Walls & Ceilings September 2011

I N S U L A T I O N

I S S U E

Solve Your Acoustics Problem With

One Word Turn to page 13 for more info

September 2011 | Volume 74, Issue 9 | The Voice of the Industry Since 1938™ | www.wconline.com

New York Insulated Upper West Side Story | Bob Drury Retires

WC08114CERTCEIL.indd 1

7/21/11 3:13 PM

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

1/2” version now available for residential applications.

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

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

The contractor’s new choice.

SCB

SSB

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

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©2011 Simpson

Strong-Tie Company Inc. CFSCWC11-C

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VO L U M E 7 4 N U M B E R 9

columns 06

Up Front by Mark Fowler

50

Finish Line by Robert Thomas

52

Straight Green

Trade News

14

Product Focus

57

Classified Marketplace

58

Advertiser Directory

New York Insulated

22 Jolly Green and Giant/ICF-SIP Special Section University of Ontario residence hall on track to being one of the biggest LEED buildings in the Great White North.

26 Everything Old is New Again Dry, dense-pack cellulose is used to insulate a grand old home in a very new way.

34 Moisture Management of Below-Grade Construction Basements

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September 2011 | Volume 74, Issue 9 | The Voice of the Industry Since 1938™ | www.wconline.com

Hybrid insulation systems provide cost-effective mix of excellent air, thermal and moisture-control performance.

Spray polyurethane foam is a viable alternative when conducting weatherization projects.

departments

I S S U E

16 Insulation Systems Engineered Right

30 Fitting Foam into Weatherization Retrofits

by Chris Dixon

I N S U L A T I O N

features

september

on the cover o D Dense-pack cellulose insulation was used in in tthis 4,000 square foot hhome in Southampton, LLong Island, N.Y.

Upper West Side Story | Bob Drury Retires

Keeping foundations dry is crucial to any building’s long life. Better waterproofing isn’t enough to do the job, sound construction practices are needed to keep water out and a structure sound for years to come.

42 Time of His Life Bob Drury discusses his almost 40-year career as executive director for the NWCB.

46 Forward, Into the Past A New York contractor uses fine detail plaster work and an artist’s approach to paint to restore an apartment building on Manhattan’s Upper West Side.

54 New Product Buzz Guide

The official publication of CLAPCA, FWCCA, and NWCB.

ON THE WEB www.wconline.com

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

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| Walls & Ceilings | September 2011

Breaking News W&C Blogs Web-only Features Special Sections W&C Architect

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

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

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

INSTALLATION

SYSTEMS Between us, ideas become reality™

FA S T E R . E A S I E R . B E T T E R . armstrong.com/transitions9wc

1 877 ARMSTRONG

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

up

FRONT BY MARK FOWLER

Too Good to be

True? Several months ago, I wrote a column entitled “Stupid Prices.” The theme of the column was the inevitable price dropping in recessionary times, sometimes to ridiculous levels. The bid prices can be so low, it is simply “stupid” low. This becomes most apparent on public works projects where a prevailing wage rate is set and mandated by law. How can bidders bid so low on a project where the government has mandated a wage? Contractors know the established wage that must be paid, and materials are not that difficult to calculate for a project, so prices should be all in the same ballpark. Superior supervision and lower overhead can save money in the bid process, but some of these bids are so low that the bidder is either completely unqualified or must be planning to cheat to bring the project in at this extreme low number.

EVERYBODY KNOWS IT I got a resounding thumbs-up from the subcontracting community on the column and even several requests the editorial be re-printed in other trade publications. I had a subcontractor call me to share a story about a client who was typically loyal, but was entertaining a ridiculously low bid. The general contractor called his subcontractor and informed him he felt compelled to use this low bid, “I just can’t pass it up” he told his subcontractor. The subcontractor gave the general contractor the “Stupid Prices” column to read and asked him consider all the ramifications of using this super-low bid.

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| Walls & Ceilings | September 2011

Consider he did, and after a few days he called his loyal subcontractor and decided to throw out the stupid low bid and stay with his qualified subcontractor. That phone call marked a good day for me, for him and his customer—he just may never know just how good. The disasters that are typically left in the wake of these stupid prices are unpaid bills, construction defects and a mountain of unpaid debt and paper work to fix the mistakes. General contractors, building owners and even suppliers may believe they are not affected by the stupid price, but we all pay for it in the long run. I recently read a news story that illustrated the full ramifications of a stupid low bid and the parties who pretend they do not know or “can’t pass it up” and now probably wish they did.

YOU’LL PAY EVENTUALLY A framing contractor in California has been ordered to pay $1.3 million and fined $200,000 stemming from a scheme to systematically and willfully fail to pay his employees the mandated state set prevailing wage. The University of California Davis housing project was investigated by the Department of Industrial Relations and California Labor Commissioner Angela Bradstreet believed the framing contractor intentionally

underpaid its workers. The rest of u the t story (and this should be a wakeup u call to people who knowingly accept super low bids) is that addia tional fine assessments were made t on o the general contractor and the material supplier. m I suspect the qualified subcontractors who bid the project using t the t correct rate with no intention of cheating knew the awarded contracc tors bid was a stupid price. What t may be a surprise to many people is that additional parties are now being fined.

