ROUGH CONSTRUCTION ISSUE
WHAT’S NEW IN INSULATION
LUMBER 2020 OUTLOOK
GYPSUM BOARD, NEVER BORING
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January / February 2020 // JANUARY - FEBRUARY 2020 1
ABOUT CONTRACTOR ADVANTAGE
Castle Building Centres Group Ltd. is a Canadian member-owned, Lumber, Building Materials and Hardware buying group representing over 300 member locations across Canada.
Contractor Advantage Magazine is the exclusive publication of Castle Building Centres Group Ltd. featuring quality Castle vendor brands available at Castle Building Centres locations. Visit castle.ca to find a Castle location in your area.
Editorial Director Castle Castle Building Centres Group Ltd. Jennifer Mercieca Publisher - Espress Labs Inc. Dan Alexander Managing Editor Teresa Christine Art Director AĂŻcha Niazy Contributors Lawrence Cummer Teresa Christine
Advertising Inquiries Jennifer Mercieca Director of Communications Castle Building Centres Group Ltd. 905-564-3307 jmercieca@castle.ca
JANUARY / FEBRUARY 2020 Volume 25 Issue 1
Material Contact Maryam Bashir Marketing Coordinator Castle Building Centres Group Ltd. 905-564-3307 mbashir@castle.ca Published and designed exclusively for Castle Building Centres Group Ltd. by Espress Labs Inc. // JANUARY - FEBRUARY 2020
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CONTRIBUTORS
TERESA CHRISTINE — Managing Editor Teresa is an accomplished communicator, copywriter and awardwinning Editor with the publication and design team at Espress Labs Inc. For fifteen years, she is also known, recognized and respected for her brand direction and creative instincts and has advised clients in various industries including construction, building materials, consumer and lifestyle. Her ghostwriting is proudly displayed through published content and across various digital platforms and print forms across the country and beyond.
LAWRENCE CUMMER — Feature Writer Lawrence (“Law”) Cummer is a freelance writer and editor and has been a frequent contributor to Contractor Advantage, Ideas and Rough Construction for nearly a decade. Over his more than 20-year career, Law has written about contracting and construction, general business, information technology, health and safety, personal finance and almost every topic in between. He has a passion for storytelling and sharing how people can work better, easier — and “smarter” — from contractors to technologists to business executives.
DANILA DI CROCE — Feature Writer Danila Di Croce is a Toronto-based writer with over 10 years of experience in the fields of media and education, including a Masters in Media Production from Ryerson University. Throughout her experience, Danila has worked in the areas of public relations, marketing, radio and television broadcast, and has contributed to various national publications on a wide range of topics including entrepreneurship, building construction, workplace health and safety and hospitality.
JENNIFER MERCIECA — Editorial Director Jennifer Mercieca is the Editorial Director for Castle & a contributor to Contractor Advantage. Her career in Communications & Content Management in the Home Improvement Industry spans over 20 years & she is currently the Director of Communications at Castle Building Centres Group Ltd.
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INSIDE
ON THE THE ON
8 23 26 36
WHAT’S NEW IN INSULATION
From sustainability to energy conservation to noise management builders are demanding more out of insulation and manufacturers are delivering.
STEELING HOME
Driven by design trends and sustainability demands, Canadians are increasingly incorporating steel into residential builds.
LUMBER 2020 OUTLOOK
They say hindsight is 2020, and there is speculation that the lumber and panel market may see a repeat of past unpredictability in the year ahead.
