludes that: “The evidence indicates that a credit that rewards avoidance of PVC could steer decision makers toward using materials that are worse on most environmental impacts …” and that, of the materials included in the study, “No single material shows up as the best across all the human health and environmental impact categories, nor as the worst.”

WHAT IS CALIFORNIA PROPOSITION 65? The purpose of CA Prop 65, enacted in 1986, is to regulate substances officially listed by California as causing cancer or birth defects or other reproductive harm in two ways. First, by prohibiting businesses from knowingly discharging listed substances into drinking water

sources or onto land where the substances can pass into drinking water sources and, second, by prohibiting businesses from knowingly exposing individuals to listed substances without providing a clear and reasonable warning. CA Prop 65 is similar to OSHA’s Material and Safety Data Sheet requirement, something architects and contractors are very familiar with. Neither is meant to be a tool for avoidance, but rather as a means to educate users about the contents of things they may come into contact with. The list of chemicals in CA Prop 65 is long. So long, in fact, that very few businesses in California are exempt from posting the required public warning. Warnings are posted in nearly every business and in every building in the state. For some good reading on the legal debacle that Prop 65 has created, go to this office of the attorney general link: http:// ag.ca.gov/prop65/pdfs/G035101.pdf. The document sums the absurdity of it all with: “Dried paint. Furniture. Parking lots. Wiring.” Really? As the attorney general points out in the document’s opening brief, the global notices present a “laundry list of dozens of chemicals” and “many of the purported exposures are so unlikely as to be virtually imaginary.”

CONCLUSION B ecause there have been such significant changes introduced in the second draft of LEED 2012, I fully expect that the USGBC will be issuing a third draft for public comment. The major revisions to draft 1 were a direct result of the thousands of public comments the USGBC received. The radical, half-baked changes that are being proposed in the current draft add much more complexity and confusion to a rating system that most of us were finally getting comfortable with. I am not sure I can go along with USGBC’s proclamation that the changes signify a bold move toward leadership. If the rating system keeps going in this direction, it will be more difficult to understand and implement and any leadership position envisioned by the USGBC will be over an ever-shrinking pool of supporters and users. 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 213.

SAFE CHEMICALS The proposed credit fails to acknowledge that CA Prop 65 also has a list of chemicals that, below a particular threshold, pose no health risks. Contact with a chemical or chemicals from the list does not automatically mean there is any danger of the development of cancer or a birth defect. In fact, the Office of Environmental Health Hazard Assessment of the California Environmental Protection Agency publishes a “Safe Harbor” list of chemicals that pose no threat to human health based on exposure and are exempt from having to be reported in accordance with Prop 65. OEHHA recognizes that many of the chemicals on this list pose no significant risk levels for carcinogens and provide information on the maximum allowable dose levels for chemicals that cause reproductive toxicity. Some of the “safe harbor” chemicals on the list include: • Benzene • Asbestos • Formaldehyde • Naphthalene • Vinyl chloride Lots of things can cause cancer or birth defects—but not at any dose and every exposure. Remember the saccharine scare that began in the late 70s? In a 2007 article written on the 30-year anniversary of the FDA’s ban on saccharine Dr. Elizabeth Whelan, president of the American Council on Science and Health, wrote, “Irrational bans on chemicals are expensive and unproductive. When the next cancer scare comes our way, remember thirty years ago—when saccharin proved to be the ‘carcinogen’ we loved.”

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industry

VOICES BY PHIL MANCUSO

MIX AND MATCH

Learn

Not to Burn When selecting the appropriate passive sprayed fire protection components, the Underwriters Laboratories Inc. “Fire Resistance Directory, Volume 1” is an essential part of the design process. This directory provides the appropriate fire resistive material thicknesses for specified hourly ratings for ceiling assemblies, beams, columns, and walls and partitions utilizing spray-applied fire resistive materials, gypsum board and intumescent coatings. W hen specifying fire resistive materials, selection of the appropriate UL fire resistance design is of paramount importance. Most UL designs are specific to a manufacturer, construction assembly, hourly rating and material type. In order to narrow down what is needed for your project, you need to have an understanding of the directory. This specific volume within the series of UL Fire Resistance Directories contains fire-rating classifications based upon ANSI/ UL 263 (ASTM E119 and NFPA 251) and ANSI/UL 1709.