EVERYONE PAYS What the story failed to address is the money the state must be spending to investigate and prosecute these cheaters. Who pays those state investigators? We do, the taxpayers. While the state may claim the assessed fines will offset much of the investigating costs, the likelihood of the framing contractor paying the fines is pretty low. He is more likely to appeal the charges, drag it out for years, run up more tax payer expense and then ultimately either settle for pennies on the dollar or file bankruptcy. We all pay for that stupid low bid in the long run. Is it any wonder why state budgets are bankrupt? I don’t blame the state. The labor department is doing their job to the best of their ability. What about checking the bids and verify the low bidder is qualified and is submitting a reasonable bid? The lowest bidder may have looked like the best deal at first, but what about at the end of the day? Someone needs to inform these owners that future construction defects may appear. Underpaid workers forced to work overtime are far more likely not to be well trained, fail to understand code compliance or simply skip important life/safety steps in construction. The end result could be that we taxpayers may be paying for that stupid price for decades to come. W&C

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EDITORIAL ADVISORY BOARD

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

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

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© 2010 CertainTeed Corporation

TM

The only gypsum board that clears the air. Doesn’t that feel better? Indoor air contains many pollutants and VOLATILEORGANICCOMPOUNDS6/# S  4HE6/# SAREFOUNDINFURNITURE CARPETS cleaning materials, and many other everyday items. With the growing awareness of the importance of indoor air quality, particularly in hospitals, schools, offices and residences, it’s time to clear the air.

AirRenew™ is the only gypsum board that actively improves air quality. s0ERMANENTLYREMOVES6/# S by converting them into safe, inert compounds. s!BSORBS6/# SFORUPTOYEARS even after multiple renovations, based on tests and analysis. s2ECYCLABLEANDWORKSWITHMOST paint and wallpaper. s0ROVIDESENHANCEDMOISTURE and mold resistance using M2Tech® technology.

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

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

NOVEMBER

ARMSTRONG USGBC-APPROVED COURSE AVAILABLE ONLINE

RED AND NATIONAL GYPSUM PARTNER FOR HEAT AND POWER PROJECT

Armstrong Ceiling & Wall Systems’ “Sustainable Ceiling Systems” is a new USGBC-approved course available online. To access “Sustainable Ceiling Systems,” visit www.usgbc. org/coursecatalog. The new addition to the USGBC catalog of courses not only addresses the contribution of acoustical ceiling systems to energy performance, indoor environmental quality, and occupant productivity but also the application of those concepts on projects. Participants will also learn how to evaluate green interior finishing products to assist their clients in their environmental efforts, and how ceiling systems can contribute to as many as 13 LEED credits. At the conclusion of the course, participants will be able to specify and apply different types of ceiling systems to maximize their impact on building design, energy efficiency and sustainability. Completion of the course qualifies for one continuing education hour toward the Green Building Certification Institute’s Credential Maintenance Program. The course is also approved as a continuing education unit by the American Institute of Architects and Interior Design Continuing Education Council.

Recycled Energy Development and National Gypsum have joined for a combined heat and power project at the manufacturer’s Burlington, N.J. facility. Supported by the State of New Jersey, the project will produce approximately 3.4 megawatts of clean electricity and deliver more than 210,000 MM Btu of thermal energy, resulting in an overall efficiency of greater than 90 percent. RED’s combined heat and power system will provide clean power and thermal energy to National’s wallboard production facility. The transformational CHP project will reduce the company’s energy intensity and greenhouse gas emissions and serve as a model for energy efficiency and emission reductions at energy intensive industrial facilities throughout the United States. RED received a $1.36 million grant from the state to support the CHP project. Funding was made available through the Clean Energy Solutions ARRA CHP Program, a grant program supported by the American Recovery and Reinvestment Act of 2009 and jointly developed by the New Jersey Economic Development Authority and the New Jersey Board of Public Utilities.

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

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| Walls & Ceilings | September 2011

PEOPLE BASF Wall Systems Southeast District Sales Manager, Jim Doyle, has been elected the new president of the Florida Wall & Ceiling Contractors Association by its Board of Directors. GZA GeoEnvironmental Inc. has named Amy Doherty senior project manager at the company’s Manchester, N.H., office. ITW Muller expands its sales team with the appointment of Rob Payne to industry manager.

Doherty

Johns Manville announced that Fred Stephan has assumed the role of vice president and general manager for the company’s Insulation Systems business. Payne

U.S.A.

PRODUCTIVITY:

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

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

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TRADENEWS Grants provided through the program were to be used for CHP facility installation and upgrade projects in New Jersey. The closing of the competitive solicitation was in October 2010.

TSN RECEIVES ISO 9001: 2008 CERTIFICATION The Steel Network has announced that its manufacturing facility in Durham, N.C., has successfully completed the ISO 9001:2008 cer-

tification for its quality management system effective in July. The scope of registration includes the design, manufacture and assembly of steel members, connectors and pre-engineered systems for use in load bearing and non-load bearing cold-formed steel construction. The certificate was awarded by NSF International Strategic Registrations Ltd., an ANSI-ASQ National Accreditation Board accredited registrar.

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“The ISO 9001:2008 certification is a testament to TSN’s dedication to provide the finest products in the light steel framing industry. It is through this quality management process that TSN delivers the most innovative engineered products in the industry providing cost savings while improving the safety of structures.” said TSN CEO Edward di Girolamo, P.E. This certification is a significant event within the light gauge steel manufacturing industry, as TSN is the first manufacturer of light gauge steel studs and connectors to achieve ISO 9001:2008 certification for its quality management system.

Aegis Metal Framing has launched a redesigned its Web site www. aegismetalframing.com. The site has been reconfigured based on analytical data detailing Web user activity over the course of two years. This user activity has helped pinpoint the most relevant and frequently accessed information for engineers, contractors and architects, including: • Spec Creator: an interactive tool to assist specifying cold formed steel trusses • Green building and LEED certification • Extensive construction detail libraries • Project case studies W&C

Solve Your Acoustics Problem

With One Word Environmental Acoustics

87 hums from phones, not exactly in silent mode

+

150 squeaks as 150 students get comfortable

+

207 periodic click-clicks waiting for class to end

=

Design Smarter Environments with Adagio® Ceilings. Add up all the distracting noise in the typical college classroom. Factor in the proven harmful effects noise has on student comprehension levels. Your answer is Adagio Ceilings Systems from CertainTeed. Nobody takes environmental acoustics more seriously. Adagio has a NRC value of 0.80 and a CAC value of 42, the best in the industry. So for those spaces where being able to hear every word is essential, it’s Adagio.

