August 2016
T Th he e V Vo o ii c ce e o o ff tt h he e M Ma as so on nr ry y II n nd du us s tt r ry y
Volume Volume 55, 55, Number Number 88
Moisture Wall Systems Keeping Out of
Also Inside: Air Barriers Valve Designs in Mixers and Delivery Systems
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www.masonrymagazine.com
on the
cover
August 2016 | Volume 55, No.8
Contents Air Barriers and Insulation The Importance of Air Barriers
16 22 Air, Vapor, and Water-Resistive Barriers: Important considerations for material selection and code compliance
Interview With Russ Snow, 2016 President of 28 An the Air Barrier Association of America
30
Mixers, Pumps and Delivery Systems Masonry Grout Pumps and Delivery Systems: Material Valve Designs
38
Moisture Management Differences Between Rainscreen Walls and Cavity Walls Case Study
and Air Circulation Help Prolong the 40 Drainage Life and Look of Austin Apartment Complex 42 Managing Moisture in Masonry Wall Assemblies of Silane-Siloxane Sealer for 44 Benefits Older Brick Buildings Case Study
MCAA Strategic Partner Program
The District Performing Arts Center, part of the El Dorado High School campus in Placentia, Calif., was designed as a multi-use concert hall and theater. Built chiefly with concrete masonry, the Center harmonizes with the existing buildings on campus and reflects the essence of the musical performances that take place within. The project won the 2015 NCMA Concrete Masonry Design of Excellence Award — Award of Merit Commercial. More details can be found on page 60 of this issue. Photography courtesy of NW Architectural Photography.
columns & departments 6 8 10 12 46 48 50 52 53 56
From The Editor Chairman’s Message Government Affairs New Products Special Report: Masonry Finds Positive Indicators Pointing to Growth Trowel Tech Business Building Classified Advertising News MCAA Upcoming Education
MASONRY (ISSN 0025-4681) is published monthly. Subscription rate $29 per year; Canada and Mexico $47 (U.S. currency); all other countries $65. Single copies $8.50. Copyright 2016 by Mason Contractors Association of America. POSTMASTER: Send address changes to MASONRY, c/o Lionheart Publishing, Inc., 506 Roswell St., Ste. 220, Marietta, GA 30060. Canadian return address: Station A, PO Box 54 Windsor, Ontario N9A 615. SEND SUBSCRIPTIONS and business correspondence to: MASONRY, c/o Lionheart Publishing, Inc., 506 Roswell St., Ste. 220, Marietta, GA 30060 Phone: 770-431-0867 or 888-303-5639 www.masonrymagazine.com. Layout & Design © Lionheart Publishing, Inc.
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The Voice of the Masonry Industry
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FROM
THE
EDITOR
Karen D. Hickey, Editor - karen@lionhrtpub.com
Excellence in Masonry There’s always something big happening in the masonry industry. In June, the 52nd annual SkillsUSA National Leadership and Skills Conference in Louisville, Ky., featured a masonry competition. Gold, silver and bronze awards were bestowed at both secondary and post-secondary levels. Regional qualifiers for the SPEC MIX BRICKLAYER 500™ have started taking place and will continue through October, in preparation for the World Championship at World of Concrete/World of Masonry in Las Vegas on Jan. 18, 2017. Tr aining prog r ams for both students and journeymen masons are offered year-round. Check with your state’s masonry contractors association or the MCAA for the next webinar or seminar near you. Though not without its challenges, the masonry industry is indeed “alive and well” (see the Special Report on page 46), and it’s progressing. Masonry-related organizations in Florida, Michigan, Minnesota, Texas, Utah and Wisconsin have already pre-
sented their awards of excellence for outstanding projects for 2016, while the AIA Montana, AIA Nebraska (sponsored by the Nebraska Masonry Alliance), and the Arizona Masonry Guild are currently judging entries. The 2016 Brick in Architecture Awards Competition has also released the names of its winning projects. To my knowledge, two 2016 Excellence in Masonry Awards programs are still open for entries: • Masonry Institute of Washington, deadline: Aug. 5. • Ohio Masonry Association, deadline: Nov. 30.
The Voice of the Masonry Industry MASONRY Magazine Official Publication of the Mason Contractors Association of America and the Canadian Masonry Contractors Association The Mason Contractors Association of America is committed to preserving and promoting the masonry industry by providing continuing education, advocating fair codes and standards, fostering a safe work environment, recruiting future manpower, and marketing the benefits of masonry materials.ion of America is committed to preserving and promoting the masonry industry by providing continuing education, advocating fair codes and standards, fostering a safe work environment, recruiting future manpower, and marketing the benefits of masonry materials.
Mason Contractors Association of America
Chairman Vice Chairman Treasurer Secretary
Robert V. Barnes, Jr. Glenn Hotmann John Jacob Gary Joyner Jed Olafson
Regional Vice Presidents
Be sure to catch the September 2016 issue of Masonry, which will feature articles covering current trends and examining industry issues, including:
CONNECTORS, ANCHORS AND FASTENERS Masonry will reveal the latest products in this field, including software applications to help get the job done right, plus a case study on saving a crumbling masonry structure. SAFETY ON THE JOBSITE How do you check your equipment and jobsite to make sure safety precautions are in place before you being work? This and much more will be covered.
For advertising information, contact Marvin Diamond
770.431.0867, ext. 208 • Toll-free: 888.303.5639 • E-mail: marvin@lionhrtpub.com n
Jeff Buczkiewicz
Executive Staff Government Affairs Representatives Director of Marketing, Education, and Information Technology Director of Development Membership Coordinator Administrative Assistant Consultant
The Keelen Group Timothy W. O’Toole Todd Fredrick Angie Parisi Lorra Lein Rashod Johnson
David Jollay (Jollay Masonry Contractors), John Chrysler (MIA), John Melander (PCA), David Hill (Pettit Construction Co.), John J. Smith (John J. Smith Masonry Co.), Brian Grant (Grant/Jack’s Masonry), Jerry Painter (Painter Masonry, Inc.), Doug Nichols (Doug Nichols Enterprises), G. Alan Griffin (Griffin Contracting, Inc.), Tom Daniel (GBC Concrete and Masonry Construction, Inc.)
Executive Office 1481 Merchant Drive Algonquin, IL 60102 Phone: 224.678.9709 or 800.536.2225 Fax: 224.678.9714
MASONRY is the official publication of the Mason Contractors Association of America (MCAA) and the Canadian Masonry Contractors Association (CMCA). The magazine acts as a sounding board without approving, disapproving or guaranteeing the validity or accuracy of any data, claim or opinion appearing under a byline or obtained or quoted from an acknowledged source. Opinions expressed by officers do not necessarily reflect the official views of MCAA or CMCA. The appearance of advertising or new product information doesn't constitute an endorsement by MCAA or CMCA of product featured.
FLASHING AND DRAINAGE Learn about various flashing and drainage materials, and getting the installation correct at the start.
MASONRY
President/CEO
Michael Schmerbeck Rick Swanson Lynn Vasquez Dennis Withsosky
Editorial Advisory Board
Even the Masonry Contractors Australia Ltd. is accepting entries until Aug. 1 for its “Excellence in Brick and Blocklaying Awards” — proof that programs like this aren’t limited to North America and that excellence in masonry is being recognized around the world. If you would like Masonry magazine to help promote your organization’s events, seminars or awards programs, email me at karen@lionhrtpub.com. Let’s spread the word! yMAS
COMING IN SEPTEMBER 2016
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Michael Sutter Paul Odom Paul Oldham Larry Vacala
August 2016 • www.masoncontractors.org
Masonry Advertising and Editorial Office
Send all advertising and editorial submissions for Masonry to: Lionheart Publishing, Inc. 506 Roswell Street, Suite 220, Marietta, GA 30060 USA Tel: 888.303.5639 • Fax: 770.432.6969 • E-mail: lpi@lionhrtpub.com www.masonrymagazine.com Publisher John Llewellyn • llewellyn@lionhrtpub.com Editor Karen D. Hickey • karen@lionhrtpub.com Copy Editor Marty M. Hohmann • marty@redclayeditorial.com Art Director Alan Brubaker • albrubaker@lionhrtpub.com Online Projects Manager Patton McGinley • patton@lionhrtpub.com Assistant Online Projects Manager Leslie Proctor • leslie@lionhrtpub.com Advertising Sales Marvin Diamond • marvin@lionhrtpub.com Advertising Sales John Davis • jdavis@lionhrtpub.com Marketing Director and Audience Development Maria Bennett • bennett@lionhrtpub.com Reprints Kelly Millwood • kelly@lionhrtpub.com
The Voice of the Masonry Industry
CHAIRMAN’S
MESSAGE
Michael Sutter Chairman
Mason Contractors Association of America mike.sutter@suttermasonry.com
Get Ready for MCAA’s Midyear Meeting Jeff Buczkiewicz and I just left Las Vegas after a full day of reviewing venues for the World of Concrete/World of Masonry (WOC/WOM) and MCAA Convention in January. MCAA is planning some new events at new venues that I promise will be a shake-up from what we have done in the past. Registration will be opening soon at www.masoncontractors.org. Be sure to sign up for our MAC PAC and PEC events we are holding at Top Golf. You don’t have to be a golfer to enjoy these events. We have put together different packages that you can purchase for the convention, as was requested by members last year. This will make registering a lot easier. Although we are still fighting for changes in the new OSHA rule regarding silica, we are also preparing for when the rule takes effect in June 2017. We already know that we will need a written plan for dealing with silica exposure on each jobsite once the rule is in place. MCAA will be providing a template for these written silica plans to all of our members free of charge. We will all also be required
to have a competent person on all of our jobsites — a person who is trained in silica exposure. This means that basically all of our foremen must be competent regarding the new silica rule. It would be very expensive to send all of our foremen to training or to bring instructors to our places of business. Therefore, MCAA will be offering Train the Trainer classes at WOC/WOM in Vegas. That way, you can send one person for this training, and that person can then provide training for all of your foremen. Our Workforce Development initiative is continuing with vigor. We are urging our legislators to continue and expand funding for the Perkins Program, which is used for high school education and training in the construction industry. Many of these students can be career-ready upon graduation, and we all know how much we can use these students in our workforce. Whenever you get a chance to talk to your representatives, let them know how important this is to our industry! Only a couple months remain until MCAA’s Midyear Meeting at the beautiful Westin Kierland Resort & Spa in Scottsdale, Ariz., on Oct. 2–4, 2016. We have lots of activities planned that will give you a taste of the Wild West out here in Arizona. From golf in the lush, green landscape to UTV riding on desert trails, we will offer it all. We will even be serenaded by bagpipes as the sun sets over The Kierland FlowRider at the Westin Kierland Resort & Spa. the nearby mountains. You can 8 |
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A bagpiper at the Westin Kierland Resort & Spa.