GYPSUM BOARD, NEVER BORING
Drywall manufacturers continue to develop new technologies and designs to make life easier for contractors and more comfortable for homeowners. // JANUARY - FEBRUARY 2020
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// EDITOR’S NOTE
E D ITOR ’S NOTE
The start of a new year brings with it reflection, resolutions, renewed hope, predictions, planning and goal setting for the year ahead. Often this means maintaining momentum from the previous year, often learning from past experiences, or possibly the opportunity to start fresh and lay a great foundation for the year ahead. In this January/February edition of Contractor Advantage, we introduce the Rough Construction Issue. In this issue, we cover some of the most important strength indicators for Canada’s construction industry. From covering trends in concrete to steel, to highlighting some of the latest innovations and forecasts for lumber, gypsum and insulation, coast to coast. Our various experts will provide a comprehensive outlook into the building envelope for 2020, to set readers off on the right track. We start the year with a collective optimism to carry forth a stable economic climate, appreciate the ebbs and flows and overcome the challenges along the way.
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ROUGH CONSTRUCTION //
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WHAT’S NEW IN INSULATION
Canada’s climate extremes have always put demands on our homes. And that’s truer now than ever before. Few elements are put to the test more than insulation when it comes to keeping the heat or the cool inside. It’s an industry with a lot of innovation and regulation. To help contractors stay in the know—and help their clients get everything they want from the products—seven industry leaders offered their perspective on what’s new, what’s trending and what’s important when it comes to insulation. INSULATION’S GROWING ROLE “As climate change increases the frequency and intensity of weather events, more builders are considering construction strategies that contribute to greater resiliency,” says Kim Friedrich marketing manager, Canada & Roofing NA Business Development, Marketing, Rockwool. That’s where insulation can play a significant role. “Insulation is no longer an afterthought as it might have been in decades past” typically, “stuffed haphazardly into vacant wall cavities and attics,” says Friedrich. “Insulation as part of home design and construction has become highly purposeful and strategic, addressing complex codes, standards and legislation, and driven by decades of building science learning.”
Photo courtesy of Rockwool
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From sustainability to energy conservation to noise management builders are demanding more out of insulation and manufacturers are delivering. Written by Teresa Christine
// JANUARY - FEBRUARY 2020
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CLIMATE CHANGE DRIVING PRODUCT EVOLUTION The insulation industry has been evolving in several ways. For one thing, products are increasingly applied and designed with climate change and extreme weather in mind.
dustry stakeholders is aimed at reaching ever more ambitious energy targets,” says Friedrich. What’s also changing is the general level of knowledge and understanding
about
insula-
tion products and their impact. “One of the most interesting
“The population in general is more concerned than ever about the environment and is creating a groundswell of advocacy for how we use our resources,” says Brent Bélanger, Architectural Services manager, CertainTeed Canada. “Well-insulated buildings reduce the use of energy resources, many of which are non-renewable.” He adds, “People are more informed and aware of these facts.”
trends is how consumers and
Regulations and programs are evolving to reflect those realities. “Building codes in Canada are becoming more rigid and are requiring a more sustainable approach in terms of thermal efficiency and the use of materials,” says Bélanger.
Well-insulated buildings reduce the use of energy resources.
While
codes
dictate
current
construction, builders are also keeping future targets in mind.
contractors resources
are
to
using
online
become
better
informed about insulation and thermal
per formance,”
says
Bélanger. “YouTube videos and self-education sites on insulat-
ing and air sealing are just two
that have helped to improve the knowledge of both applicators and consumers.” examples
“The Pan Canadian framework on climate change driving codes is mandating all new construction be Net Zero ready by 2030 and Net Zero by 2050, helping to
reduce CO2 emissions,” explains Salvatore D. Ciarlo, Architectural Solutions, codes & standards & technical services manager Canada, Owens Corning. And there are plenty of other programs addressing sustainability, as well. “A vast and growing contingent of initiatives from all levels of government and in-
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Gino Allegro, Canadian sales manager, Johns Manville, and Chair of the Board of Directors of the North American Insulation Manufacturers Association says builders and homeowners increasingly recognize the effectiveness of insulation and its value as an affordable investment. “When homeowners make the investment to build or renovate, they tend to do it properly,” says Allegro. “Because insulation isn’t a huge expense,
FEATURE STORY // WHAT’S NEW IN INSULATION
Photo courtesy of CertainTeed Canada // JANUARY - FEBRUARY 2020
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DuPont Performance Building Solutions Build your way at PerformanceBuildingSolutions.DuPont.com Construction.tyvek.ca Copyright © 2018 DuPont and Dow. All rights reserved. The DuPont Oval Logo and DuPont™ are trademarks of E.I. du Pont de Nemours and Company or its affiliates. The Dow Diamond Logo and Dow™ are trademarks of the Dow Chemical Company or its affiliates.