You’re not just solving a design problem. You’re helping teachers teach and students learn.

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product

FOCUS

on

Software and Web Services Single-member sizing software ILEVEL Forte 2011 software is a free, single-member sizing tool for vertical and horizontal framing members, including freestanding posts, studs, columns embedded in wall systems, beams, joists and headers. The software sizes dimension lumber and engineered wood products and accounts for seismic and wind loads. If you read this article, please circle number 173.

BIM modeling CERTAINTEED GYPSUM The company has introduced BIM objects for building, design and construction professionals’ use in project design, specification and scheduling. The objects are available through Reed Construction Data’s proprietary SmartBIM Library and include details and systems on the company’s gypsum and sheathing boards. Providing Autodesk Revit users with access to manufacturerspecific systems in context makes it easier for design professionals to streamline project specification and workflow. This offering provides architects, contractors, builders and dealers with one partner to provide service and support for commercial and residential building projects.

ADVANCED ESTIMATING

The Digital Takeoff Table 2 solution integrates with the latest version of On-Screen Takeoff to generate digital construction takeoffs. The product is a hands-on digital takeoff solution that furthers the technology developed for the original Digital Takeoff Table solution (released by On Center in 2009). Designed to increase takeoff speed and accuracy, the solution includes a 21.3-inch write-on monitor, a patented cordless grip pen, 16 customizable ExpressKeys that give users access to On-Screen Takeoff-specifi c shortcuts and grip pen calibration to better simulate writing with a pencil on paper plans. The solution includes all hardware, as well as the Takeoff integration file. On-Screen Takeoff licenses are sold separately.

The EDGE estimating software application now includes USG Ceilings products. The company also issued seven new Seismic Technical Guides to help building professionals better understand and comply with seismic ceiling design requirements outlined in the International Building Code. Estimators can easily select from a library of pre-loaded USG ceilings products which make estimating and procurement more accurate and efficient. Enhanced system features further simplify the estimating process for complex takeoffs. So when an estimator selects “seismic installation,” any additional components and labor necessary to install in accordance with the code are included in the estimate automatically. Professionals can also improve their dealer communications by generating detailed quote requests or purchase orders that list exact item descriptions with carton quantities.

If you read this article, please circle number 175.

If you read this article, please circle number 176.

If you read this article, please circle number 174.

Hands-on digital takeoff solution ON CENTER SOFTWARE/WACOM

Damage and estimate costs application XACTWARE XactScope is a sleek, intuitive application that contractors and insurers can use to scope room dimensions, search line items and estimate property losses from their smart phones. Users can then send the information to their desktop version of Xactimate, the company’s estimation software, to be included with assignments or to supplement new projects. Users can download XactScope

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Seismic guides and ceiling products application

| Walls & Ceilings | September 2011

for free at the BlackBerry application store and it will be available on the iPhone and other personal devices. The product is compatible with the latest version of Xactimate 27.1 and is bundled into Xactimate Professional at no additional cost. Once the application is installed, users can register it on Xactimate so the two platforms can communicate with each other. Users can then download price lists and scope losses anytime, anywhere. If you read this article, please circle number 177.

We’re Redefining FRP

FRP Wall Panels Manufactured with 20% Post-Industrial Recycled Content

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Insulation SYSTEMS ENGINEERED RIGHT O

ne of the key components of sustainable homes and buildings is a thermally efficient and dry building envelope that minimizes the leakage of air through the home. Air leaks in walls and attics decrease occupant comfort by permitting the entrance of cold or hot air, depending on the season. They can also contribute to low indoor air qualit y by allowing in dust and airborne pollutants, as well as water vapor, which can cause mold growth if trapped in wall cavities for too long. In addition, air leakage leads to higher utility bills. According to the U.S. Department of Energy, the average American household spends approx imately $1, 30 0 a year on energy used for heating and cooling and 25 to 40 percent of this energy is lost due to leakage in a typical residence. To solve the air leakage problem, many of today’s contractors are taking a systems approach to insulation, installing products in wall cavities and attics that work together to impede air flow, reduce heat loss or gain and maintain a dry building envelope. Hybrid insulation systems combine the best attributes of two or more insulation products to provide a cost-effective airtight seal around the home as well as high thermal efficiency and superior moisture control. This leads to increased occupant comfort, improved thermal performance of the building envelope over the life of the home and makes the system a key component of an Energy Star rated home. Houses and buildings with hybrid insulation systems are extremely energy-efficient, which is good for the environment and

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| Walls & Ceilings | September 2011

Hybrid insulation systems provide a cost-effective mix of excellent air, thermal and moisture-control performance. By Randy Straight reduces utility costs for the home or building owner. One good example of a high-performance hybrid insulation system combines 1 inch of closed-cell spray foam insulation, fiberglass batt or blown-in insulation and a smart vapor retarder. In this article, we’ll take a closer look at each component, what it contributes individually and show how the components together can offer even more to the building envelope.

CLOSED CELL SPRAY POLYURETHANE FOAM INSULATION Made from polyurethane, SPF insulation offers a thermal resistance of up to R 6.4 per one inch of installed thickness—one of the highest insulating values available on the insulation market today. It’s sprayed as a liquid into the intended area and expands to several times its initial size, filling crevices, gaps and other hard-to-reach spaces. This creates a very effective air barrier. In addition to excellent insulation attributes, applying SPF insulation to exterior walls and attic ceilings also provides additional structural support and racking strength. There are two types of SPF insulation— closed cell and open cell. Closed- cell SPF is comprised of tiny cells packed together tightly and inflated with a gas that causes the foam to expand. Closed-cell SPF is more durable than open-cell, has a higher R value and a stronger resistance to air and moisture and

is the choice for high-performance hybrid systems. One downside to using SPF as a stand-alone insulation is that it can have a significantly higher installed cost than fibrous insulations. A hybrid insulation system, however, gives homeowners the same air permeance performance by applying a 1- to 2-inch flash coat of closed-cell SPF. One inch is all that is needed, as SPF’s superior air resistance meets code-required air infiltration standards. The remaining portion of the wall cavity can then be filled with fiberglass batt or blown-in loose-fill fiberglass insulation.