go to the resort’s website, www.kierlandresort.com, and look at all of their amenities, including pools, a lazy river, a 110-foot water slide and a golf course, not to mention numerous restaurants and shops within walking distance. If you have never attended a Midyear event before, I urge you to give it a try. It is at our Midyear Meeting that we set the agenda for our committees for the coming year. Be sure to attend these meetings to learn where your MCAA committees are headed. Unlike the convention in Vegas where we are all too busy to really have an in-depth conversation, the Midyear Meeting is much more relaxed and intimate. This is where all the networking takes place. Strike up a conversation with another mason contractor or a supplier who is not in your market, and you can share ideas that work and those that haven’t worked so well. I can’t begin to tell you the benefits I have received by sharing ideas with other contractors. This is where long-lasting friendships are born every year. Registration is available online, so please take advantage of this awesome event. yMAS The Voice of the Masonry Industry
GOVERNMENT
AFFAIRS
By Stephen Borg
Looking Ahead to the New Year Congress recently adjourned for the Presidential Nominating Conventions in Cleveland and Philadelphia and their four-week summer District Work period. As a result, news out of Washington, D.C., will likely be slow or overshadowed by the November elections. Therefore, I wanted to take this time to put an important event on your radar: the 2016 MCAA Midyear Meeting in Scottsdale, Ariz., on Oct. 2–4. Your participation will help the Mason Contractors Association of America’s (MCAA’s) leadership, legislative committee, and myself lay the groundwork for our legislative agenda moving into 2017, when we will have a new U.S. President and a new Congress being sworn in. Looking into my crystal ball, I foresee MCAA continuing to place a heavy pr ior it y on workforce development issues and the impact that many of the regulations put forth by the Obama administration have had and will continue to have on our industry and economy. However, it is imperative that you, the MCAA members, show up in Scottsdale in order to continue conversations on issues that are impacting your business, your states and our industry. MCAA’s leadership, legislative committee and I will be there, having conversations on the issues we need to make a priority in Washington in the upcoming year. We would love to meet with as many of you as possible. 10 |
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It may seem like the start of 2017 is a long way off from the beginning o f O c t o b e r. B u t p r e s i d e n t i a l transition planning will have already begun within both parties, returning committee chairmen will have their eyes on moving major legislative packages in the first couple months of the new presidency, and both chambers will be staking their flags on major issues. One issue that has the potential to impact the masonry industry immensely — and which has already started to be talked about on both sides of the aisle — is the need for a comprehensive overhaul of our nation’s tax code. We need to hear from you on how the tax code impacts your business, both positively and negatively. What better place to begin having those conversations than in sunny, warm Scottsdale? I have used this column many times in the past to encourage you to participate in the MCAA Annual Convention, the annual Midyear Meeting, and the annual Legislative Fly-In. Let me use this column again to encourage you to get involved, to stay involved, and to make your voice heard. The MCAA has been building a brand and respect in Washington, D.C., for many years, but it can only be as strong as you, its members, make it. Decisions are being made every day in Washington and in state capitols throughout the country that impact your business and our
August 2016 • www.masoncontractors.org
If elected officials are
not hearing from us, I can guarantee you they are hearing from the other side of the issue.
industry. If elected officials are not hearing from us, I can guarantee you they are hearing from the other side of the issue. So, as you take a break from the summer heat and transition into the fall, take time to think about how the government is impacting your business, take time to talk to your colleagues in the masonry industry, and make plans to join us in October for the Midyear Meeting. We need to hear from you, we need you to be involved, and we want to engage those who are making decisions every day that impact your business and the masonry industry as a whole. yMAS
The Voice of the Masonry Industry
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PRODUCTS To submit a new product, contact: Karen Hickey • Email: karen@lionhrtpub.com
www.masonrymagazine.com • 888-303-5639, Ext. 230
We’ve made it fast, easy and convenient to request FREE information about any product or service in this issue. To request information online, go to: www.masonrymagazine.com. Click on ‘FREE Product Information’ (right top corner), then… 1. Select the issue of the magazine you are reading 2. Check the box next to the advertiser you are interested in 3. Provide your name, address and business information 4. Click submit.
Kraft Tool Shawnee, Kan.
Bonded Braided Nylon Mason’s Line: A Mason’s Friend Most bricklayers have experienced sagging, unraveling or inferior mason’s line. Valuable time can be spent correcting problems caused by poor quality mason’s line. These problems can be prevented by using a higher-quality bonded braided nylon mason’s line. Kraft Tool Co. produces one of the strongest premium professional bonded braided nylon mason’s Lines available. Kraft’s line is abrasion and alkali resistant, and passes a 170-pound weight test. Kraft’s line also uses only highly visible colors that are always bright and consistent. www.KraftTool.com
Bon Tool
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Lewis Pins Available in New Sizes
Lithium-Ion Batteries Feature Enhanced Power-to-Weight Ratios
Bon’s Lewis Pins are now available in seven sizes, with hole ranging from 1/2 to 1 1/4 inches, and lengths from 3 1/2 to 7 inches. These are ideal for lifting granite and other hard stones. Lewis Pins are inserted into opposing holes drilled into the top of the stone, at about a 15° angle from vertical and directly above the center of mass. They operate by gripping the stone as the weight of the stone is taken up by a crane or winch.
STIHL AP 100 and 300 lithium-ion batteries deliver heavy-duty performance in light and affordable packages. At just 1.8 pounds, the AP 100 produces the same energy content and run times with 31 percent less battery weight than the previous model. The AP 300 allows users to tackle larger projects with fewer recharges, producing 28 percent more energy content while remaining the same weight as the previous model (3.8 lbs.). Both batteries are compatible with the full line of STIHL battery products.
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BASF Wall Systems
QUIKRETE
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MaxFlash Liquid Flashing Membrane MAXFLASH is a one-component elastomeric material for use as a flexible flashing membrane at rough openings. It can also be used to prepare sheathing joints for subsequent application of BASF air/ water-resistive barrier membranes. It can be used as a membrane for flashing rough openings, small penetrations and as a detailing compound for preparing sheathing joints for application of an air/water-resistive barrier membrane. MAXFLASH bonds to a wide range of substrates, including poured concrete/unit masonry.
QUIKRETE Mobile App The QUIKRETE Mobile App provides easy, onetouch access to the information you need for building and repair projects from start to finish. Professionals can find the relevant information they need for a specific job at the right time. With one touch, contractors can access a product’s technical specifications, calculate product quantities, and even find the closest store to a jobsite. The app is available for both iPhone and Android devices. www.quikrete.com
www.wallsystems.basf.com
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www.stihlusa.com
Cummer Manufacturing Dubuque, Iowa
Watt-R-Tank Provides Hot Water to Jobsites The Watt-R-Tank is an insulated water tank that can be built to any size. Powered by 220V (optional 110V), it has an adjustable thermostat from 90 to 150°F. Fill it with water, leave it plugged in overnight and hot water will be ready at the jobsite so that mason can start working right away. Use the electricity already provided at the jobsite instead of trying to recoup propane costs. Use the hose to place water directly into a mixer. www.cummermanufacturing.com
The Voice of the Masonry Industry
PRODUCTIVE Faster means more...
The TotalFlash® masonry cavity wall flashing system comes to the jobsite pre-assembled with materials you know (flashing membrane, drainage mat, weep tabs, termination bar and drip edge). Plus free takeoffs, cutting for wall openings and expert bid help. Flashing installation time drops by up to 50% so masonry goes up faster—and faster means you’re more productive.
Call or email for samples: 800.664.6638 x509 • samples@mortarnet.com
mortarnet.com
MCAA MASON CONTRACTORS ASSOCIATION OF AMERICA
www.masoncontractors.org
The Importance of Air Barriers By Peter Barrett
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The Voice of the Masonry Industry
FOR BOTH NEW CONSTRUCTION AND REMODELING PROJECTS, the right combination
of air barriers and insulation is important to the overall effectiveness of a masonry or wood-framed wall system. Increasingly, architects and builders recognize that a well-performing air barrier will maximize the effectiveness of the insulation, help reduce energy costs, and avoid potential moisture problems. As designers and architects get more and more creative, air barriers are even more important. Copyright Denver Botanic Gardens. Photo by Scott Dressel-Martin
www.masonrymagazine.com
August 2016
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AIR BARRIERS
Fully adhered air barriers, like DELTA-VENT SA, eliminate many of the potential problems caused by ordinary air barriers.
Leaks: A Big Issue Air leaking into the walls can be a significant problem for buildings. Air penetrates through the cladding or masonry, through penetrations and fasteners, or through window and door openings, wasting energy. This non-con-
ditioned air makes the insulation less effective. Contractors are the last line of defense to ensure that the structure is airtight. Attention to detail during installation is critical, but using high-performance air barriers makes it easier to end up with an energy-saving, airtight structure. Reducing Risk H ouse wraps have been the generally accepted weather enclosure solution for many years. Over time, however, house wraps have gone from being an adequate solution to one that is now viewed as just “good enough” to meet code. Technology has made higher-performance air and water barriers a preferred choice for contractors and builders who aren’t satisfied with just meeting building codes. Typically, building codes take time to catch up to product improvements. However, forward-thinking builders and contractors are using higher-performing air and water barriers before they are required by building codes. Not only does this keep them up to date with current thought in building science, but it also keeps these builders ahead of their less progressive competitors. A contractor can be at greater risk because mechanically attached (nailed) house wraps are more prone to installation problems. Frequently, the wrong type of fastener is used or seams and penetrations are not completely taped and sealed, allowing air to flow past the air barrier. House wraps are also prone to being ripped, torn or even blown off due to high winds that hit the structure before the cladding or masonry exterior has been installed to protect the house wrap. As more homeowners go online to educate themselves, they have access to home energy auditors with tools like thermography and infrared thermometers. What used to be an acceptable level of air leakage is no longer acceptable.
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The Voice of the Masonry Industry
Custom Submittal Sheets are available upon request
WIRE-BOND
AIR BARRIERS
Blower door testing and HERS ratings are focusing attention on the integrity of the air barrier. When leaks in the air barrier are identified as the problem, the contactor is the most likely person to be blamed. The contractor may then be expected to remedy the situation, which can be expensive if it requires removal of the cladding. The architect, builder and house wrap manufacturer will all point out that it was the contractor’s installation errors that caused the problems. Two Choices Contractors have two choices to protect themselves while assuring the builder and homeowner of an airtight enclosure. The first choice involves continuing to use a house wrap product. In this case, the contractor needs to make sure that the installers pay extra attention to the installation details. The contractor will need to make sure every detail is inspected, then plan that some details will have been missed and need to be corrected by his crew. The contractor will also need to inspect the barrier an additional time just before the exterior cladding is installed to see if there has been any damage caused by high winds or openings created in the barrier by other trades (e.g., utilities). The remaining openings will need to be repaired one final time before the final cladding is installed.
The second choice for the contractor is to insist on or encourage the builder to use a higher-performing, fully adhered air and water barrier, such as DELTA-VENT SA from Cosella-Dörken or VP 160 by Henry. Self-adhered air and water barriers eliminate many potential problems with fasteners and poorly taped (or untaped) overlaps and seams. They also won’t be damaged by high winds. A fully adhered air barrier costs more than an ordinary house wrap but saves the time it takes to install a mechanically fastened house wrap correctly and repair subsequent installation issues. A fully adhered membrane also makes it easier for the builder to pass a blower door test and improve the HERS rating, while protecting the contractor from costly callbacks. It’s a New World With the growing focus on energy efficiency and technology that can quantify a structure’s air leakage rate, contractors need to protect themselves by knowing what products will result in the best results. Contractors can no longer just do what they are told or be satisfied with just meeting building code. yMAS Peter Barrett is product manager for Cosella-Dörken Products, Inc. He can be reached at pbarrett@coselladorken.com.