FEATURE STORY // WHAT’S NEW IN INSULATION
they’re likely to install the insulation where they can get even distribution of heat and cool comfort throughout the house and give thought to how they can get the best possible energy efficiency.” There’s a good chance that trend will continue to grow. David Kelly, corporate account manager DuPont Performance Building Solutions, who predicts we’ll see even more government incentives and consumer desire to upgrade insulation and air sealing in existing, older housing stock across the country. “It is definitely one of the renovations that
easily pays the homeowner back with energy savings,” says Kelly. PRODUCTION AND SUSTAINABILITY Insulation manufacturers are also addressing how insulation is made and sold, to help reduce its impact on the environment. Knauf Insulation, for example, has developed an alternative to the phenol / formaldehyde binder traditionally used in fiberglass products. “The plant-based binder holds our product together and
Photo courtesy of DuPont Performance Building Solutions
// JANUARY - FEBRUARY 2020
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Photo courtesy of Knauf
gives the product its unique appearance,” says Gary Romes, manager business development, residential/light commercial, Knauf. “All of our products are formaldehyde-free and made from sustainable resources, such as recycled glass and sand.” He adds that the company’s Eco Batt residential products have an extra level of environmental certification. And in a nod to today’s well-educated, well-researched consumer, Knauf Insulation also participates in Declare, a voluntary self-disclosure program aiming to transform the building materials industry towards producing and using healthier
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and more ecologically sound products through ingredient transparency. “Glass fibre insulations containing high recycled content and plant-based binders are further evidence of how producers are working to make insulation more green,” says Bélanger. “We are seeing a major transparency movement where manufacturers are publishing Environmental Product Declarations to inform users as to the amount of resources used during the life-cycle of the product.”
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FEATURE STORY // WHAT’S NEW IN INSULATION
Other sustainability initiatives are gaining traction, as well, including the use of spacesaver packaging which means more insulation per bag — and fewer plastic bags going to landfill, points out Ciarlo. While Friedrich notes that her company’s wool products save approximately 100 times the energy over the course of their service life than it takes to produce them. Plus, they are manufactured using basalt rock — an abundant natural material — as well as recycled slag. APPLICATION INNOVATION When it comes to installing insulation, there are improvements and trends to keep in mind too. While there are many tactics to meeting the code requirements and initiatives, they all tend to focus on the building envelope, and highly insulated wall and roof assemblies, in particular. “Existing homes, and in particular older residential housing stock, represents a significant opportunity to improve energy efficiency and reduce fossil fuel dependency and carbon emissions,” says Friedrich. The introduction of energy, renovation and retrofit programs, as well, has increased demand for thermal insulation products. For improved energy conservation in homes and businesses, more and more builders are looking to continuous insulation. Kelly explains, “Continuous insulation is an uninterrupted layer of insulation that spans over structural members without thermal bridging, other than fasteners and services.” It’s in demand, he adds, because it helps reduce the potential for condensation within the wall where mold and mildew can accumulate undetected. Continuous insulation can be applied to both the interior or exterior of a building, as well. “In commercial construction, building codes now call for the use of continuous exterior insulation in order to meet requirements for
Photo courtesy of Owens Corning
// JANUARY - FEBRUARY 2020
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FEATURE STORY // WHAT’S NEW IN INSULATION
Photo courtesy of Johns Manville
higher R-values,” says Friedrich. It’s a trend, she points out, that’s gaining traction among residential builders, as well. “A lot of times with construction even though you insulate your home well you get those cold spots that can penetrate through the wood or steel studs,” says Allegro. “That’s especially prevalent where steel studs are used. So exterior sheeting is a growing piece of the insulation world, helping to solve that problem.”