FIBERGLASS INSULATION Fiberglass is the most commonly installed insulation material for a variety of reasons—it is readily available, easy to install, naturally fire-retardant and provides proven thermal resistance that won’t lose R value from settling. The flash coat of closed-cell SPF insulation in hybrid systems provides air sealing and allows fiberglass insulation to perform to its optimum level, rounding out the energy savings performance while providing unmatched acoustical performance. M a ny hybr id i nsu lat ion sys tems call for fiberglass batts, since they are a very familiar product to all contractors. However, using a blown-in loose-fill insulation is an even more effective option and highly recommended, as it can fill more nooks and crannies and it can deliver

September 2011 | www.wconline.com |

17

Insulation SYSTEMS ENGINEERED RIGHT

a greater thermal performance than batt insulation.

SMART VAPOR RETARDER Smart vapor retarders, made from a polyamide film, are a relatively new development in the building products industry and are known for their ability to change permeability with ambient humidity conditions. This process allows closed building envelope systems to help reduce the risk of mold and mildew problems by increasing their drying potential with seasonal climatic changes. With a high resistance to water vapor permeance throughout the winter, smart vapor retarders protect the hybrid cavity like traditional poly or kraft vapor retarders. But unlike traditional solutions, SVR can react to relative humidity by altering pore size, allowing water vapor to pass through it. When conditions change within the cavity— and relative humidity increases above 60 percent—the pores in the material expand and its permeability increases. This trans-

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| Walls & Ceilings | September 2011

Insulation SYSTEMS ENGINEERED RIGHT

formation permits drying to occur in the cooling season through the process of vapor diffusion. Thus, its lowered vapor permeance supports the drying process only when needed, which decreases moisture accumulation within the wall cavity as well as moisture damage and mold growth that can result. Smart vapor retarders can be used in place of traditional vapor retarders with unfaced fiberglass insulation to provide an insulation system that is ideal in some of the more severe climate condition areas, in terms of both temperature and humidity. In addition, they may be installed as an interior air barrier system combined with recommended tapes and sealants. It is important to consult state building codes before installing, as vapor retarder placement can vary between climate zones.

WORKING TOGETHER AS A SYSTEM A hybrid insulation system featuring closed-cell SPF insulation,

blown-in fiberglass insulation and a smart vapor retarder provides a thermal protection and air and moisture resistance similar to that of a wall cavity filled with closedcell SPF insulation. An insulated 5½-inch wall cavity with batt insulation alone would produce an R value of between 18 and 21. If the cavity instead had blown-in fiberglass insulation by itself, the R value would be about 23. With a hybrid system, the R value increases to 25 as well as a superior air barrier provided by the SPF. A s st ated ea rl ier, one of t he biggest selling points of a hybrid insulation system is its ability to reduce air infiltration while offering greater thermal performance and smart moisture control. Air sea l i ng is requ i red by most of today’s building codes, so why not expand your offering to include hybrid insulation systems and provide a more effective air seal and increased thermal resistance all in one system? In the long run, the

benefits to the home or building owners will significantly outweigh a slightly higher installed cost. Hybrid insulation systems truly offer the best of both worlds in insulation performance. W&C Randy Straight is manager of technical services at CertainTeed Corp. If you read this article, please circle number 275.

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ICF/SIP SPECIAL SECTION

Jolly Green and Giant V

illage Suites Oshawa is a 556bed student residence built for the University Of Ontario Institute Of Technology, Canada’s fastest growing university. The building is currently being evaluated by the CaGBC for LEED Platinum certification and if successful, at 270,000 square feet will be one of the largest LEED Platinum certified buildings in Canada. The Village Suites’ high-performance building envelope derives its thermal performance from a variety of elements and illustrates a number of important scientific building principles. • • • THERMAL PERFORMANCE • THROUGH ENHANCED R VALUE • The high performance envelope • is built with an insulated con• crete forms system. The foam • insulation in the Logix Plati• num Series walls is provided by • Neopor, which was patented • by BASF in 1995 and currently

University of Ontario residence hall on track to being one of the biggest LEED buildings in the Great White North. By Andy Lennox enhanced by millions of graphite particles that act as infrared absorbers and heat reflectors. Neopor is different from regular EPS in its look, wh ich is silver/g ray, and its thermal performance, which is roughly 13 percent greater than a regular Type II EPS. Regular Type II EPS provides an R value of about 4.0 per inch at 75 degrees and Neopor delivers an R value of about 4.7 per Project: Village Suites Oshawa, Oshawa, Ontario inch at that same temperature. Status: In evaluation for LEED Platinum Thus Neopor provides greater Square Feet: 270,000 R value than normal EPS withProduction Dates: August 2009-October 2010 out increasing wall thickness. Project Cost: $35 million The interior and exterior Owner: DC Land Corp neopor-enhanced Logix PlatiArchitect: Lintack Architects Inc. num Series foam panels are Structural Engineer: MTE Consultants Inc. each 2.75 inches thick for a General Contractor: Dundurn Edge Developments Inc. total of 5.5 inches of foam insuICF Installer: Tradewind Construction lation in the wall. At an R value ICF Supplier: Logix Insulated Concrete Forms Ltd. carries the McDonough Braungart’s C2C (Cradle to Cradle) service mark. Used extensively in Europe and Asia for many years, Neopor is quickly gaining market acceptance in North America. Neopor is an expanded polystyrene product that is performance-

PROJECT NOTES

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| Walls & Ceilings | September 2011

of 4.7 per inch, the R value delivered by the foam insulation is 25.8. When the R value of the drywall and air films is added, the R value of the Logix wall assembly comes in at 27. It is important to note that in this ICF wall assembly the insulation is continuous. Therefore, any thermal bridging and resultant heat loss through framing members is completely eliminated.