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The Voice of the Masonry Industry
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Air, Vapor, and Water-Resistive Barriers Important considerations for material selection and code compliance By Tom Gangl MASONRY-CLAD BUILDINGS LEAK. They leak air, vapor, and water. These leaks place an environmental load on the building envelope, structural components, mechanical systems, and even building occupants. If left unchecked, these loads can result in building component and system failures. To prevent such failures, barrier systems are used to stop or at least control the leaks. While it is logical to use the correct barrier system for the job at hand, sometimes we don’t. Air barriers first appeared in cold climates, where vapor barriers were employed in wall systems. By combining the air and vapor control, the air-vapor barrier (AVB) was born. Of course, a vapor barrier is really a Class-I vapor retarder, considering that even the quintessential “vapor barrier” — 6-mil poly — has some degree, albeit low, of moisture vapor permeance. As their benefits became widely recognized, air barriers moved beyond cold climates and into more temperate zones. Along with this migration came the adaptation of vapor-permeable air barriers. Interestingly, the term AVB stuck. Some people still refer to the air barrier — even the vapor-permeable variety — as an AVB. This habit underscores the trap that designers and constructors can fall into, thinking that all barriers are the same. Let me be clear: not all barriers are created equal. To avoid the trap, it may be best to consider the functions of each barrier, exclusive from one another, before combining barrier systems to gain design and construction efficiencies on the wall. While the different physical forms that barriers take — mechanically fastened sheets (wraps), sheet-applied membranes (SAs), fluid-applied membranes (FAs), boardstock (BS), and spray polyurethane foam (SPF) — may be obvious, their capabilities are often less clear. The inaccurate reference to vapor-permeable air barriers as AVBs notwithstanding, the ambiguity around barriers is particularly evident when it comes to air and water-resistive barriers (WRBs). Air barriers are not the same as WRBs. Consider this for a moment: air barriers are addressed in the International Energy Conservation Code (IECC), while vapor barriers and water-resistive barriers are addressed independent of one another in the International Building 22 |
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Code (IBC). These two different codes address functionally different barriers. Makes sense, doesn’t it? To state the obvious: air barriers stop — or, more precisely, retard — air. To achieve an acceptable level of whole-building air tightness, air barrier materials defined in the 2012 IECC sec. c402.4.1.2.1 as having an air permeance of ≤0.004 cfm/ft² @ 0.3-inch w.g. when tested per ASTM E2178 are integrated using accessory materials to create assemblies. These assemblies, per the IECC, shall have average air leakage not to exceed 0.04 cfm/ft² @ 0.3-inch w.g. when tested per ASTM E 2357, ASTM E 1677, or ASTM E 283. Another requirement of air barriers is continuity throughout the thermal envelope. Joining these assemblies together in a continuous, air-tight manner is essential and means that contractors don’t install an air barrier system. Rather, they create one using air barrier materials. The air barrier system, when properly constructed in the field, resists air flow in both directions and works to keep conditioned air inside the environmental separator and prevent outside, unconditioned air from leaking past it. The benefits of a properly designed and constructed air barrier system include greater occupant comfort, improved indoor air quality (IAQ), reduced HVAC cycling, and efficient (lower-cost) equipment performance, not to mention code compliance. In addition, because air is a highly effective transport mechanism for water vapor (but not the only mechanism), a second benefit can be realized: keeping airborne water vapor out of wall assemblies. This is a good
August 2016 • www.masoncontractors.org
RIGHT: The secondary benefit of air barriers is actually the primary role of the water-resistive barrier (WRB): keeping wall assemblies dry. The Voice of the Masonry Industry
www.masonrymagazine.com
August 2016
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AIR BARRIERS
thing because sometimes water vapor turns into liquid water as it cools to its dewpoint, affecting hygroscropic or water-sensitive building materials. For example, wood rots, steel rusts and gypsum crumbles. This secondary benefit of air barriers — keeping wall assemblies dry — while valuable indeed, is actually the primary role of another unique barrier: the water-resistive barrier (WRB). WRBs predate air barrier usage in U.S. construction codes by several decades. Consistent with the concept that all barriers are not created equal, it makes sense that IECC building code requirements for air barriers are different than IBC requirements for water-resistive barriers. For example, the IECC allows air barrier placement anywhere within the thermal envelope. In contrast, the IBC directs the installation of WRBs over the exterior face of sheathing. By keeping sheathing dry after water leaks past the primary cladding Most sheathing and cladding manufacturers require the use of codeapproved WRBs. It is also a requirement of the building code IBC Sec. 1404.2.
(and it will), the WRB, along with flashing, represents the second defense against water. The third defense against moisture remains the air barrier, which is designed to stop air that may be moisture-entrained and can potentially side-step the WRB, which may lack the inherent capacity to sufficiently retard moisture-laden air. Since WRBs are intended to stop water (not air), it should not be surprising that WRBs are tested to an entirely different set of standards than air barriers. Despite the WRB’s long-established role in keeping wall assemblies dry, sometimes an air or air/vapor barrier is mistaken for a water-resistive barrier and installed in its place. Installing an air barrier in place of a water-resistive barrier is a bad idea. I liken it to wearing flip-flops instead of boots on a construction site. Indeed, most manufacturers of sheathing and cladding – the wall assembly components most often in closest proximity to an installed air barrier — make little or no reference to air or vapor barriers but include explicit requirements for a water-resistive barrier in their framed construction details, installation guidelines, and warranty literature. Lest these manufacturers’ redundant pleas for a WRB are ignored, the IBC calls for the use of an “approved” water-resistive barrier over sheathing (ICC-IBC 1404.2). Suffice it to say, mistaking the air barrier as the WRB is ill advised. Just because a particular air barrier can be installed on a sheathed wall doesn’t 24 |
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August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
The Right Mix For over 90 years, MQ Essick plaster/mortar mixers have been the preferred choice of professional masonry contractors. The ergonomic PRO12 Series mixer uses a powerful hydraulic drive to mix through the toughest mix designs. The unique over center design discharges material into a 10 cubic foot, polyethylene MUDTUB which can transport up to 1,000 lbs. of mortar.
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AIR BARRIERS
mean it should be installed without proper qualification. This is a particularly salient point when it comes to fluid-applied air barriers. These systems have grown in popularity, and justifiably so, given their relatively low cost, ease of achieving high-quality installation, and timetested ability to avoid displacement (not just during the construction phase but over the service life of the building), among a host of other benefits. However, a fluid-applied air barrier product that is not specifically identified as a WRB by the manufacturer probably A fluid-applied air barrier has been easily applied to a CMU backup wall around protruding brick ties. has not been evaluated to perform as a WRB per ICC-IBC Sec. 1404.2. Because a fluid-applied material comes out of a bucket are limited to air control. To validate the performance or drum, it lacks brand and other identifiers once installed of fluid-applied barriers as water-resistive barriers, ICC on the wall. Likewise, unfortunately, it lacks any code comEvaluation Service has established Acceptance Criteria 212. pliance references on the wall. ICC-ES AC-212 for a Water-Resistive Coating to be used as a To realize the benefits of a fluid-applied air water-resistive Water-Resistive Barrier on Sheathed Construction. To pass the barrier (AWRB), the barrier must be capable of performing acceptance criteria is to pass the ICC-ES’s stringent thirdboth air and water control in an installed environment. The party testing, which transcends a manufacturer’s sample IECC requirements for air barrier materials and assemblies tests in a lab and includes structural, racking, restrained
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Designed by contractors, built for contractors.
August 2016 • www.masoncontractors.org
www.iqpowertools.com 888-274-7744 | Fax 888-428-4485
3/10/16 3:10 PM
The Voice of the Masonry Industry
Image courtesy of International Code Council.
A code report, also known as an ICC-ESR, provides evidence that the named barrier performs as a water-resistive barrier as called for in IBC 1404.2.
environmental conditioning, and water penetration testing of entire assemblies. This comprehensive test set addresses the recognized conditions observed on framed assemblies, which is precisely where WRBs have been called into use by building codes for decades. To be sure, the behavior of a framed wall is demonstrably different than that of a belowgrade or above-grade CMU wall when considering the cyclic and transverse loads imposed upon these assemblies. If a fluid-applied WRB system is capable of maintaining integrity and withstanding water penetration through all these tests, it becomes recognized as a WRB by ICC-ES through the issuance of a code-report — also known as an ICC-Evaluation Service Report (ICC-ESR). This report provides evidence to the public as well as code officials worldwide that the named barrier performs as a WRB as called for in IBC 1404.2. When selecting materials for sheathed wall projects, where WRBs are required per the building code, one can properly identify fluid-applied air barriers that are also WRBs by going directly to the qualifying body, the ICC Evaluation Service. On the ICC-ES website, www.icc-es.org , simply follow the link for evaluation reports and search by manufacturer or product to correctly ascertain whether a particular fluid-applied air barrier meets the ICC-ES requirements of a WRB. You can also visit www.enershield.basf.com to learn more about Enershield fluid-applied air/water-resistive barriers. This product is not only an IECC and Air Barrier Association of America (ABAA) qualified air barrier, but after extensive independent third-party evaluation, is also recognized as a water-resistive barrier by ICC Evaluation Service LLC and meets the WRB requirements in IBC-1404.2. yMAS Tom Gangl is market segment manager, BASF Corp., Construction Systems. He can be reached at tom.andrew. gangl@basf.com. www.masonrymagazine.com
August 2016
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An Interview with Russ Snow
2016 President of the Air Barrier Association of America By Karen D. Hickey
RUSS SNOW, BUILDING SCIENCE SPECIALIST FOR W. R. MEADOWS was recently elected president of the Air Barrier Association of America (ABAA). He took time away from his busy schedule to speak with Masonry Magazine about the ABAA and its relevance to the masonry industry.
Masonry Magazine (MM): Let’s start with an easy question. How does the ABAA differ from the National Air Barrier Association (NABA)? Russ Snow (RS): The main difference is that NABA is based in Canada, and ABAA is based in the U.S., although some ABAA members are based in Canada. The two groups share a lot of the same educational programs, as well as the Quality Assurance Program. There is definitely some overlap. MM: Why would a mason or mason contractor be interested in the ABAA or become a member? RS: The ABAA has done a number of demos and training classes across the U.S. for the masonry industry. We’ve done quite a bit of work with the International Masonry Institute (IMI), partnering with them to train mason contractors on installing air barriers. We also partner with them to conduct half-day and full day general education events. These programs are geared not only toward architects, but also general contractors and trade contractors. The most recent was a half-day “Air Barrier Education Event” on June 14 in Kansas City. The presentations covered the basic principles of heat, air and moisture flow and how they impact building performance; the challenges faced when installing air 28 |
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barrier systems; the basic requirements and design considerations of air barriers; and how the latest R&D is reducing the liability during the design, installation and life of these systems. MM: What do mason contractors need to know about air barriers? RS: Mason contractors need to ensure the continuity of the air barrier, so it’s important they have a full understanding of it. Oftentimes, the mason won’t be involved in the installation of the air barrier, so they may not understand the importance of its continuity, and they may start putting holes in it. The way masons have been working for decades becomes more complex because substrate preparation of the backup CMU has a significant impact on the air barrier installer. We do have a number of masonry contractors who have begun installing air barriers as a way to increase their potential scope of work. Some contractors want to “own the wall” — the backup wall, the air barrier, the insulation and the brick façade. All these elements are connected, so these contractors see it as a business opportunity. The ABAA is helping to train these individuals. The ABAA offers training and certification in 10 main air barrier materials. Masons tend to become certified in
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
Half-day ABAA/IMI air barrier workshop in Kansas City. INSET: Air barrier installer training for mason contractors, Chicago.