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ACOUSTIC DESIGN Though not typically the main driver when it comes to building design, there’s a growing demand for the sound-managing properties of insulation, as well. “Builders are increasingly interested in the acoustic value of insulation,” says Allegro. “There’s more demand for home offices and home theatres, and so greater need to think about soundproofing. This is true not just in custom homes, but also in track homes.” The thinking is, ‘Home insulation isn’t all that expensive so why not provide some acoustical value, as well?’
Photo courtesy of Isolofoam
Stone wool is a top choice thanks to its dense composition and nondirectional fibre structure.
“We see communities becoming denser, especially in our major urban centres,” says Bélanger. “That translates into more concentrated levels of noise. So, moving forward, insulation will continue to be an integral part of the design solutions needed to solve sound problems.” Friedrich says she’s witnessed this shift, as well. “Because of the realities of today’s increasingly dense and noisy environments, a growing number of home builders are planning for sound insulation as part of whole building design,” says Friedrich. She adds, “Stone wool is a top choice thanks to its dense composition and non directional fibre structure, allowing it to achieve excellent sound management, and it also contributes to other objectives such as fire protection, moisture management, building resiliency and occupant comfort.”
PROBLEM SOLVING ADVANCES The industry is innovating in plenty of other areas too, in response to a wide range of needs and trends. For example, says Geneviève Labonté, vicepresident, marketing and innovation, Isolofoam, “Under-slab insulation and radiant floor heating is getting more popular in every market.” In support of that development, specialized panels (including the ISORAD V2) help ease installation of that technology, she says. There are other practical advancements too. “Labour shortages on building sites are an issue in nearly every market,” says Labonté. Isolofoam has created products to help solve this problem and save time and effort on job sites. “The products offer great insulation value but also have a unique clipping system that keeps panels where you want
// JANUARY - FEBRUARY 2020
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them, to avoid wasting time putting them back in place.” As builders plan further into the future (thanks in part to longrange code requirements), insulation manufacturers have done the same. “The long-term thermal resistance has to be considered for insulation products that contain expansion gas,” says Labonté. “By January 2021, no building insulation containing HFC gas will be allowed in Canada.” She adds, “Expanded polystyrene which is the type of insulation material Isolofoam produces is not concerned with these two elements since it does not contain any gas other than air.” MULTITASKING AND THE FUTURE Looking ahead, it’s likely builders and consumers will increasingly be looking for—and finding— insulation products that tick several boxes at once, including energy conservation, sound insulation, fire resistance and moisture control, all while meeting or exceeding building code requirements. Insulation is, in many ways, the quiet multi-tasking star of the building world, helping support the environment while also contributing to the creation of safer, quieter, more efficient buildings that support homeowners’ comfort and wellness. —
Photo courtesy of Rockwool
FEATURE STORY // WHAT’S NEW IN INSULATION
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// STEELING HOME
STEELING HOME
Driven by design trends and sustainability demands, Canadians are increasingly incorporating steel into residential builds. Written by Jennifer Mercieca
Drive through a growing number of Canadian communities and you’ll spot something interesting: more and more homes are incorporating steel into their design. “The last couple years we’ve definitely seen a huge trend of residential design making the move toward steel,” says Greg Gardenits, director of
sales & marketing, Western Canada, Westman Steel Industries. There are several factors driving that trend. The biggest is a growing concern over the health of the planet. Steel, he says, fits that bill. “All the steel we use is recycled. We take spare parts and melt them down. We basically take that steel and reinvent it.”