SUBDIVIDED FOR YOUR CONVENIENCE Although it may look overwhelming to a first time user, the UL Fire Resistance Directory is well structured and relatively simple to use. It utilizes an alphanumeric system in order to designate the type of assembly being protected and the type of material used to protect the construction assembly. Each letter designates a specific type of assembly. These types are separated into categories along with their corresponding letter designations; floor and ceiling—D and G Series; concrete slab—J Series; floor beams and joists—N Series; roof and ceiling—

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| Walls & Ceilings | October 2011

P Series; roof beams and joists—S Series; columns—X, Y & XR Series; and walls and partitions—U Series. The various types of passive fire protection products are categorized along with their correspondi ng nu mber desig nat ions: rig id board fire resistive materials—300 Series; gypsum board—500 Series; S F R M s —70 0 a n d 8 0 0 S e r i e s ; and intumescent coatings — 60 0 Series. Unprotected assemblies (not requiring fire protection to the underside of decking) which utilize these various types of fire protection products for the structural steel members are classified in the 900 Series designs. It is also important to note that beams and joists are included in two types of test assemblies. One type of assembly contains a full representation of the floor or roof construction. These systems will determine a protection method on both the deck (if necessary) and the supporting beams and joists. These are identified in the D, G, J and P Series letter designations. The other type of assembly is a partial representation of the floor or roof construction. These systems only determ ine thick nesses on the supporting beams and joists and are commonly used for beam substitutions. These allow for thicknesses advantages, hourly ratings or beam types that are not available within the assemblies and are identified in the N and S Series letter designations.

Beam substitutions are permitted in accordance with the introductory portion of the UL Fire Resistance Directory, Volume 1. In order to substitute an N or S Series beam into a D, G, J or P Series assembly, it must contain the same UL classified fire resistive material and must be used within assemblies that have similar or greater heat dissipation if the floor or roof construction specified within the design in which the beam is being transferred. For example, you can substitute an N Series floor beam and joist into a D, G or J Series floor and ceiling assembly. However, you cannot substitute an N Series floor beam into a P Series roof and ceiling assembly. Determining the hourly fire resistance ratings and the construction assemblies requiring the hourly ratings is essential. Hourly ratings are determined based on model building code criteria. Hourly ratings are expressed in both restrained and unrestrained classifications. The restraint classification must be made by the project structural engineer and is one of the most important criteria in selecting the appropriate UL design. It should be understood that the intent of the International Building Code is that the building is considered unrestrained unless otherwise indicated on the drawings by the structural engineer. It is also important to note that the introductory portion of the UL Fire Resistance Directory, Volume 1 has specific criteria that need to be met in order for the construction type to be considered restrained. The required thickness of fire protection material may vary depending upon the construction assembly’s classification. The items needed in order to determine the appropriate UL design for floor and ceiling assemblies, at minimum, are the type(s) of fire protection product to be used, hourly rating requirement, depth of the floor decking, minimum thickness and type of concrete (lightweight or normal weight) and minimum structural steel size.

To select the appropriate U L design for roof and ceiling assemblies, you need to determine, at minimum, the type(s) of fire protection product to be used, hourly rating requirement, depth of the roof decking, type(s) of insulation used and the minimum structural steel size.

MEASURE TWICE, CUT ONCE The UL Fire Resistance Directory, Volume 1 allows for various thickness calculations for both beams and columns. Beam thicknesses are deter-

mined based on the tested member listed in the design for the specified hourly rating and utilizing the beam thickness adjustment formula as listed in the introductory portion of the UL Fire Resistance Directory for alternate beam sizes. Column designs list both tested member minimum types and sizes and typically list alternate formulas to determine thicknesses. Beams and wide flange columns are expressed in terms of W/D ratio. Hollow, shaped tube steel members are expressed in terms of A/P ratio.