AIR TIGHT AND FOOLPROOF A ir leakage, or the unintended movement of air across the thermal boundary, generally contributes to the majority of energy loss in conventional framed construction. Air can transfer heat and moisture not only through the envelope, but in the case of framed construction it may enter into the cavity wall— introducing a conductive current which decreases the thermal value of the insulation. Sealing air leaks can be very complicated. Building paper and spray or blown insulation may help seal some gaps initially, but complete air sealing requires additional detailing of gaskets and sealers at the sill plates and continuous attention to repair holes made by tradesman. This adds a layer of complexity to the building process and requires a level of attention to detail which is difficult to achieve on most construction sites. Also, the points of air penetration in a framed wall cavity, such as

sheathing joints, floor/wall joints and insulation gaps only get worse over time as the framing shifts. Air barriers joints and seams also need to withstand positive or negative pressures from wind, stack effect and mechanical ventilation. Sealants at the time of construction only provide minimum protection against future air leaks. The best defense against air leaks is to build with a material which by its very composition has no air leakage independent of the skill of the workforce. This is the case with the concrete core of the Logix wall. As the ready-mixed concrete is placed

on site, it forms a monolithic concrete wall which is virtually air tight. Penetrations in the wall, such as windows, doors or utility service pipes are clearly identifiable and can be sealed for air tightness. T he C a nad ia n Mor tgage a nd Housing Corporation quantified the additional thermal performance provided by the air tightness of ICF technology in the 2005 study titled “Monitored Thermal Performance of ICF Walls in MURB’s.” In this study, they monitored a building quite similar to Village Suites and concluded, “The results

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GREEN CONSTRUCTION PANEL FOR SIPS DRAGONBOARD DragonBoard, the industry leader in MgO boards, is UL Classified, fire/moisture/mold/insect-proof and green. The panel has passed the SIPs 15-minute corner-burn test, as well as ASTM E136, E119, E84 and G21. Additionally, DragonBoard is VOC-, asbestos- and formaldehyde-free. Visit www.dragonboard.com for more information. If you read this article, please circle number 251.

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from this test suggest that the design heating and cooling loads and subsequent sizing of the building’s heating and cooling system may be based upon an air infiltration rate that is up to 60 percent lower than standard construction.”

THERMAL MASS AND YOU High mass wall structures such as concrete have the added benefit of increasing the energy performance of a building despite having a low R value. Concrete can provide a thermal lag as it absorbs the temperature differential between the indoor and outdoor temperatures. This property of concrete is known as the “thermal mass effect.” The thermal mass effect is influenced by differences between the indoor and outdoor temperatures. Since heat flows naturally from a warmer place to a cooler place, two scenarios can affect the mass effect of concrete: 1. Outdoor temperatures which fall above and then below indoor temperatures, and 2. Moderate climates and the transitional periods between the heating and cooling seasons. CMHC together with NRC/IRC and Natural Resources Canada measured the thermal mass of ICF walls in their recent study “Field Monitoring of the Dynamic Heat Transmission Characteristics through ICF Wall Assemblies over a Full Year Cycle of Weather Exposure.” This study concluded that ICF thermal mass provides a five-day thermal lag which contributes energy savings to the building above and beyond the R value of the assembly. This study also supports previous CMHC research which has shown that the thermal mass effect in ICF walls can be used to downsize the mechanical systems.

COMPLETING THE HIGH-PERFORMANCE ENVELOPE The concrete deck roof is coated with a white-colored, highly-reflective, polyester-reinforced membrane to reduce the amount of radiant heat absorbed into the building and minimize the amount of energy needed to cool the upper floors in the summer months.

Double glazed, low-e argon windows were used to reduce solar heat gain. The window openings were designed, sized and placed to permit natural daylight to reach 75 percent of the interior spaces.

AUGMENTING THE HIGH-PERFORMANCE ENVELOPE ERV units were installed in each unit to maximize indoor air quality and to recover up to 70 percent of the heat of the exhausted air. Also, a watt meter was installed in each unit to monitor energy consumption. Evacuated heat pipe solar panels were installed on the roof to heat water via sunlight. Additionally, a photovoltaic panel array was installed to take advantage of the Ontario Green Energy Act. Finally, Village Suites has committed to purchase 50 percent of contracted energy requirements from renewable sources such as solar-, wind- and water-generated sources.

built to prevailing minimum building codes. The development is a notable achievement in building science and a job well done by the design and construction team at Village Suites. Andy Lennox is vice president of marketing for Logix. If you read this article, please circle number 276.

THE BOTTOM (ENERGY) LINE Design modeling projects a 75 percent reduction in heating and cooling costs and a 50 percent reduction in electricity usage as compared to a building

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Everything Old is I

n 2011 2011, Bill Chaleff Chaleff, off C Chaleff h a lef ha lef f & Rogers A rchitects, came to Community Environmental Center (CEC) with a challenging situation. Chaleff’s client, who owned a vintage mansion in Southampton, Long Island, wanted to repair the house and wanted a sustainable solution for insulating the exterior walls so that the original interior plaster faces of the walls could be preserved. T he problem: It was Januar y and icy temperatures blanketed the northeast. Damp-spray cellulose, which CEC ordinarily would have recommended, would freeze from exposure to the cold weather. CEC’s solution: Dry, dense-pack cellulose.