Photo courtesy of Westman Steel // JANUARY - FEBRUARY 2020
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Photo courtesy of Westman Steel
Once it’s used in a building, steel’s durability supports sustainability, since there’s less need to replace it any time soon. “That’s what steel represents,” says Gardenits. “It’s got a lot of life, a lot of longevity to it. There are higher up-front costs. But you may have to replace a traditional roof three or four times in the lifetime of the same product in steel.” In the context of a big build or renovation, Gardenits says homeowners are increasingly seeing steel as a smart investment. One other practical concern driving interest in steel, Gardenits notes, is that “depending on the region, many homeowners have concerns about fire, as well. When you’re looking at a product like steel, it’s not fireproof, but it’s flame resistant and
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a steel roof, for example, doesn’t burn as quickly as a traditional shake or shingle roof would.” Designers and homeowners are warming to the look of steel in residential buildings, as well, partly because of the product’s versatility. “Steel can give you a traditional look, a contemporary look, and anything in between. It helps you get away from the traditional types of products like stucco or vinyl siding and give a little more texture and interest to a surface. Designers will often incorporate multiple colours and profiles of steel in the design of a home. Combining different profiles and textures and colours can give a home a unique contemporary look.
// STEELING HOME
Photos courtesy of Westman Steel
Choice when it comes to colour is something the industry is increasingly offering, thanks to demands by architects, designers and contractors, including one that’s a bit counter intuitive. “For years the industry worked to make sure steel didn’ t rust,” says Gardenits. “And now we have a lot of architects wanting to specify rusted-looking steel in their designs.” Using steel that’s still rust-resistant, the company managed to source and offer a painted product that creates an authentically ‘rusted’ look that’s been hugely popular with customers. Manufacturers make every effort to respond to the demands of the design community. Having steel in the repertoire, adds a whole new range of looks architects can use, whether that’s traditional, contemporary or modern. Most importantly, the design elements are offered in a way is sustainable to meet yet another of the ind ustry’s biggest needs. —
// JANUARY - FEBRUARY 2020
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LUMBER 2020 OUTLOOK
Written by Lawrence Cummer
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They say hindsight is 2020, and there is speculation that the lumber and panel market may see a repeat of past unpredictability in the year ahead. Entering into the new year, the continued impact from parasitic epidemics, market uncertainties and, most importantly, anticipated supply challenges loom particularly large. “The biggest single issue as we move into 2020 is going to be curtailments,” said Kelvin Johnston, senior buyer, commodity lumber and panels at Castle Building Centres Group Ltd. in the late fall of 2019. “We have seen several lumber mills close, and a big OSB mill in the U.S. that went down [recently]. They are closing, and a with lot of these mills it’s not a two-week closure, they’re more permanent.” “With so much production coming out of the market, we’re going to see prices pushed up a little higher,” he believes. Photo courtesy of Tolko
With that in mind, Johnston noted late October and November of 2019 broke with traditional pricing trends. While usually the slow (and low) period, the industry instead was seeing the highest lumber prices of the year.