self-adhered, spray polyurethane foam, and fluid-applied air barriers. We’ve trained hundreds of masonry contractors over the years. ABAA also offers a Quality Assurance Program that can distinguish qualified mason contractors from the rest of the pack. MM: You’ve mentioned the Quality Assurance Program twice now. Tell us more about the program and its benefits. RS: The QAP, as we call it, aims to provide the highest level of confidence that the air barrier will be installed correctly and to the highest industry standards. ABAA’s QAP is modeled after the standards laid out in the ISO 9000 program. The air barrier assembly is often a non-maintainable component of the building enclosure. There is one chance to ensure correct installation prior to the application of other components in the building enclosure. Repair costs can be up to 60 times more expensive than ensuring proper installation the first time around. As such, the job must be done right the first time. Only contractors who have met ABAA’s mandatory quality assurance and training requirements are awarded accredited contractor status. These contractors have completed air barrier training. They are required to sign a licensing agreement to ensure professional conduct and are obligated to meet the requirements of the QAP on a continuous basis. The QAP is widely promoted by ABAA to architects, engineers, building envelope specialists, general contractors and owners. The intent of the program is to create a level playing field for contractors to compete on quality, rather than simply on price. www.masonrymagazine.com
An architect who specifies ABAA accredited contractors and the QAP reaps the following benefits: • Decrease in liability. • Assurance that the installation meets the specification requirements. • Providing the best for your client in an emerging industry. • Support from an impartial body. • Detailed records of each project from start to finish. • Assistance in project discrepancies. • Technical resources for architects. In addition, ABAA’s website provides an online search tool to locate the accredited ABAA contractor in your area, or a manufacturer or distributor of a specific product. The Air Barrier Association of America (ABAA) is a national, not-for-profit trade association for the building enclosure industry. Their membership includes manufacturers, architects, engineers, trade contractors, researchers, testing and audit agencies, consultants and building owners. Their mission is to promote the use and benefits of air barrier systems, educate the public about air barrier systems and develop a professional air barrier specialty trade and industry dedicated to the installation of effective air barrier systems in buildings on a nationwide scale. ABAA offers training, certification, product evaluations, contractor accreditation and site quality control audits. ABAA is active in the areas of research, education, standards development, building codes and technical resources for the air barrier industry. yMAS For more information, visit www.airbarrier.org. August 2016
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Masonry Grout Pumps and Delivery Systems:
Material Valve Designs By Todd Ferguson
GROUT PUMPS AND MATERIAL DELIVERY SYSTEMS ARE UTILIZED ON JOBSITES to fill concrete masonry units (CMUs), providing structural stability to masonry walls according to project specifications. These pumps and systems include material valves designed to allow the flow of grout from the equipment to the block. The most common material valve designs in the industry are the swing-tube, ball-check, rotor/stator and auger material delivery systems, each having their own advantages. Masonry grout pumps with swing-tube (S-tube) material valve designs offer the most compatible system for pumping fine or coarse grouts. The S-tube valve is a proven technology used on virtually every concrete pump truck (boom truck). In the masonry industry, contractors can take advantage of the same technology on a smaller scale, more suitable to their job size. The S-tube is an S-shaped steel pipe that allows continuous flow of material from two material cylinders in the pump. These two material cylinders contain a piston to push material through the cylinders. As one cylinder draws in material from the hopper, the other is loading material into the S-tube. The S-tube valve “swings” Material Valve – Swing-Tube several times per minute, alternating between each material cylinder. 30 |
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August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
Masonry Grout Pump on jobsite in Perth, Western Australia. Photo courtesy of Brunswick Sales
It has a full-flow internal fluidway. This allows the S-tube to work with material mix designs containing coarse aggregates. For example, masonry contractors wanting to use a 3,000 psi (207 bar) mix design containing aggregates up to 1/2-inch (12.5-mm) diameter would select a masonry grout pump with S-tube valve design to ensure those larger aggregates pass through the pump. Maximum aggregate sizes stated by the manufacturer may be as high as 3/4 inch (19 mm), although pumping these large aggregates may require a higher compressive strength mix design and large-diameter material delivery hoses. S-tube pumps are especially suited to pumping grout from ready-mix trucks because of their ability to keep pace with the yardage coming out of the truck. They can also be used with mortar mixers, although it is important to consider that a grout pump will almost always pump faster than the mixer can produce materials. Bottom line: the S-tube is the choice for high-production, continuous pumping of fine or coarse grouting materials — especially when sourced from ready-mix providers. Pumps with ball-valve or ball-check designs are also used for masonry grouting. These designs are used www.masonrymagazine.com
on mechanically driven and hydraulic grout pumps. The ball-valve design uses two balls made of either steel or hard plastic to create suction between the hopper and material cylinder in the pump. One ball is located below the material hopper, and the other at the discharge of the pump. The material cylinder contains a piston, which forces material from the hopper valve toward the discharge. This cylinder is constantly cycling forward and backward when the pump is switched on. As the cylinder cycles back during the retract stroke, the discharge ball is seated, sealing off material from flowing out of the discharge. At the same time, the hopper ball is “unseated,� allowing material to flow from the hopper into the cylinder. The opposite is true in the forward stroke: the hopper ball is seated, sealing off material from entering the cylinder from the hopper, and the discharge ball is unseated, allowing material to pass out the discharge into the grout hose. Ball-check pumps may include a single cylinder or may combine a main cylinder with a compensating cylinder to reduce the surge effect caused by the retracting and extending of the piston. Contractors wanting to use maximum aggregate sizes published by ball-check pump August 2016
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MIXERS, PUMPS AND DELIVERY SYSTEMS
m a nu f a c t u re r s m ay have to limit the overall aggregate percentage, while maximizing cement and compressive strength of the material, in order to make a pumpable mix for a ballcheck system. Ball-check pumps are generally very good at handling a highMaterial Valve – Ball Check slump material, cement slurry, mortar or high-strength grout containing 3/8-inch (9.5-mm) aggregates. Bottom line: the ball-check design is suited to medium to high production and works best with fine aggregate mix designs. Another design used for specific masonry projects, the rotor/stator pump, offers a solution for lower-production jobs. This design is also called a “worm pump” or “moyno,” based on the original U.S. manufacturer’s trade name. It includes a rotor made of alloy or stainless steel shaped like a drill bit. The rotor is placed inside a molded stator made of polyurethane, designed to encapsulate the rotor while leaving enough space for rotation. The rotor/stator design provides a continuous, smooth flow of material without
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Ball-check Valve Pump Discharge
Ball-check Valve Pump in Tennessee
pulsation. It can receive material from a hopper mounted over it. Normally, the hopper has a large cutout in the bottom called an “open throat,” which allows material to freely enter the rotor. Because of the small space between the rotor and stator and the susceptibility to wear, these designs have very strict limitations on aggregates. Most of these pumps are not able to handle over 1/8-inch (3-mm) particle sizes. Rotor/stator production rates are well below the average outputs of S-tube and ball-check pumps. Still, these pumps have their place for lower-production jobs, such as tuck pointing, mortar spray and other void-fill requiring a precise, smooth flow of material. Bottom line: rotor/stator designs can provide a continuous flow of grout without aggregates. Material delivery systems offer a simple yet efficient valve design. They consist of an auger that continuously feeds grout from a large-caMaterial Valve – Rotor-Stator pacity hopper to the dispensing hose. Delivery systems are elevated above the masonr y wall and use the force of gravity to move grout through the dispensing hose into the CMUs. These systems Rotor-Stator Pump essentially take the
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
EZG
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MIXERS, PUMPS AND DELIVERY SYSTEMS
Material Delivery System
Material Delivery System with Engine
place of manually pouring buckets of grout into the walls by offering a machine to automate the pouring of grout with an auger. The standard unit is powered by auxiliary hydraulics from a forklift, which is also used to lift it into position. The forklift operator controls the auger. It can be configured into an extended auger tube for higher vertical reach. Extending the auger tube reduces the maximum aggregate to 1/2 inch (12.5 mm), whereas the standard auger configuration is compatible with 3/4-inch (19-mm) aggregate grout mixes. The auger can be reversed to stop grout flow for an extended period of time and is easily removed for cleanup. Because they have to be elevated for use, material delivery systems are best suited for smaller batches of material from a mortar mixer versus larger loads from ready-mix trucks.
Material Valve – Auger System
Bottom line: the auger system is an option for masonry grouting with a forklift when overhead space is accessible and the size of the project is suited to mixing onsite.
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The GROUT-N-HOPPER features a remote-controlled valve at the hopper, eliminating heavy, uncontrollable hoses.
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August 2016 • www.masoncontractors.org
The WATT-R-TANK is a large capacity, heated water tank, eliminating the need to close in the mixing site.
563-552-2733 The Voice of the Masonry Industry
Masonry grout pumps for any job For over 60 years Airplaco has been the brand masons have trusted for quality equipment. When you pump with Airplaco you pump with confidence. Flexible financing options available; we’ll work with you to find a solution that fits your business. Contact us to talk with a representative or visit us online to watch our machines in action.
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MIXERS, PUMPS AND DELIVERY SYSTEMS
Product to Watch
Toro’s UltraMix Mortar Mixer Line Ma t e r i a l v a l ve d e s i g n s a r e available to suit the needs of every masonry contractor. Whether their priority is material specification, production rate, aggregate size, material source, flow characteristics or design simplicity, contractors can choose a material valve to match their grouting requirements. Contractors should also rely on manufacturers of grouting pumps and delivery systems to review grout specifications and recommend the most suitable grouting solution for the project. yMAS Todd Ferguson has more than a decade of experience in specifications for grouting equipment, accessories, materials and applications. He is international sales representative for Airplaco Equipment, a manufacturer of grout and shotcrete pumps. For more information, call (513) 321-2950 or visit www.airplaco.com.
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The new UltraMix lineup from Toro delivers the ultimate in mixing performance, thanks to an exclusive symmetrical drum and patented paddle configuration. The unique design boasts more paddle and drum contact with the mortar, and the Toro-exclusive paddle design moves mix horizontally, as well as in the circular motion. This ultimately maximizes productivity for busy masonry contractors by providing an ideal mixture while reducing mixing time. In addition to producing an outstanding mortar blend, the new UltraMix line features rugged and reliable components that are designed with durability in mind. The reinforced paddle rubber features two layers of woven fabric for added strength, minimizing tearing and increasing overall paddle life. Additionally, the drum boasts high-strength steel, which effectively resists pounding during mixing or transport. The UltraMix line is also equipped with solid steel dump handles, and a high-strength telescoping axle. This feature allows the wheels to adjust from a towing width to under 36 inches, allowing the unit to easily pass through a door opening. yMAS For more information, visit www.toro.com.
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
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Differences Between Rainscreen Walls and Cavity Walls By Steven Fechino
Rainscreen veneer terra cotta during installation.
RAINSCREEN WALLS HAVE HAD A FEW DIFFERENT DEFINITIONS OVER THE YEARS. Rainscreens can be designed with products and configurations that assist in creating both pressure-equalized and nonequalized or drained/back ventilated systems — all still in line with the correct definition, but resulting in some industry confusion. What Makes a Rainscreen? The term rainscreen originally referred to the outer shell of the façade, usually an aesthetically based material that functioned as a barrier to protect the building from weather or man-made elements. Weather, of course, is wind, rain, humidity, temperature and sunlight, whereas manmade elements can be anything that impacts the structure, such as sprinklers, surplus snow pushed against the structure (common in northern states), flying debris and noise. There are many other elements, but the point is that the rainscreen is a protective barrier. Its components are engineered to function as a complete system: the rainscreen material, the type of channel and clip arrangement used to fasten the rainscreen veneer, the dimension of the air gap, the three-dimensional drainage mesh, and the air barrier and flashings. Rainscreen, when defined as the façade material, is typically a terra cotta, precast, composite or metal panel, or even 38 |
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a very thin stone with lightweight structural backing. The lightweight material is a composite fastened independently to a framework that supports the façade to the substrate and creates the mounting attachment points for the façade material. Rainscreen façade material can be installed with a gasket-sealed, material-to-material joint (horizontal and vertical joints) or with open material-to-material joints (horizontal and vertical joints). The term pressure-equalized system has led some to believe that sealed walls will be drier than those that have open joints. In comparison to cavity wall construction, sealed walls are definitely the preferred choice to stand the test of time and performance, but a rainscreen wall is slightly different. Cavity Wall vs. Rainscreen Construction Masons are most familiar with cavity walls. While we have seen mass and composite walls, 99 percent of our veneer work has been in cavity wall construction. Cavity wall con-
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
Product to Watch
DEWALT Introduces the FLEXVOLT Battery System