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| Walls & Ceilings | September 2011

Dry dense-pack Dry, dense pack cellulose celllllul ulo lose is used to insulate a grand old home in a very new way By Leroy Anthony The four-story house had been built in 1926 and the 4,000 square feet of original stucco walls were in sad condition. Cracks were plentiful as were the remains of earlier repairs. According to Chaleff, “There were splotches, discoloration and patches were evident.” That cosmetic concern on the part of the client was what triggered the renovation, but it evolved into a heavy-duty maintenance regimen. Ultimately, says Chaleff, whose Eastern Long Island firm has been specializing in sustainable architecture

for 35 years, “The project included remediation on some of the structure, installing a proper weather barrier and drainage plane, replacing the leakiest kinds of windows you can imagine and adding flashing to insure the integrity of the structure into the future.”

NEW SOLUTIONS IN PLACE OF OLD FIXES A s for insulation, the building had been treated in the past with blown-in and batt fiberglass i n ma ny places (wh ich Cha lef f

walls that are open to the elements is quite another. In Southampton, the severe winter wind threatened to scatter the cellulose all over the place. So the Chaleff-CEC team decided to wrap the building with what Chaleff calls “a very tough membrane, which had a reinforced scrim in it.” This permeable, translucent, polyethylene wrap allowed CEC’s cellulose installers to see and reach the cavities they were filling and the polyethylene wrap (from Par/Pac Inc.) also prevented the dry cellulose from blowing out past the line of sheathing and siding. By closing the outside of the stud cavities with a translucent wrap, holes could be made in the wrap and the dry dense-pack cellulose could be blown into each cavity and easily inspected.

New Again removed) and in other places there was no insulation at all. Orig inally he had envisioned blowing damp-spray cellulose into open walls against the backs of the house’s plaster walls. But Community Environmental Center, a Queensbased non-profit that provides energy efficient retrofits to buildings in the New York Metropolitan Area, advised blowing in dry, dense-pack cellulose manufactured by FiberAmerica. The dry cellulose would not freeze in the open bays and it would provide optimal insulation once the walls were closed up. Furthermore, if damp-spray had been applied from the exterior, the overspray would have gone into the

landscape la ndscape where it would have been land difficult to recover for recycling and reuse. CEC primarily uses cellulose to insulate walls from the inside. In fact, CEC has been working with both dry and damp-spray cellulose for years, finding that buildings insulated with cellulose reduce air infiltration by 25-40 percent over traditional fiberglass insulation and thus require less energy to heat and cool. In addition, cellulose does not deteriorate, retards fire (it has a Class-A noncombustible rating) and vermin can’t stand the stuff. But blowing cellulose into a protected space where the air is still is one thing; blowing cellulose into exterior

OUT WITH THE OLD Before installing the vapor-permeable wrap, Chaleff’s workers stripped everything open and gutted the bays, removing all the old insulation and skinning any old nails from the beams. Then they closed the walls temporarily with plywood u ntil C EC ’s seven-person crew arrived to attach the vapor-permeable wrap and blow in the cellulose. Attaching the wrap was a precise task. The plywood, which would later be re-cut and reused for the building’s sheathing, came down and CEC’s crew climbed onto scaffolding to fasten the barrier with large staples on both faces of each 2-inch by 5-3/4-inch wood stud. The wrap was first tacked to the outside edge of each stud. Then by stapling on the stud face past the outside edge by a ¼-inch or ½-inch (and stapling vertically every 1½ inches) the wrap was made taut. When CEC’s crews sprayed the dense-pack cellulose into the cavities, the cellulose did not blow out past the framing line, allowing the sheathing to be installed easily and properly.

September 2011 | www.wconline.com |

27

“We used a truckload of staples,” says Chaleff. “If you look carefully at the photos, it’s clear that the staples are virtually stitched edge-to-edge.” Once the vapor-permeable wrap for a section was in place the entire process moved swif tly. Despite the wind and cold, CEC completed the insulation in a total of five days, stopping periodically to allow Chaleff’s workers to prepare another section of wall. The majority of the cavities were 5-inches deep, but other bays were 8- to 9-inches deep. The crew installed at least 3 ½ pounds of dense-pack per cubic foot.

IN WITH THE NEW For Chaleff, the dense-pack solution was ideal. “We wanted to create a wall that was free to dry to both the interior and the exterior,” he says. “We were looking for thermal symmetry in the wall’s design and construction: the building would experience both heating and AC loads, so putting a vapor barrier on one side or the other would be wrong for half the

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Leroy Anthony is the director for construction services for the Community Environmental Center If you read this article, please circle number 277.

time. Traditionally a vapor barrier is put on the inside for the heating season, which means it would be in the wrong place during the cooling season. It doesn’t matter that our cooling season is short. What is of concern is that there is a cooling season which could cause condensation within the wall cavity and result in mold, mildew and even structural damage. A vaporpermeable wall construction avoids those problems completely.” “As far as I know,” says Chaleff, “cellulose is the only product that will give you the moisture wicking that protects and safeguards a building from leaks and moisture infiltration. Cellulose defuses the moisture throughout the entire bay, allows it to dry and keeps the moisture in the framing below the danger point of 19 percent.” “And that,” he adds, “was why I was adamant that we have a wall design which allows for drying and takes full advantage of cellulose’s ability to wick and diffuse free water. I will not use foam products or fiberglass in a cavity wall. Generally I don’t even build with cavity walls because cavities allow for condensation. I build all my new work with Structural Insulated Panels (SIPs). But where we have restorations or renovations, as we did in Southampton—

or too small an area to warrant shipping SIPs—then the only product I will use is cellulose.” Bonus features, such as the thorough and effective sealing of all voids and use of a 100 percent recycled and totally benign material, are the frosting on the cake. As we turn the world of building and construction around to be more in line with the principles of sustainability then use of dense-pack cellulose and its brother, damp-spray, will be major players in the solution. W&C

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Fitting

FOAM into Weatherization Retrofits A

s energy costs continue to fluctuate, homeowners are seeing the benefits of becoming more ecosavvy. One growing area of focus is weatherization. When you consider that up to 40 percent of a home’s energy loss can be attributed to air infiltration*—a combined with recent government incentives—it’s easy to see why. This booming new market offers contractors an opportunity to expand business offerings and increase revenue streams by providing a service that homeowners are actively seek-

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| Walls & Ceilings | September 2011

Spray polyurethane foam is a viable alternative when conducting weatherization projects. By Tim Kenworthy ing out, in large part due to the increased awareness recently brought to home air sealing and weatherization through various government programs. In addition, the government recently extended the insulation tax incentive, meaning homeowners will receive a tax credit for a certain percentage of material costs, making this a prime time for weatherization contractors to build their businesses.