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Photo courtesy of Tolko
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FEATURE STORY // LUMBER 2020 OUTLOOK
“I’m a little concerned we are setting up with a lot of the same market indicators (as coming into 2018): we’re at a strong fall, which for this time of year is unusual; and when we go into next year we’re going to have a lot of mills where the production is gone, so we’re going to have a lot of production missing out of the marketplace.” While supply in 2018 was curbed by logistic challenges that have generally been solved, with new home starts still having decent strength, Johnston suggests mill closures have the same effect. “With this lack of production, or definitely lower production than we’ve seen in a few years going into next year, we could see a run of prices again in 2020.” Demand of course is difficult to predict. “We always try to shake the crystal ball, and it’s more
like a snow globe,” said Chris Armanini, manager, plywood, LSL & EWP sales & marketing at Tolko Marketing and Sales Ltd. Still, Armanini says demand continues to be solid. “Housing starts in Canada continue to surprise to the upside, even if we go through periods that slow down a little, then we go into higher periods. Look more recently at Toronto and Vancouver, markets there are starting to not just stabilize but turn back up.” He echoed other lumber experts that the amount of production capacity being pulled out of the market, particularly in B.C., is something industry watchers must pay attention to. “As the province comes out of the harvest, and two OSB mills have been permanently closed, as well as a fair num-
Photo courtesy of Tolko
// JANUARY - FEBRUARY 2020
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ber of sawmills. It remains to be seen what impact those will have, but any time you remove from the supply side, if you don’t see a corresponding impact on the demand side, it sets things up for the potential for markets to be higher.” Last year was a tumultuous one, said Mike Park, National Panel Buyer, AFA Forest Products Inc. “Take a look at the markets and you can see they’ve been very volatile.” He says uncertainty has driven that volatility, including around U.S.-China relations and Bexit, as examples. “I think it’s just leading in general for people to be unsure.” Of course, the mill closures and supply curtailments of 2019 loom large, and Park expects them to ripple through the coming years. The reduction in B.C. lumber production, close to 15%, over a short period of time, has been “staggering,” “B.C. bore the brunt of recent production cuts with well over 2 billion ft. taken off the market as well as in excess of 500 million ft. of reductions to the remaining mills. Additional reductions in the U.S. Pacific Northwest takes the total over 3 billion ft. That’s approximately 67,000 truckloads,” Park noted. “The permanent closures are a result of declining basket of fibre as a result of the pine beetle kill that inflicted the province over the past number of years.” Since the ’90s, these rice-sized bark beetles have been a blight on western North American forestry, wiping out millions of hectares of lodgepole pine. Photo courtesy of AFA Forest Products
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FEATURE STORY // LUMBER 2020 OUTLOOK
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FEATURE STORY // LUMBER 2020 OUTLOOK
“The pullback in production in 2019 will likely have a long-term impact to 2020 and beyond. With that, we can speculate that prices will increase in 2020 with supply cuts and high log costs carrying over.” As well, Park predicts premium lumber will become harder to source, so builders should expect more fir lumber being made available in lieu of SPF. Of course, mill shutdowns in both Canada and the U.S. are expected to impact the availability of OSB (Oriented Strand Board) products as well, noted Carmen Mazzei, national OSB and panel manager at CanWel Building Materials Division. He attributes many factors to these closures,
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including wood supply and lower than expected housing starts in the U.S. “OSB supply may be a factor heading into 2020, pending activity mainly in housing,” Mazzei said. “With the shutdowns seen, if the housing market picks up in the U.S. to levels expected two years ago, there could be some shortages, and definitely prices will be higher than they are today.” Plywood mills too are under pressure from rising production costs and lower priced imports ending North America, Mazzei said. With all the changes, challenges and pressures on the industry, it’s hard to foresee what the year will bring. —
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// JANUARY - FEBRUARY 2020
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GYPSUM BOARD, NEVER BORING Drywall manufacturers continue to develop new technologies and designs to make life easier for contractors and more comfortable for homeowners. Written by Lawrence Cummer
Photo courtesy of CGC Inc.
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ROUGH CONSTRUCTION //
// JANUARY - FEBRUARY 2020
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FEATURE STORY // GYPSUM BOARD, NEVER BORING
Gypsum may not get the attention of many other building products, but manufacturers are always looking for ways to evolve their boards and related products. While not always the top focus of homeowners during a reno or new build, builders and contractors know the crucial role gypsum plays, and manufacturers continue to innovate with an eye on safety, convenience and performance. “The big thing, especially from our company because it’s one of our core values, is safety,” says Kevin Baker, product manager for wall board at CGC Inc. It is with safety in mind, he says, that CGC has been developing new and improved lightweight
Photos courtesy of CGC Inc.