struction is simply a veneer material, separated by an airspace, sometimes insulated, On June 21, 2016, DEWALT introduced its new and usually with an air and/or vapor barrier. FLEXVOLT system, featuring the world’s first batteries that Flashings usually round out the base of the automatically change voltage when a user changes tools. walls and at the masonry opening locations, The FLEXVOLT battery system gives users “the power of corded, the freedom of cordless.” extending from the substrate beyond the face The company hosted an invite-only event for the conof the veneer. In cavity walls, moisture that enstruction media at the Four Seasons Hotel in Baltimore, ters the cavity has two preferred paths to keep Md., to unveil this innovative product. Masonry Magazine the substrate dry: either it is moved by gravity was among the guests. The 6.0Ah battery will be available in the fall of 2016, to the flashing level before exiting the cavity, or and the 9.0Ah battery in early 2017. The batteries power it can become a vapor and evaporate through DEWALT’s brushless 60V MAX* and 120V MAX* FLEXVOLT tools. Batteries and tools are althe face of the veneer by means of weeps, soffit ready being pre-sold through various outlets. vents or (in the case of terra cotta veneers) the The key to the new batteries is their ability to switch between DEWALT tools. With patent-pending technology, FLEXVOLT batteries automatically change voltage depending on mortar joints. whether they’re being used in a 20V MAX* or 60V MAX* tool. Two FLEXVOLT batteries (of Cavity walls connect the exterior veneer the same amp hour) together power the new DEWALT 120V MAX* tools. In other words, to the substrate with wall ties that span high-power applications that previously required corded tools can now be tackled using across the cavity. The individual ties have FLEXVOLT cordless tools. Both the 6.0Ah and 9.0Ah FLEXVOLT batteries extend the runtime of existing DEWALT 20V many shapes and can be installed between MAX* tools. They also power five new 60V MAX* tools and two new 120V MAX* tools (with two courses of concrete masonry units (CMU) batteries). Among the new 60V MAX* FLEXVOLT brushless tools is a 7 1/4-inch circular saw. or attached directly to the substrate, which FLEXVOLT batteries are backward-compatible with most existing DEWALT 20V MAX* could create moisture contact directly with tools and chargers. The FLEXVOLT battery has more than3X the power than the DEWALT 18V NiCad. the substrate wall. Using hot-dipped galvaSeveral new 20V MAX* tools also operate off the FLEXVOLT system. These include a nized or stainless steel connectors will help portable power station and a Bluetooth LED area light. In addition to the tools, FLEXVOLT prevent corrosion because they will be a High-Efficiency Accessories are engineered to maximize runtime. likely path for water to follow; however, the For complete details, visit www.dewalt.com. principles of a well-functioning cavity airspace will control a majority of the surplus moisture. In the past, rainscreen was a general term, usually used to In comparison, the same basic principles exist for cavrefer to a façade material. However, the term now typically deity walls and pressure-equalized walls: we attempt to manfines the entire system of either hat channel, girt or rails, air age the water that enters the air gap between the substrate’s barrier or structurally fastened insulation systems where the protective weather barrier and the veneer or fastened veneer façade material is secured to a framework independently from material, and keep the inner and outer wythe drier, thereby the attachment to the substrate wall. The joints between the preventing such problems. individual units that comprise the façade are either sealed using So, what is the difference between most cavity walls and gaskets or left open. Open joints can often have a semi-sealed, a rainscreen wall? In many cases, the cavity of a cavity wall, three-dimensional mesh with a backer material placed against which is typically much larger than a rainscreen air gap, will the back of the façade if insulation is not present; this allows air deflect due to external atmospheric forces and material diand vapor to access the air gap. mensional changes. Thermal exposure will form negative When discussing open joints, we are not talking about a pressures within the cavity, possibly leading to vapor and head or bed joint that is 3/8 inch wide, left completely open. moisture penetration beyond the air barrier into the wall inWe are talking about a joint that can be configured several terior. In short, a cavity wall is not usually a rainscreen wall, ways. One of the most common is to use a slightly open ship and a rainscreen wall that has a small cavity (a.k.a. an air lap joint. The open joint is designed to allow only air into gap) is not typically referred to as a cavity wall. the air gap, and this happens when the material-to-material Pressure-equalized walls are the basis for one type of joint, whether horizontal or vertical, fits over the lower unit rainscreen wall. The open material-to-material joints found or adjacent unit, thus preventing the passage of wind-driven in many rainscreen systems will experience pressure equalrain. This will also work with the rainwater that runs down ization when the external wall pressures are applied to the the building because of gravitational forces. Due to the joint face of the wall and the open joints allow the air gap presin the façade material, water typically does not find its way sure to nearly equalize with the external pressure. It is not back up and into the wall through the ship lap joint. logical to believe that the pressures will ever be exactly the Another feature of rainscreens in pressure-equalized same. Equalization principles, or normal air movement, walls is the placement of limiters or dividers to create chanprevent pressures found in the cavity from becoming neganels within the air gap to compartmentalize air movement. tive. These negative pressures, if present, would force moisThis involves simply installing stainless steel, composite, ture into the substrate walls, gaps in electrical and plumbing rubber or foam strips that fit snugly in the air gap and are intersections, and areas that have exhibited displacement taller than they are wide to limit air movement to a localized (either large or very small) during or after construction. area within the wall. Pressures in the air gap (wall cavity) www.masonrymagazine.com
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MOISTURE MANAGEMENT
>>> CASE STUDY
MOISTURE MANAGEMENT will require less change in the center of the walls and can be dimensioned much larger than sections surrounding the perimeter of the wall, where the compartments would require smaller sections to achieve similar results. Here is a rule of thumb: moisture, air and water always move from high to low. For instance, wet material (high moisture content) moves to dry (low moisture Rainsceen veneer terra content); high vapor moves to cotta used alternatively to clad a column and ceiling of low vapor (from outside to inside structure. during the warmer months); and high temperatures move to low temperatures (outside to inside during the warmer months). With this in mind, it becomes easier to visualize rainscreens and the principles that make them function well in so many different climate zones. Air barriers and flashings are critical in rainscreen design because they are placed against the substrate and are the final defense for keeping things dry. Air barriers, when used in rainscreen systems, will be chosen with different criteria than a cavity wall, though they serve a similar function. The difference in performance is based on the pressure differentials between the air gap and the outside of the building. Air barriers must be durable, so that deflection or “pumping “does not occur and create negative pressures within the air gap. Flashing of the rainscreen wall, when designs require, would follow standard flashing procedure. The flashing should include a small drip edge — in many cases, smaller than the drip found in most cavity wall construction; flashing membrane, usually dark in color; and termination bars, sealed to the air barrier to mechanically support the flashing for the life of the building. Many rainscreen systems do not require a mortar collection device or individual weep, as the veneer is typically placed away from the substrate without mortar, allowing full drainage of the water that enters the air gap. One of the major differences of a rainscreen system versus a cavity wall system is that the layout of the veneer must be exact to keep the building lines horizontal. Shimming of the Z-girts or hat channel is sometimes required to keep a square, level and plumb façade. Having an exact layout from the beginning at all corners of the building will provide a big return for the installer. In cavity wall construction, the installation of brick and mortar allows for slight corrections to be made in order to make the proper bond. On the other hand, rainscreens do not typically offer the same compensation levels. Therefore, it is recommended to spend the extra time up front, before installation, using quality instruments to set your points. Once installation begins, repairs or unit replacement can usually be performed in the specific location by sliding and resetting the units. This is vastly different from repairing a wet-mortared brick veneer project, where stocking, sawing, cleaning and debris disposal become part of the repair. 40 |
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Drainage and Air Circulation Help Prolong the Life and Look of Austin Apartment Complex L o c a t e d i n A u s t i n , Te x a s , a new apartment complex offers luxury one- and two-bedroom apartments. Each of the 13 unique floor plans feature hardwood or stained concrete flooring, granite or quartz countertops, stainless steel appliances, spacious walk in closets, and a private balcony. Amenities include an athletic center, a swimming pool and an outdoor grilling area. For this particular apartment complex, the developer wanted to eliminate as much concern about Driwall Rainscreen 020-1, a moisture issues as possible. Mold drainage and ventilation mat and decay can ruin the profitability installed on the exterior walls of a project. With the increase in of construction, can be used building “tightness” for thermal behind a variety of exterior protection, moisture problems veneers, including stone, are on the rise, causing a greater stucco and fiber cement. need for hydrostatic pressure release and a ventilation method. A decision was made to incorporate Keene Building Products’ Driwall Rainscreen 020-1 to alleviate any future concerns related to moisture behind the variety of exterior veneers, which included stone, stucco and fiber cement. DriwalI Rainscreen 020-1 is a quarter-inch-thick drainage and ventilation mat used behind exterior wall systems. The entangled net drainage and ventilation mat eliminates incidental moisture penetrations and problems in siding applications. With the increase in energy efficiency in the building envelope, there is less potential for thermal leakage. By eliminating a ventilation method, siding applications have seen an increase in moisture issues. It was essential to have a means of drainage and circulation of air to help prolong the life and look of the stone, stucco and fiber cement used on this apartment complex. The full-wall DriwalI Rainscreen 020-1 product rolls over the weather-resistant barrier to separate it from the exterior veneers. The airspace that is provided assures that any moisture that penetrates the siding can drain to the exterior. Moisture and ventilation are essential to proper construction. This Austin, Texas, apartment complex is allowing the walls to breath and stay dry. yMAS
Rainscreen wall systems have been in our industry for a long time. They have stood the test of time, function as intended, offer particular aesthetics to a project and can be managed by many masons with little or no training. yMAS
August 2016 • www.masoncontractors.org
Steven Fechino is engineering and construction manager with Mortar Net Solutions, makers of TotalFlash and BlockFlash. For more information, call (800) 664-6638, or visit www.mortarnet.com.
The Voice of the Masonry Industry
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Managing Moisture in Masonry Wall Assemblies By Ted Winslow WHILE THE QUEST FOR INCREASED R-VALUES HAS LED TO DRAMATIC REDUCTIONS IN AIR MOVEMENT THROUGH BUILDING ASSEMBLIES, it has also reduced their ability to dry when they get wet. Inwall systems allow this moisture to dissipate while maintaining the desired degree of airtightness. One way to create moisture escape routes is through construction techniques. Another is through the use of products that employ advanced air/moisture barrier technology. The “Moisture Sandwich” if there’s no mechanism for it to dry quickly, problems like The intended consequence of the tight-envelope wood rot and mold can occur. construction techniques mandated by various building Capillary suction is a result of surface tension and adhecodes is significantly less air leakage. The unintended sive forces between water and the vertical plane of the wall. consequence is that moisture, which finds its way inside Moisture held there can be driven through tiny pores in the the wall cavity – and moisture will always find a way into weather-resistant barrier and permeable wall sheathing and wall cavities – can get trapped there, creating a “moisture into the wall’s interior by the heat of the sun — a phenomesandwich.” non known as solar or vapor drive. There are four primary physical mechanisms by which Masonry products like brick and cultured stone are moisture infiltration takes place: water flow, airborne moissometimes referred to as “reservoir” cladding because they ture flow, vapor diffusion and capillary suction. absorb and store moisture. As soon as this moisture is Water flow is the most basic of these mechanisms. As driven inside the wall and encounters a cold surface, it conrain or snow falls, gravity pulls it down a building’s exdenses, and the potential for mold growth and damage to terior, where improperly installed flashing can divert it wood framing increases the longer the area stays damp. into the building. Wind-driven rain can penetrate openHelping Moisture Escape ings in the exterior cladding at imperfect mortar joints, laps, utility and electrical cutouts, etc., and gain access to Exterior wall and roof systems are the first line a wall’s interior. of defense against rain, snow and subtler problems like Vapor diffusion occurs when water vapor flows through building materials due to differences in air pressure on either side of the wall. The flow direction is from the high-pressure side to the low-pressure side. The direction and intensity of this flow vary with season and geographic location. Higher temperatures inside a building increase vapor diffusion to the outside in cold climates, while the direction is reversed when outside temperatures are warm/humid and the inside of a building is cool and dry (due to air conditioning). Whichever the direction of the flow, moisMoisture will get trapped in the wall between the continuous extruded polystyrene ture can accumulate when this vapor coninsulation (XPS) foam board (on the exterior) and poly (on the interior), with no ability to denses on cold surfaces inside the wall, and dry. This can create a “moisture sandwich.” 42 |
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August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
condensation and vapor drive. To protect against the heavy moisture flows caused by precipitation, exterior finishes should be backed by a drainage plane, which redirects water that breaches the outside of the wall away from the building. Ventilating airflow – which enables dampness behind the exterior cladding to dry more quickly – can be facilitated by the use of rainscreen systems that create a capillary break, a space that disrupts the surface tension that holds water in place on a wall surface and allows it to drain out of the assembly. A 1-mm gap will facilitate drainage; bigger gaps may be called for to create ventilating airflow to promote drying in wetter climates. It’s also important to plan a moisture escape path for condensation and water vapor on the inside of the wall. Cold air contains less water than hot air, and diffusion will carry moisture from a warm place to a cold place. In order to allow the inside to dry, poly sheeting, vinyl wall coverings and low-perm paint should be replaced with more advanced vapor retarders. Choosing the Optimum Vapor Retarder In “mixed-climate” regions like most of North America, moisture travels into and through walls in different directions from winter to summer. Typical polyethylene vapor barriers do well at keeping moisture out of the wall cavity in the cold season, but can trap it there when summer heat reverses the direction of vapor drive – a problem that can
be exacerbated when airtight construction techniques and moisture-retaining reservoir cladding products are used. An ideal approach is to incorporate a material that can vary its vapor permeance. “Smart” vapor retarders do just that. These materials are specially engineered to accommodate the effects of seasonal weather changes on moisture flow by altering their physical structure in response to changes in relative humidity (RH). During winter, when RH is low, smart vapor retarders provide high resistance to vapor movement from the interior into the wall cavity. But when RH increases to 60 percent or higher, the material opens up, allowing water molecules to pass through and preventing moisture from condensing inside the wall. Conclusion Moisture issues require appropriate products and solutions based on climates, environmental conditions and building codes. Smart vapor retarders can be a particularly valuable component of wall systems in areas with mixed climates. Incorporating ventilation drying in a wall cavity would be another tactic to combat the damaging effects of moisture. The key is to make sure that moisture that gets into the wall system has a path to get out. yMAS Ted Winslow is product manager, Building Science, Systems & Technical Marketing for CertainTeed Insulation.