A SMART APPROACH TO WEATHERIZATION Traditional air sealing methods in existing construction such as cau lk ing and weather st ripping require extensive time to apply. An alternative to these applications that creates an effective barrier is using low pressure spray polyurethane foam. Using SPF is one of the easiest, most efficient ways to

stop air infiltration in new and existing construction. Low pressure SPF kits are available with no additional equipment necessary to install. Small two-component kits are easy to transport and fit into tight spaces like crawlspaces and attics where high pressure spray foam rigs would be cumbersome. Minimal training is necessary and the product can be applied with only one laborer, so incorporating low pressure SPF into a business model is a cost-effective approach to entering a growing market.

SEALING CRITICAL AREAS Air infiltration in existing homes is most prevalent in key areas such as attics, crawlspaces and rim joists. Sealing these critical areas with SPF can greatly improve comfort and reduce energy costs for homeowners. Closed cell spray polyurethane foam is the best option when air sealing because it can also act as a vapor retarder, assisting with other common problems in existing homes that can lead to moisture and mold.

SPRAY POLYURETHANE FOAM APPLICATIONS: Attics Vented attics can often be the best environment for employing air sealing methods with low pressure SPF because attics typically contain several spots of air and moisture penetration. These problem areas include top plates, junction boxes, can lights, pipe penetrations and drywall-towood connections. Quickly spot treating these problem areas with a product like Handi-Foam SPF will seal unwanted air through these penetrations. Look for additional prod-

ucts to assist with spot treatments such as can light covers to help prevent the risk of fire hazards. A quick flash coat of SPF (approximately 1/2-inch thick) on the entire attic floor is an even more effective way to ensure the tightest seal for the entire attic. When used in conjunction with traditional insulation methods, such as blown-in cellulose or fiberglass, this small flash coat of SPF will stop air infiltration while the traditional insulation material will add R value to maintain the building codes. Accessory products such as baffles will help keep air flowing through the attic to help prevent moisture and ventilation issues. Sealing baffle bases with SPF will assist in overall air sealing while maintaining the necessary ventilation. Fomo Products recently completed a retrofit project on a home in northeastern Ohio. Prior to starting the project, Fomo conducted a blower door test—an EPA Energy Star recognized diagnostic method for measuring air exchanges. This testing was performed by a certified thirdparty Building Performance Institute accredited Building Performance Analyst. A critical seal was performed by applying SPF to the thermal bypasses. Critical seal points included top plates, pipe penetrations, drywall-towood connections, junction boxes, can lights, soffits and baffles. In addition, a 1-inch coat of SPF was applied over the entire attic floor to create an airtight critical seal and to stop air infiltration. This provided an R value of 6.2. The blower door test conducted after the attic seal was complete showed that air exchanges per hour dropped significantly, by 25 percent, before the cellulose was reinstalled.

Rim Joists Rim joists are another prime spot for air and moisture infiltration. Traditionally rim joists have been insulated solely with fiberglass, which does not stop moisture infiltration and could lead to mold problems when exposed to the elements. Additionally, since fiberglass is a thermal barrier and not an air barrier, it can’t stop air infiltration—the best defense against energy loss. Creating an air barrier becomes vitally important in a rim joist because this is the primary area where cold,

2011 INSULATION TAX CREDIT The current federal insulation tax incentive that homeowners can take advantage of is 10 percent of material costs up to $500. Most spray polyurethane foams are considered to be qualified products. Contractors should be informed about state and local tax incentives as well. Visit the IRS Web site (www.IRS.gov) for additional information about the insulation tax credit. moist air infiltrates a house, potentially contributing to moisture related problems like molding and rotting. Sealing around the gaps in the rim joist (and then re-covering with the existing fiberglass) will also help prevent moisture from reaching the fiberglass to help prevent mold issues. Sealing the rim joist with SPF can be done in three easy steps. First, remove any existing fiberglass. Then spray a flash coat of spray (approximately 1/2- to 3-inches thick) in the rim joist to create an airtight seal. Then the fiberglass can be placed over the SPF to further insulate and reach designated R values.

September 2011 | www.wconline.com |

31

FOAM Recent case studies show a 10 to 20 percent reduction in air exchanges simply by sealing a home’s rim joists. For example, Fomo Products recently worked to seal rim joists on a 2,400-square-foot home in Kansas, built in 2007. By simply applying SPF to the rim joists, a reduction in the annual infiltration rate estimated at 11.4 percent was achieved. This reduction in air infiltration translated to an estimated cost savings of 19.3 percent in heating and cooling expenses, according to Hathmore Technologies, the certified HERS energy rater that performed the testing. Crawlspaces Crawlspaces can be a major contributor of moisture in a home, as well as cause “cold spots” in the first main floor. Ideally, a crawlspace should be kept dry and tightly sealed and SPF is one of the easiest ways to insulate hard-to-reach areas like crawlspaces. One common approach to sealing vented crawlspaces involves completely sealing the underside of the first