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products for its portfolio, as well as its focus on fire-resistance and sound attenuation. “The benefits are for a contractor carrying, lifting and installing (panels) all day. They have reduced weight but still achieve high performance, so it’s easier on them.” HEAVY FOCUS ON LIGHT WEIGHT Baker points to three recent products under the Sheetrock brand that demonstrate the company’s lightweight developments: its ½"UltraLight panels; ½" Ultralight Mold Tough panels; and, 5/8" UltraLight Firecode X panels. The company’s Sheetrock Brand UltraLight Panels can be used for interior wall and ceiling applications. The ½" (12.7 mm) gypsum panels are re-engineered to be lightweight using a patented, composite design to make them easier to lift, carry and install for quick installation and decoration. Sheetrock Brand UltraLight Panels Mold Tough are similarly lightweight ½" panels with a high strengthto-weight ratio composite design. They feature a noncombustible, moisture-resistant core that is encased in 100% recycled moisture and mold-resistant green face and brown back papers. They meet ASTM standards for ½" waterresistant gypsum wallboard and ½" exterior gypsum soffit board. Sheetrock Brand UltraLight Panels Firecode X is formulated to achieve all of the strength and performance characteristics as standard 5/8" (15.9 mm) gypsum panels, but at a significantly reduced weight. The panels have a re-engineered Photos courtesy of CGC Inc.
// JANUARY - FEBRUARY 2020
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FEATURE STORY // GYPSUM BOARD, NEVER BORING
core encased in 100% recycled face and back papers that form a high strength-to-weight ratio composite design. It’s intended for commercial or residential applications where 5/8" Type X panels are required. MAKING EASIER WORK In addition to lighter boards, manufacturers are listening to contractors and trying to find other ways to take some of the effort and strain out of the job. Aneil Mahadeo, Ontario territory sales manager for Continental Building Products says his company has been developing new products, such as its Rapid Coat Versa Pro joint compound, based on user focus groups. Only available in Canada, Rapid Coat Versa Pro is an all-purpose, professional grade joint compound that has been specially formulated to deliver superior performance with less energy — whether applied with machine tools, knife or trowel. It is premixed and ready to use right out of the container. “When you spread it, you find it very creamy, very forgiving and very light,” he says of the new joint compound. He says this is in demand because it requires a less experienced hand, increasingly important as talent becomes harder to find He says it sands easily, with less ef fort and less physical strain on the installer. “But once you create a compound that is lighter, creamier and easier to sand they will hopefully use a 220 (grit), but in some cases they’ll use a 180 (grit) sandpaper.” Photo courtesy of Continental Building Products
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ROUGH CONSTRUCTION //
Photo courtesy of Continental Building Products
FINISHED BEFORE YOU START Some custom homes and commercial applications need a high-end finish. To ensure a top-grade finish and, again, make life easier, Mahadeo says his company has developed the Rapid Deco Level 5 System. Using the company’s skim-coated Bison Board drywall and complementary joint compound, the system can produce consistently smooth walls and ceilings. Typically, Level 5 finish, which creates the most uniformity on the wall surface, requires a final
skim-coat phase (which includes sanding) to minimize the appearance of joints, fasteners and any inconsistences. By skipping the skimcoat phase, he says, the system achieves a Level 5 finish, but at the same speed and ease as Level 4. The Rapid Deco Level 5 System also requires fewer materials and supplies to reach that top aesthetic, takes less time on the job, and doesn’ t require the highly skilled labour for hand- or spray-applying the skim coat.