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www.masonrymagazine.com
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MOISTURE MANAGEMENT
By Mary-Grace Rosalin and Sarah Coull
Benefits of Silane-Siloxane Sealer for Older Brick Buildings A Vancouver television station, Channel M, is located in a stately brick building in the
heart of the city’s bustling Chinatown. The building was in poor condition when the station’s owners undertook major renovations before moving into the five-story, 3,400 m2 (37,000 ft2) structure. Internally, the transformation meant more than $1 million in renovations to create space for administration, production and a street-level studio. Externally, it meant removing nearly 20 years of city grime. “We chose Kryton’s Hydropel for this project,” says Mark Melim, operations manager at All West Cleaning Services. “We’ve worked with the product many times in the past, and we’ve always been pleased with the results.” Designed specifically for sealing brick, concrete and masonry, Hydropel is a penetrating silane-siloxane sealer that works by chemically reacting with silicaand alumina-based materials below the surface of the substrate. This reaction forms a long-lasting waterrepellent barrier that protects the surface from the elements and won’t crack, peel or fade with time. And since the finished application is virtually invisible, the natural beauty of this remarkable brick building will be visible for years to come.
Above: Located in Vancouver, B.C., Canada, the building which now houses Channel M required waterproofing against the damp weather of Canada’s West Coast.
Why Use a Penetrating Silane-Siloxane Sealer? Penetrating silane-siloxane sealers are composed of small and larger molecular structure that efficiently penetrates even a highly dense substrate such as brick, leaving a hydrophobic surface. Silane-siloxane bonds chemically to the pores inside and below the surface of brick and masonry substrates, keeping water from entering the brick. The penetration allows the substrate to maintain its natural texture, and the sealer will be almost undetectable on most concrete or brick surfaces. This type of penetrating sealer is highly effective in protecting structures from moisture, even in hightraffic, exposed areas. They are water based and contain minimal VOCs, which makes them an attractive option for contained areas. Due to their chemical composition and because they penetrate below the masonry surface, most penetrants are resistant to UV degradation. Most important, these types of sealers will not trap interior water vapor, as penetrating silane-siloxane sealers are 100 percent breathable.
Alternative Sealers Acrylics, silicone and epoxy coatings are some common alternatives for sealing concrete, brick and mortar in restoration projects. While these options do provide waterproofing protection, they also possess noteworthy drawbacks. Most of these alternative sealers have higher molecular structures, mostly non-penetrative, leaving a film on the substrate. While the film-forming products are effective in keeping the water from entering the brick, they face a challenge in keeping the substrate “breathable.” Acrylics perform well against UV damage, and can give the substrate a glossy, attractive finish. However, they have the tendency to darken the substrate, altering the aesthetics. Epoxies, meanwhile, have the tendency to “chalk” when subjected to UV light, thus limiting their application to interiors only. Also, while epoxies produce a durable, abrasionresistant finish and excellent water repellence, some products are impermeable and can trap moisture. Often these products do not provide a long-term solution, degrade in the presence of high traffic and/or UV rays, and contain harmful VOCs.
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Inset: Penetrating silane-siloxane sealers, when properly balanced, allow water to bead on top of the substrate.
What to Look for in a Penetrating SilaneSiloxane Sealer Check for the following three characteristics when choosing a penetrating silane-siloxane sealer: • Water based. Water-based penetrating silane-siloxane sealers typically have lower VOCs, can be readily applied, are non-flammable, and are easy to clean up when application is complete. • Low VOC content. Penetrating sealers can vary from high VOC (more than 400 grams per liter) to low VOC (less than 100 grams per liter). Low VOCs are more user and environmentally friendly and are not considered dangerous or harmful. • Water repellant. Water should visibly bead, approximately 90°, on the surface where the product is applied. Always be sure to perform a small test patch to account for proper coverage application, as the properties of different substrates vary widely. Ensure the solids content noted in the sealer is appropriate for the substrate to which it will be applied. Higher solid content works well for highly absorptive, porous surfaces, such as hollow concrete block. Most concrete surfaces tend to be denser, and using a sealer with a high solid content could lead to unwanted surface residue, as the sealer may not be able to soak in properly. yMAS
August 2016 • www.masoncontractors.org
Mary-Grace Rosalin is an R&D lab technician, and Sarah Coull is a technical writer, both for Kryton International Inc. For more information, visit www.kryton.com.
The Voice of the Masonry Industry
IDEAS IGNITE with the next generation of masonry The Museum at Prairiefire honors the region’s most prominent features — its prairie fire burns and rolling landscapes. Hear the vision behind the museum from its designers, and see how Echelon Masonry helped its creators achieve the seemingly impossible.
See the full story at EchelonMasonry.com/Inspiration
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Special Report
By Ken O’Neil
Masonry Finds Positive Indicators Pointing to Growth Oldcastle APG Invests in Future of Masonry DESPITE A SERIES OF CHALLENGES AND A SHADOW OF UNCERTAINTY ABOUT THE MASONRY SECTOR IN PAST YEARS, new technologies (including integrated wall systems), a higher level of aesthetics in manufactured stone veneers and a resurgence in the desire for mixed material looks, all bode well for the industry. Manufacturers are noting an optimistic uptick in masonry demand as well, validated by research group IBISWorld, which projects an annual growth rate of 5.8 percent by 2020, from $23 billion in 2015. The number of industry operators is expected to increase at an average annual rate of 3.8 percent to 49,788. This rising demand will also boost employment, which is forecast to increase at an average of 6.0 percent per year over the next four years to 197,084 workers.
Performance wall systems, like the InsulTech ICMU and EnduraMax, deliver innovative masonry solutions that expedite installation time, help meet code and expand the portfolio offering of masonry professionals.
Coupled with advancements in both production and performance of their products, masonry manufacturers such as Oldcastle APG are bullish on the industry, with reason. Masonry contracting — using brick, block and concrete — accounts for an estimated 68.4 percent of industry revenue, the highest revenue-generating service in the masonry profession.* While the masonry industry faces a number of daily challenges, such as sourcing new jobs, meeting deadlines, finding quality labor, reducing callbacks, and increased competition, there are promising solutions from dedicated partners like Oldcastle APG, who can keep them ahead of the rising demand for masonry materials that include wall systems, manufactured stone and advanced mortar formulations. The ability to embrace all of these solutions will help ensure the future of masonry. 46 |
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From retail and hospitality to senior living facilities, the demand for structures that blend in well with the community, as well as feel more like home, has increased. Buildings are also now warmer and less institutional, as facades of stone around the foundation, in entryways and foyers and even interiors serve as an economical accent. While solid block remains an economical way to build, the exteriors lend themselves to more thoughtful designs where masonry serves as the perfect accent. It’s also a growing trend for block construction in new buildings like hospitals, schools and retail to rely on high-performance wall systems to meet codes, save energy and manage moisture. These systems often feature a masonry unit as the final exterior layer. As part of a commitment to making substantial investments in these new products for a more sustainable industry, Oldcastle APG recently launched a stand-alone consolidated
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
masonry brand under the name Echelon Masonry. This multi-million-dollar endeavor delivers a first of its kind, integrated one-source solution backed by a national network of regional expertise. However, Oldcastle APG’s commitment to the masonry professional extends beyond brands and a broad array of products. The company has pledged substantial funding to The Masonry Foundation for use in the promotion and expansion of the industry. Although masonry has seen a dip in the skilled labor pool that installs it, masonry technology continues to evolve as means to solve this challenge. Oldcastle APG is betting on the future with its investment in innovative solutions to the issues dogging the masonry community and supporting organizations charged with the same goal. From funding training for a new labor force, to increasing efficiency on the jobsite with high-performance wall systems and innovative new products, Oldcastle APG will continue to demonstrate confidence in the future of the industry. It will take the willingness of manufacturers and the masonry community to solve these issues, not just talk about them. Architects make up another group of professionals betting on masonry, especially for customized projects with very specific material performance demands and a level of artistry, such as the Museum at Prairiefire in Overland, Kan. Unveiled last year and featured in the June 2016 issue of Masonry Magazine, the museum’s architect needed very specific custom colors not found in nature. Working closely with D&D Masonry, the architect was able to bring the concept of the region’s prairie fires, intentionally set for land management, to life with the look of flames and charred embers. Another example is the new Mesa Community College Performing Arts Center, featuring exposed masonry and raked stucco on metal stud framing on its 450-seat amphitheater, installed by M.A.G Construction, Gilbert, Ariz. The venue also relied on a masonry interior to achieve its acoustical quality. Hundreds of other examples of municipal, civic and religious structures all point to the demand for quality masonry. Of course, masonry will not be used for every building being constructed, but with a proven track record of tangible innovation; current trends in mixed materials; environmental needs for wall system solutions; and the strides in new manufactured masonry aesthetics, the sky is the limit on how the industry can charge ahead. Oldcastle APG is poised to become a powerful asset and partner for the masonry community and category. With the right investments, innovation and skill, we can all ensure the success of our livelihood for generations to come. We’d love to hear your thoughts on the future of masonry. Email us at echelonmasonry@oldcastle.com. yMAS Ken O’Neil is the executive vice president of sales, marketing and product development for Oldcastle APG, Atlanta, Ga.