Once you have the basic understanding of the UL Fire Resistance Directory, you should be able to determine the appropriate design needed. Most manufacturers of UL classified fire resistive materials provide technical support in assisting you with the design selection process and thickness required. W&C Phil Mancuso is technical services manager for Isolatek International. He can be reached at [email protected]. If you read this article, please circle number 214.

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CONTRACTOR PROFILE

ALL IN THE FAMILY HEGGEM-LUNDQUIST

I

t would probably be an easy argument to suggest Heggem-Lundquist is the busiest wall and ceiling contractor working in Denver. The Mile-High City firm, which has operated for more than 60 years, specializes in metal framing, drywall, acoustical ceilings, EIFS/stucco, paint, wallcoverings and specialty finishes. According to the company’s COO Ruthanne Lundquist-Zueger, the contractor has approximately 80 projects they are currently working on with 200 employees working daily to make this construction happen. The company mission statement reads: “To provide our customers with quality work and a can-do attitude, to promote productive relationships, to provide a safe work place for the employees, and to provide a culture of continual improvement.” The company works throughout the state of Colorado and performs on all levels of construction, from small tenant finish work to large commercial projects.

FAMILIES JOIN The company’s roots began back in 1935 when Uno J. Lundquist was hired as a painter by J. Famer Heggem. The pair worked together until 1949, when Lundquist started his own company, Uno J. Lundquist Fine Painting and Decorating. Throughout the next decade, relocations and name changes reflected the company’s growth and in 1960 saw the opening of its Drywall Division. In 1962, the two parties merged to become Heggem-Lundquist Paint Co. Today, the company can still boast that it is a family-owned business that operates successfully, work-

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| Walls & Ceilings | October 2011

ing on several important projects throughout Denver and the state. Ruthanne, Kirk and Beth Lundquist all began their careers with the company over summers, doing deliveries and working in the warehouse and performing miscellaneous office work. Heggem-Lundquist has worked on many government and high end commercial projects of note. Currently, the company has contracts for the Denver Federal Center, the VA Hospital and many more. The Denver Union Station is another important job worth noting and should be completed by Heggem-Lundquist in 2013.

THINGS WILL CHANGE W hen asked what she has seen change most over the course of her 25-year career with the company, Ruthanne pointed to the way business is done now. “What amazes me is how technology has changed what we do,” she says. “We had one computer when I started and used the big ledger paper, no fax machines, no cell phones and no e-mail—things were simple. Bids were done by a scale and green sheets were hand delivered to the general contractor’s office. To me that transformation has changed and made information much easier to obtain but business more difficult to perform. “Now, there is much more paperwork which doubles the amount of work that we used to do,” Ruthanne says. “But we still try to have that personal touch with the clients as much as possible, whether it’s going to see them or to hand deliver a bid or billing. Again, it’s the client relations that are most important to us.”

MOUNTAINS CLIMBED Despite hard economic times, this year the company is expected to meet or exceed its annual sales volume. Ruthanne says that normally the company has 80 to 100 projects ongoing at any given time. “The real challenge of running an operation of this size is that it takes time to organize, plan and schedule resources to meet the demands of our clients on time with a standard of quality that exceeds industry standards,” says Ruthanne. “With our diverse scope of work it takes collaboration and the quick response from all team members to mobilize workers, products, equipment, etc.,” she says. “The more demanding the job the more teamwork is needed.” As a long-term supplier to the company, Gypsum Products has worked with Heggem-Lundquist since the mid-80s. Gypsum Products was acquired by Allied Building Products in 2003. ABP knows the value of keeping long-term customers and is looking forward to cultivating the same relationship with the contractor as its predecessor has done. “We have valued the years of working with Heggem-Lundquist and that relationship continues today,” says Larry Haligas, Mountain Region, Regional Manager with Allied Building Products and former co-owner of Gypsum Products. “We are very proud to be a distributor to such a well-run family business.” For more information, please visit the company’s Web site at www.heggem-lundquist.com. W&C If you read this article, please circle number 215.

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