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It is available in five types to address specific needs. Rapid Deco Level 5, general purpose skim-coated drywall; Rapid Deco Level 5 with Mold Defense, which is specially formulated to inhibit mold and mildew growth; Rapid Deco Level 5 Type X, for maximum fire protection; Rapid Deco Level 5 with Mold Defense Type X, engineered for fire-, mold- and mildew-resistance; and, Rapid Deco Level 5 Type X with Mold Defense and Protecta Abuse Resistance, to resist fire, abuse, mold and mildew. SILENCE IS GOLDEN Controlling sound transfer between rooms and units is becoming ever more important, experts attest. And with that, has come innovation around controlling the acoustical properties of gypsum. “As families become smaller and consumer finances change, there’s been an increase in multifamily dwellings, such as condos and townhomes. More of ten, people live and work in closer quarters, so protecting inside rooms from ambient noise is increasingly important,” says Brent Bélanger, architectural services manager at CertainTeed. “In addition, acoustical requirements for buildings have become stricter in recent years, particularly in hotels, restaurants, hospitals, schools and other public facilities.” To meet this demand, CertainTeed has developed its SilentFX QuickCut drywall, a high-performing, sound-dampening gypsum board that is composed of two layers of ultra-dense drywall and a visoelastic polymer centre to greatly reduce sound transfer. “Its composition helps reduce the layers of board required to achieve a high STC (sound transmission class) rating, and its design makes it score and snap easily, reducing labour and construction time,” Bélanger says. Photo courtesy of CertainTeed
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OUTSIDE IMPROVEMENTS Nisha Brown, director of marketing at Georgia-Pacific Building Products, says her company has been innovating around its exterior gypsum board, especially for commercial, light commercial and multi-family dwellings. The company’s DensElement Barrier System integrates three products, and their installation steps, into one. It uses technology dubbed AquaKor to transform gypsum sheathing into a water-resistant barrier and air barrier by integrating a fibreglass matt and gypsum core into a single surface that blocks bulk water but allows vapor to pass through. “It’s no secret that there is a major skilled labour shortage and everyone is feeling it. A lot of what was going through our minds a few years back was, ‘How do we make things easier? How do we help people skip certain steps? Can we handle (this step) essentially within the factory?’,” she says. The result was the DensElement Barrier System, which she says provides the efficiency to get the job done faster and easier. “I’d like to say it’s a smarter sheathing. It does more work than traditional sheathing does, because it has the water-resistant barrier and air quality (attributes) integrated within that board.” Brown notes the company has also taken its approach of integrating water and air barriers into its OSB panels. “On a high level we’re talking about resiliency and part of that
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FEATURE STORY // GYPSUM BOARD, NEVER BORING
is the reduction of waste and these integrated approaches serve just that. When you have multiple products and one going on top (of the other), not only do you have more materials, but you have more waste on the job site.” She says integrating products reduces materials and allows for fewer workers on the jobsite given one can handle multiple applications.
“Products like DensElement Barrier System gets the wall built faster and dry-in quicker and gets heads in beds faster.” WASTE NOT, ESPECIALLY TIME Waste of materials and time is, of course, a topof-mind issue as we enter a new decade with new challenges. At the same time, contractors can’t compromise on quality work.
Photo courtesy of Georgia-Pacific Building Products
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FEATURE STORY // GYPSUM BOARD, NEVER BORING
“Construction waste in the form of both time and materials is a major challenge facing contractors, which is compounded by the fact that contractors will likely continue to face labour shortages in 2020,” Bélanger says.
and formulated surface paper to prevent cracking, chipping and blistering. The company’s NOCOAT PRO automated corner system improves speed and efficiency for the application of drywall corners.
One way that he suggests CertainTeed helps to tackle the challenge of labour and time is by handling one of the trickier aspects of drywall installation: corners. It’s NO-COAT Structural Laminate (SLAM) drywall corners have a tapered, high-strength, copolymer core that requires less mud, resists impact and eliminates rust. It also comes with built-in joint tape for better adhesion
“From the side of contractors, gypsum installers face the same labour shortages and shorter project timelines impacting many of the building trades,” Bélanger says. “They want products that can be installed quickly, reliably and with fewer hands in order to ensure project quality and reduce potential call backs.” —
Photo courtesy of CertainTeed
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