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*Source: IBISWorld, a global market research firm, is based in New York City. www.masonrymagazine.com
August 2016
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T R O W E L
TECH
Jeremy Douglas
Mason contractors across the country face similar challenges when out in the field. With the help of Hohmann and Barnard’s director of technical services, Jeremy Douglas, Masonry delivers answers to some of your most technical, complicated questions. Q. I’ve always stuck rigid insulation board directly against a fluid-applied air barrier material while it’s still wet, so it sticks to the backup wall. I have a job where I’ve been told I can’t do that, but instead I have to use a special clip that slides over the anchor to hold the insulation in place. Wouldn’t it be better to adhere the insulation directly to the wall? A. Believe it or not, I’m asked this question almost every day due to the multitude of anchoring systems we see on our projects, and the need for maintaining energy performance. Let’s look at this from various perspectives. First, whether adhered or using an anchor clip, it is imperative that the insulation remain tight to the backup wall in order to maintain its intended R-value. It is suggested that a loosely laid extruded polystyrene insulation can lose between 15 and 20 percent of its R-value if an air gap of even 1/4–3/8 inch is left. With energy code requirements demanding higher performance from our walls, the requirement of a mechanical attachment or retaining clip is becoming more prevalent. Many anchors hold the insulation on their own or will have a retaining device, such as a large-diameter washer, integrated into the anchor itself. Other systems that don’t have this integrated piece can use a secondary retaining clip to secure the insulation prior to the brick installation, ensuring the insulation is and remains tight to the backup wall. This can be particularly useful on hook-and-eye-style 48 |
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anchorage systems, where even though the hook portion of the system may retain part of the insulation, construction tolerances may not keep it set tightly. This leads us more dire c tly to your question about adhering the insulation, or, more specifically, adhering Loosely laid insulation greatly reduces the R-value of the insulation. the insulation directly to a still-wet application of a fluidadhesive or sealant confirmed to applied air barrier system. While this be compatible with both the air has been done with some regularity in barrier system and the insulation. the past, it is not a great idea. Just like This material must be free of any various types of insulation, an air barrier solvents in order to work with most system can only guarantee a particular air barriers used today. In many cases, performance criteria at a specific a sealant or filler accessory for the air thickness. If we are embedding a sheet of barrier system is a good product to insulation into an uncured fluid-applied look at first, as they are usually fairly membrane, that required thickness will inert and unlikely to cause damage likely become depleted, and therefore the to the insulation. But, as mentioned, system becomes non-uniform in its rate confirm adhesion strength as well as of vapor permeance. Additionally, varied compatibility. thickness of the membrane will likely Ultimately, the important thing is diminish its ability to elongate during that the insulation panels are retained movement or span various small cracks tightly to the backup wall. How that or voids as we depend on it to do. will happens is really subject to field condialso likely create curing issues with many tions and specified anchors, though we types of air barriers, as they depend on must always maintain the integrity of air exposure for that process to advance. all adjacent systems, especially the air This does not mean that adhesion barrier. yMAS of the insulation to the barrier isn’t Jeremy Douglas, CSI, CCPR, has possible, but it means we may need nearly 20 years of experience in the masonry industry working with to reconsider how we achieve that. veneer systems. He is director of First, before we go about adhering the architectural services for Hohmann insulation panels, the air barrier must & Barnard and can be reached at be fully cured. From here, we might JeremyD@h-b.com. employ a thin bead of a construction
August 2016 • www.masoncontractors.org
The Voice of the Masonry Industry
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BUSINESS
BUILDING
By George Hedley
Motivate With Money I get asked about employee incentive and profit sharing programs by every contractor I coach. Construction business owners seem to be looking for the magic bullet that will motivate their people to work harder and produce more. Some hope that providing a financial inventive will improve their bottom line. Others hope more money will make people work harder or faster. And other business owners feel they should give away some of their profit to earn employee loyalty and respect. Whatever your decision regarding incentive compensation, the results will vary based on how your program is designed, implemented and managed. Which type of bonus works best? Incentive compensation, profit sharing or bonuses can be broken down into two types: • Arbitrary compensation bonuses are gifts based on what the boss feels is the right amount to pay for good work, reward for a positive attitude, or a thank-you for a job well done. It is often based on what the boss thinks is expected to keep employees happy. • Earned incentive compensation is based on a specific formula that rewards for actual results based on tasks, accomplishments or milestones you want to measure. Arbitrary compensation does not encourage employees to do their jobs faster or better. Often it’s expected as part of the overall employee compensation package because other 50 |
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companies do it or employees feel entitled to something at year-end. Arbitrary extra pay is no more than a gift of generosity from the employer, as it is not earned or required. It’s a nice gesture and will keep some employees from looking for jobs elsewhere until after they get their year-end bonus check. While gifts might build a small amount of employee loyalty, they won’t have much effect on finishing jobs faster, ahead of budget, or improving your bottom-line profit. Earned incentive compensation, based on achieving specific targets and measurable results, will produce positive bottom-line improvement from employees. If people know what’s expected, see regular weekly results, get feedback as to their ongoing performance, and are compensated for hitting their targets, they will hit them on a more regular basis. For example, salespeople who get paid on a sliding scale for increasing profit margins typically sell higher-price contracts than those with the same commission percentage, regardless of margins. Field tradesmen who are paid by the piece of work they install usually work faster than hourly workers who don’t have clear goals or production targets to shoot for. Field crew foremen who (1) know crew hour targets before they start work, (2) are responsible for hitting total crew hours, (3) receive weekly feedback, and (4) are compensated for achieving or improving crew hours, typically spend fewer crew hours than those who are told to try and do their best without any knowledge or feedback as to their results. And project managers who get
August 2016 • www.masoncontractors.org
Giving bonuses
and
incentives without targets is like playing without end
football zones
or scoreboards. a percentage of the gross or net profit on jobs they manage will push their foremen and superintendents harder, and generally try harder to save more money and negotiate harder with subcontractors and suppliers. Motivation without measurement doesn’t work! When employees don’t know the results expected and don’t have a reason to achieve them, why should they want to go the extra mile? When the boss sets clear milestones for managers and employees to hit, the company will make more money. For example, if you want an eight-month project finished in seven months, a generous bonus for the crew or superintendent will keep the team focused on achieving the goal and motivate them to hit the early completion target. Without a financial incentive, the target is a nice idea, but it is of no benefit to the crew to finish early or work harder. Years ago, my company’s workers’ compensation insurance rating was suffering due to field employee claims for careless jobsite injuries. We implemented a “Safety Bucks” program to motivate the crews to work closely together and The Voice of the Masonry Industry
watch out for unsafe workers or conditions. Each worker received $1 per day if the entire crew had no accidents. If anyone on the crew had an accident, no one received the safety bucks for the entire project. We paid this cash bonus quarterly. This measurable incentive system instantly focused everyone on all of our field crews to make safety a priority and make sure there were no unsafe conditions on jobsites. This program really worked, as it kept everyone focused on the target. Plus, I always enjoyed giving out bags of bucks to my field crews for no accidents!
As a professional construction BIZCOACH and popular industry speaker, George Hedley helps contractors increase profits, grow and get their companies to work! He is the best-selling author of “Get Your Construction Business to Grow & Profit!” available at his online bookstore at www. HardhatPresentations.com. E-mail
GH@HardhatPresentations.com to sign-up for his free e-newsletter, join a peer mastermind BIZGROUP, implement the BIZ-BUILDER BLUEPRINT, or get a discount for online courses at www. HardhatBizSchool.com. George Hedley HARDHAT Presentations, 800-851-8553
What can you measure to improve results? Examples of measurable clear targets include: • Total man-hours to complete a job. • Hours without an accident. • Project milestones completed by a certain date. • Customer referrals. • Project punch-list or close-out completion. • Improving your bid-hit ratio. • Customer satisfaction. • Project profit. • Project completion and sign-off by customer. • Change order profit. • Estimating accuracy. • New customers signed up. • Increase in average job size. Giving bonuses and incentives without targets is like playing football without end zones or scoreboards. By setting the results you want your employees to achieve and measuring results, you can design an incentive compensation program that will reap rewards. Making the most money you can is fun if you make it a measurable priority. Too often, managers get so busy they don’t have time to do the little things, like setting and tracking productivity to boost their bottom line. To g e t s t a r t e d , e m a i l G H @ HardhatPresentations.com get your free copy of the first chapter of George’s new book. yMAS www.masonrymagazine.com
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The Voice of the Masonry Industry
INDUSTRY
NEWS Acme Brick Names New VP and CEO, Receives Spirit of Enterprise Award Paul Morg an, a n 1 8 - ye a r ve t er an w ith Acme Brick Co, has been promoted to vice president and chief financial officer to replace the recently retired Judy Hunter. Paul Morgan Morgan will be responsible for the finance, tax, accounting, credit, payroll, payables, planning/ budgeting, and the administrative services functions for the Fort Worth (Texas) general office. After earning his C.P.A. from Abilene Christian University in 1980, Morgan joined Acme in 1997 as controller. In related news, The Fort Worth (Texas) Chamber of Commerce honored Acme Brick Co. with the Chairman’s Spirit of Enterprise Award at its annual meeting in June. The award, the Chamber’s highest honor, is given annually to a local organization that has demonstrated true commitment to local business growth and community development. Acme Brick has grown to become t h e n a t i o n’s l a r g e s t c o m p a ny producing brick and masonr yrelated products. Nationwide, it now has more than 60 sales locations and
www.masonrymagazine.com
Please submit your news and events to: karen@lionhrtpub.com
25 brick plants in the central and southeastern U.S. For the full history of Acme Brick Co., visit their website at www.brick.com.
W. R. MEADOWS’ Russ Snow Elected President of Air Barrier Association of America W. R. MEADOWS is proud to announce that its Building Science Specialist, Russ Snow, LEED AP, has been elected president of the Air Barrier Association of America (ABAA). In his role at W. R. MEADOWS, Snow develops specs and provides technical support on building enclosure and related products. He has 20 years of experience in the construction industry.
He completed his Building Science Program at the University of Toronto and has most recently attained the Building Science Specialist of Ontario designation. His experience includes building envelope, concrete restoration and products used in the treatment of concrete. Snow is a member of the ASTM E06, ASTM D08 and American Concrete Institute committees. He has also been involved with Construction Specifications Canada and is involved nationally with the CSC Educational Maintenance Task Team, including being the Chair of the Technical Representative Course Committee. ABAA is the national voice of the air barrier industry in America, and is News continued on page 54
Statesville Brick Hosts NCMCA Chapters
The North Carolina Masonry Contractors Association (NCMCA) president Bob Gates (left) was on hand to present Leland Eckard (second from right) with an NCMA 2015 Concrete Masonry Design Award of Excellence Award of Merit — Commercial Division for Master Masonry’s work on the new chapel at Lenoir-Rhyne University in Hickory, N.C. Also pictured: Ray Love (second from left), representing the National Concrete Masonry Association (NCMA) and Adams, an Oldcastle company; and Sonny Rankin (right) of Statesville Brick Co., which hosted the June meetings of the NCMCA Metrolina and Western Carolina Chapters at their Lake Norman conference center. Statesville Brick provided the brick for the Lenoir-Rhyne chapel project, which also won a “Brick in Architecture Gold Award” from the Brick Industry Association (BIA). Adams, an Oldcastle company, provided the concrete masonry units. yMAS
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INDUSTRY NEWS News continued from page 53
dedicated to the education of all parties involved in building construction. It also provides the industry with premier training to both designers and contractors, as well as providing a listing of materials and assemblies fully evaluated by the association. The ABAA ensures products’ standards and requirements are up to code as guidelines continue to change. Visit www.airbarrier.org for more information about ABAA.
2016 SkillsUSA National Masonry Competition Winners Announced The winners of the 2016 SkillsUSA national masonry competition were announced on June 24 at the 52nd annual SkillsUSA National Leadership and Skills Conference in Louisville, Ky. More than 6,000 career and technical education (CTE) secondary and post-secondary students competed in 100 different craft, technical and lead-
ership fields as part of the SkillsUSA Championships. 2016 marked the fourth year that NCCER has sponsored the national masonry competition. Masonry Technical Committee Chair Bill Kjorlien of Argos USA led the organization of this year’s event. In the masonry competition, high school winners included: Kelby Thornton of Concord, N.C. (gold); Benjamin Gibson of Ravenna, Ohio (silver); and Mack Odell of Fort Scott, Kan. (bronze). Post-secondary winners were Cody Harrison of Mount Pleasant, N.C. (gold); Cody Palmer of Media, Pa. (silver); and Trevor Huntley of Wellsville, N.Y. (bronze). Almost 50 contestants constructed projects composed of brick and block set on a concrete block base. Contestants received detailed drawings to which they were expected to closely adhere to while building their masonry projects. Winners were decided based on the combined results of a written exam and evaluation of the competition project by a panel of journey-level judges. Technical committees made up of industry representatives tested the skills needed for successful entry-level performance as a mason. Safety practices and procedures were also judged as a component of each contestant’s overall score. A national education team also assisted the masonry national technical committee. Members included Al Herndon, Florida Masonry Apprentice & Educational Foundation; Todd Larson, Wisconsin Indianhead Technical College; Richard McKnight; and Richard Nagy.
SkillsUSA 2016 masonry winners
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New Members The Mason Contractors Association of America (MCAA) is proud to welcome the following new members to the Association. The MCAA would like to thank them for joining their fellow mason contractors nationwide in helping to build a strong and successful masonry industry.
AUGUST 2016 Advanced Masonry Restoration, Inc. St. Paul, Minn. 651-766-8080 www.advancedmasonry.com Contractor Member
Allen Masonry & General Contracting, Inc. Seffner, Fla. 813-597-3289 www.allenmasonrygc.com Contractor Member
Block Shear Pittsburgh, Pa. 412-445-0703 www.blockshear.com Regional Associate Member Discover the many benefits your company is missing by not becoming a member of the MCAA. Call 800-536-2225 or visit www.masoncontractors.org/join to join the MCAA today. Together, we are stronger.
NCCER, which also sponsored the SkillsUSA carpentry competition for the seventh year in a row, is proud to recognize the winners of both competitions. Visit www.nccer.org or www. skillsusa.org to learn more.
News continued on page 59
The Voice of the Masonry Industry
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Education Calendar The following is the MCAA’s education calendar: August 3
September 14
October 19
The Impact of Rework on Construction and Some Practical Remedies
How to Prepare a Professional Masonry Submittal Package
How to Become an Equal Partner With the General Contractor
Location: Online Discipline: Ethics and Business Practices Credits: 1.5 Cost: Free
August 10
Basic Masonry Estimating Seminar Location: Online Discipline: Bidding Practices Credits: 4 Cost: $200 MCAA members, $300 non-members
Location: Online Discipline: Ethics and Business Practices
Location: Online Discipline: Ethics and Business Practices
Credits: 1 Cost: Free
Credits: 1.5 Cost: Free
September 15
October 26
Overview of Masonry Special Inspection, Codes and Standards (NCMCA Module 7)
DOL Regulations
Location: Greensboro, N.C. Discipline: Codes and Standards Credits: 6 Cost: $150
August 17
Full Contact Project Management Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
September 21
Multi-Employer Pension Withdrawal Liability and the Financial Risks to the Company and Your Assets Location: Online Discipline: Ethics and Business Practices
August 24
OSHA Investigations Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
Credits: 1 Cost: Free
September 28
How to Develop and Implement an Effective Quality Control Program
August 25
Blueprint Reading and Estimating Basics (NCMCA Module 6) Location: Greensboro, N.C. Discipline: General Credits: 4 Cost: $150
Location: Online Discipline: Codes and Standards Credits: 1.5 Cost: Free
October 5
Scaffold Plank Identification and Inspection Processes
August 31
Communication Between the Structural Engineer and Masonry Contractor Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
September 7
A Crystal Ball — Early Warning Signs of Construction Claims and Disputes
Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
November 2
Seismic Requirements of the Building Code Location: Online Discipline: Codes and Standards Credits: 1 Cost: Free
November 30
Harassment and Discrimination Basics Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
December 7
Masonry Past, Present and Future Location: Online Discipline: General Credits: 1 Cost: Free
Location: Online Discipline: Safety Credits: 1 Cost: Free
October 12
Assuring the Successful Continuation of Your Family Business Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free
Location: Online Discipline: Ethics and Business Practices Credits: 1.5 Cost: Free
Online classes available at: www.masoncontractors.org/live For more information and to view a complete list of all upcoming education, please visit www.masoncontractors.org/education 56 |
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2
0
1
6
2016 REGIONAL SCHEDULE
1. Missouri - Wednesday, June 15, St. Louis, MO Call: Craig Kasten (314) 565-4892. 2. Florida - Friday, Aug. 5, Panama City Beach, FL Call: Sam Prater (404) 513-6609 3. Ohio - Saturday, Aug. 13, Cincinnati, OH Call: Brian Tillett (513) 615-4986 4. Utah - Friday, Aug. 19, Salt Lake City, UT Call: Patrick McCarthy (801) 809-9506 5. Oregon - Wednesday, Sept. 7, Aurora, OR Call: Don Dodroe (206) 718-2632 6. Colorado - Thursday, Sept. 15, Littleton, CO Call: Riley Allen (303) 819-7459 7. Wisconsin - Thursday, Sept. 22, New Berlin, WI Call: Dan Neuens (414) 313-3210 8. Texas (Houston) - Thursday, Sept. 22, Houston, TX Call: Trey Harris (214) 728-4592 9. Quebec - Wednesday, Sept. 28, Montreal, QC Call: Alain Jette (514) 942-1270 10. Pennsylvania - Thursday, Sept. 29, Crum Lynne, PA Call: John Paci (610) 656-1608 11. Louisiana - Friday, Sept. 30, Metairie, LA Call: Larry Theobold (985) 519-7161 12. Ontario - Wednesday, Oct. 5, Waterloo, ON Call: Dean Garbutt (519) 240-7265 13. Oklahoma - Thursday, Oct. 6, Tulsa, OK Call: Carson Wann (918) 230-6124 14. Illinois - Thursday, Oct. 6, Chicago, IL Call: Matt Pfotenhauer (630) 707-8200 or Luke Kisielewski (630) 414-7618 15. Arizona - Thursday, Oct. 13, Phoenix, AZ Call: Dennis Berger (623) 764-8369 16. New Jersey - Thursday, Oct. 13, Clinton, NJ Call: John Mulvaney (973) 229-0201 17. Texas (Dallas) - Thursday, Oct. 20, Dallas, TX Call: Trey Harris (214) 728-4592 18. North Carolina - Thursday, Oct. 20, Charlotte, NC Call: Marty Schiraldi (305) 812-0687 19. Alberta - Friday, Oct. 21, Edmonton, AB Call: Denis Charbonneau (403) 966-4041
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A D V E R T O R I A L
Contractor Tip of the
Month | By Damian Lang
Incorporating Standard Operating Procedure You want to grow your business, right? But you’re already doing all that you can. You’re at capacity and running so hard that you can’t go any faster. Even the thought of doing more sales stresses you out. Also, adding more projects to your team would only create more chaos and confusion among them. Sound familiar? You’re not alone. I often hear the exact same thing from managers seeking advice on growing their construction companies. My suggestion is simple and crucial. Your company is most likely lacking the right standard operating procedure (SOP). For most construction companies, I find that the SOP is more like the SOC: standard operating confusion — confusion about tasks, processes and teamwork. The company operates day in and day out fighting the same fires they fought the day before, as if every day were the first day on the job. Jason Allman with Allman Brothers Masonry recently joined me on the back patio of my home. It’s a welcoming spot overlooking trees, ponds, water fountains and a few golf holes I’ve developed. Not surprisingly, not far into the evening, our conversation turned to business. Not because it was on any agenda, but because we live it and love it. Jason grew up in the masonry business as a laborer and bricklayer and is now a project manager and estimator. Though he has worked for years in the business, he said the means and methods of doing construction work still have him scratching his head. “Sometimes it seems like we’re operating in a state of confusion,” he said. “Bricklayers will put a 2-inch piece next to an opening instead of a half and a 6-inch piece; some will lay brick going backward instead of forward; and the laborers seem to set the scaffold differently from one day to the next.” Jason, like all of us, wanted to know how to build a well-oiled operation. “How do you get to the point of focusing on growth when you are constantly
managing the operation?” he asked. I told Jason I believe every construction company should set up SOPs so there is a system in place that seldom fails. We all know one company — recognized by the golden arches — that has mastered SOPs. Just look at their fish sandwich, for example. Whether I order one in Ohio or Oregon, I know it will always be the same, with just a little too much tartar sauce for my taste. In some ways disappointing (because it’s an otherwise satisfying lunch), the restaurant’s SOP requires every store to put the same amount of tartar sauce on the sandwich. No doubt this procedure caters to the majority of McDonald’s customers. When Jason asked what possessed us to put SOPs in place, I explained that we learned the hard way. Nearly 25 years ago, one of our crews left a brace off the outside of a conventional scaffolding setup so they could more easily access the scaffolding. At about 30 feet high (and fully loaded with brick), the scaffolding collapsed while the crew was eating lunch. If the collapse would have happened before or after lunch, workers would most likely have been severely injured, or worse. We were lucky. Although the collapse was costly, it was a hugely valuable mistake. Worried that a scaffolding collapse could happen again, I visited other jobsites and found that, at times, laborers would stack scaffolds five high/ two deep with brick, or four high/two deep with block while attempting to get ahead of the bricklayers before they got on scaffolding, not considering the potential danger of the extra weight. We immediately developed the following SOPs for all jobsites: • No scaffolding is to be set without a brace on both the inside and outside, regardless of the situation. • Brick is to be stacked on scaffold no more than three high and two deep.
•
Block is to be stacked on scaffold no more than two high with one standing behind the two.
This SOP ensures that scaffolding on all jobsites will be secure and not overloaded by laborers. The standard (among many others) was developed, documented and published, and must be followed by every employee. If you find yourself frustrated on a daily basis about the way things are being done at your company, you need to develop SOPs that become part of your culture. They should be documented and delivered to your team as part of a field manual. This manual clearly defines what is expected of the crew, both individually and as a team. The SOPs should be communicated to all field employees at regular (no less than quarterly) meetings, so everyone understands the ways things are done at your company. Let’s face it. It’s hard to be frustrated with a fish sandwich when you know exactly how much tartar sauce will be added before you order it. It’s your job to make sure your team knows how much tartar sauce you expect to be on the fish sandwich — before they make it. Damian Lang owns and operates several companies in Ohio. He is the inventor of the Grout HogGrout Delivery System, Mud Hog mortar mixers, Hog Leg wallbracing system, and several other labor-saving devices used in the construction industry. He is the author of the book called “RACE— Rewarding And Challenging Employees for Profits in Masonry.” He writes for Masonry Magazine each month and consults with many of the leading contractors in the country.
All rights reserved, © 2016 Damian Lang, President of Lang Masonry Contractors, Inc., and EZ Grout Corp.
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INDEX TO
INDUSTRY NEWS News continued from page 54
Jan Boyer Honored as a Woman of Influence 2016 by Central Penn Business Journal
Janet L. Boyer, executive director of both the Pennsylvania Concrete Masonry Association and the Cast Stone Institute, was recently honored by the Central Penn Janet L. Boyer Business Journal as a 2016 Woman of Influence. The Women of Influence awards were bestowed on Friday, June 24, 2016, at the Hilton Harrisburg, Harrisburg, Pa. Founded in 2010, the Women of Influence program is a regional effort by the Central Penn Business Journal (CPBJ) to find and recognize female leaders who have a significant positive impact on the region’s businesses and communities. In its seventh year, the program is considered a true honor to those who are nominated and selected. Nominators were asked to complete a cover sheet with basic contact information and to submit a narrative describing the nominee’s career accomplishments, leadership, vision, community service and mentoring activities. Judges were asked to read, review and score each of the nomination areas to find the most well-rounded, highest-scoring women. Boyer has a bachelor’s degree in education from the Indiana University of Pennsylvania. Her affiliations include serving on the board of The Masonry Society, as board secretary for the Masonry Alliance for Codes & Standards, on the Foundation Review Committee and state alliance member of the National Concrete Masonry Association, and much more. She says the best part of her job is “working with people who are passionate about creating beautiful, enduring structures and hardscapes.” When asked what advice she wished to pass along, Boyer said, “Owning a business is very rewarding, but it also takes time and dedication. In order to be successful, there is no such thing as an eight-hour day. You also must be a good communicator with clients and others to maintain business relationships.” yMAS www.masonrymagazine.com
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Get FREE INFORMATION from these advertisers now. You’re busy, but you need to find out about this product. We’ve made it fast, easy and convenient to request FREE information about any product or service in this issue. To request information online, go to: www.masonrymagazine.com. Click on ‘FREE Product Information’ (Right top corner) then… 1. Select the issue of the magazine you are reading 2. Check the box next to the advertiser you are interested in 3. Provide your name, address and business information, and click submit. Not close to your computer? Request information by phone. Dial toll free 888-303-5639, Ext.230. Follow the voice guidelines to request FREE information. In a hurry, and you don’t want to wait? We have provided the advertiser’s website and phone # for your convenience. You can call direct for information on the products and services you have been reading about in this issue. Don’t forget to tell them you saw their ad in MASONRY Magazine.
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C O V E R
PROFILE District Performing Arts Center, Placentia, Calif. Acknowldegements 2015 Concrete Masonry Design Awards of Excellence — Award of Merit Commercial
Mason Contractor Frazier Masonry Corp., Lancaster, Calif.
Architect SVA Architects, Inc., Santa Ana, Calif.
Photography NW Architectural Photography
Details The District Performing Arts Center, located on the El Dorado High School campus in Placentia, Calif., is a music, dance and theater center. Students throughout the Placentia-Yorba Linda Unified School District interested in the performing arts have access to the facility. Designed as a multi-use concert hall and theater, the arts center has a stage large enough for more than 120 student performers and seating for 635 spectators. Numerous design workshops were held with program coordinators from the high school and from the larger school district in the early design stages. The objective was to produce a design flexible enough to accommodate the school district’s diverse performance venue needs. The Center was built chiefly with concrete masonry because the block helped accomplish the design vision for the facility:
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that the building materials both harmonize with the existing buildings on campus and also reflect the essence of the musical performances that take place within, all in a cost-effective manner. SVA Architects, Inc., set the standard for future campus development by tapping into smart building technologies. “To that end, concrete masonry was one of the primary design aesthetics of the building, and the outcome exceeded the goals of the school district and community,” said Robert Simons, AIA, president and partner of SVA Architects. Concrete masonry units are affordable, durable and sustainable, according to Simons. By integrating them into the building design, he was able to provide enough thermal mass to moderate the facility’s temperature, resulting in reduced energy usage and increased
August 2016 • www.masoncontractors.org
savings in maintenance costs over the life of the building. California is considered a high seismic region and higher standards are required for public school facilities. The center was designed with structural steel roof framing and CMU shear wall to resist high seismic lateral forces. Moreover, “concrete masonry comes in several forms; it can be a very flexible material when color and texture are used creatively,” said Simons. Along with a series of screen panels that wrap around the exterior, the design team used various types of concrete masonry units and projecting block patterns to create a subtle, yet dynamic façade. The new Performing Arts Center is a versatile and attractive, yet a truly economical, venue for the performing arts and sets the standard for future campus development using concrete masonry. yMAS The Voice of the Masonry Industry
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