WEATHERIZATION ASSISTANCE PROGRAM Government assistance with energy effi cient upgrades is available for homeowners who meet certain income guidelines. For more information about this program, visit the Department of Energy’s Energy Efficiency and Renewable Energy Web site at www.eere.energy.gov. floor (including the joists) with SPF and then covering it with an ignition barrier. Another method for creating unvented crawlspaces, involves covering the walls and floor with a vapor barrier and then applying SPF to seal and insulate from the rim joist down the walls and then following this up with an ignition barrier. Homes have reached up to 30 percent savings on their annual energy bill after utilizing just one of these applications, which is a significant benefit to the homeowner. It is important to note that it is necessary to wear air purifying or supplied air respirators during crawlspace applications due to a lack of proper ventilation.

areas can help homeowners realize significant energy savings but an even greater reduction in energy can be reached by combining these seals. For example, by combining a critical seal in the attic with two inches of SPF applied to the rim joists in the basement, a 2 ,600 -square-foot home built in 1983 achieved a 19.5 percent reduction in hourly air exchanges. In addition to critical seal areas, SPF can be used to seal around gaps, cracks and pipe and wire penetrations to create an air barrier and increase energy efficiency. Visit www.fomo.com to see a weatherization video and view these applications in action.

A WINNING COMBINATION

HELP FOR CONTRACTORS

Sealing any of these single critical

Various companies are offering weatherization contractors turnkey assistance programs and product resources to take their home performance contracting businesses to the next level. Comfort RX, for example, offers an assistance program that includes premium air seal products, marketing, application and product training, a full-circle marketing co-op program and comprehensive technical support for contractors, all without the costs of a franchise. For more information, visit www.comfortrx.com.

WORKING SMART For every job using two-component spray polyurethane foam, the Center for the Polyurethanes Industry (www.spraypolyurethane.org) recommends several safety standards. Contractors should wear glasses or goggles, nitrile gloves, cover all exposed skin and use a NIOSHapproved respirator. *Source: The Department of Energy Tim Kenworthy is a BPI-certified building analyst and Refill Technologies Group Department Manager at Fomo Products. If you read this article, please circle number 278.

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Moisture Management OF BELOW-GRADE CONSTRUCTION BASEMENTS

B

uilding on a strong foundation has been a well-recognized principle of construction for thousands of years, but we still continue to violate the concept. One of the most violated areas of below-grade construction is the failure to include moisture management. Joseph Cubby said, “Learn the past. Decide the present. Build the future.” With apologies to Cubby, let us examine common below-grade construction moisture management errors from the past that are still in practice, then make some decisions today on how to correct them so that we can build stronger foundations for tomorrow’s residential and commercial properties. Most residential and commercial structures feature below-grade construction that is usually 10- or 12-inch CMU, or 8- or 12-inch poured concrete. A much smaller percentage involve ICF and wood walls. The footings (or caissons)

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| Walls & Ceilings | September 2011

Keeping foundations dry is crucial to any building’s long life. Better waterproofing isn’t enough to do the job, sound construction practices are needed to keep water out and a structure sound for years to come. By John Koester that support these walls can vary in depth and width depending on a variety of soil conditions. The basements may be fully below-grade or partially exposed (a berm) and there may be walkouts; many configurations are possible. However, they all have one thing in common—unique moisture management requirements (see Image 1). The two most common sources of moisture that impact below-grade construction are infiltrating moisture (in liquid form entering through walls or f loors) and condensing moisture (in vapor form being deposited on the interior surfaces of the basement walls and floors to create water droplets). These are very dif-

ferent concepts in the realm of the laws of physics, but in many cases, absolutely connected in the realm of wet and dry basements. The factor in common is temperature. Moisture (water in the fill that surrounds below-grade construction) can impact this construction detail in many ways. There are two that are most relevant to this discussion. First, moisture can pressurize against the surfaces of belowgrade construction and force its way through voids in this construction detail creating leaks. Second, moisture, because of its molecular density, can transmit temperatures 25 times more efficiently than air to the exterior surface of the below-grade

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construction to potentially create a dew point temperature on the interior surface of the below-grade construction creating the possibility of condensation (see Image 2). It’s back to the old rules of moisture management: keep moisture away from, and off of, construction details and get it out of construction details as quickly as possible. If these two rules are adhered to, there will be less risk of moisture damage to the construction detail.

LEARN FROM THE PAST How do wet basements happen and how can they be avoided? In some cases because of an insufficient budget, a wet basement is unavoidable. A cheap lot, poor soils with little or no drainage and the lack of resources to fund a high-quality drainage and waterproofing system can definitely lead to a wet basement. Sometimes, the best way to avoid a wet basement may be to not build one. Any and all conditions can be overcome, or at least greatly improved, but it won’t happen for free. So if the soil conditions of the lot you can afford are not appropriate for below-grade construction and the budget is tight, it is wise to choose another foundation option for your structure. A dry basement begins with a building site that can be managed to control moisture. The familiar phrase

Image 2

“high and dry” comes to mind when planning a foundation. In the nautical world, high and dry is a bad thing, but in the world of below-grade construction it’s the pinnacle of moisture management perfection. When you get to start with a high-quality building site, a wet basement isn’t very likely (Image 3). However, do not let looks deceive you. Once you have found an exceptional building site, be sure that the purchase agreement contains a contingency for a soils report generated by a licensed soils engineer. The information used to create this type of report comes from borings — cores of soil taken at varying depths in prescribed locations on the building site. Taking ownership of a building site that can’t be built on is a bad start. Finding out from the excavator that the soil conditions are bad and will require soil reconstruction and/or budget-busting oversized footings or pilings to support your structure is also a very bad start. The soils report should also contain information about the water table and the presence of any potential chemical contaminants. If there is any question about adjoining lots that may leech in contaminants, they should be tested too. The structural engineer will take the information from the soils report and design the appropriate structural footing and

walls that form the basement and support the structure. Once the site has met the critical tests, the next step in the process is jobsite moisture management during construction. The below-grade construction phase of many building sites is negatively impacted by poor or non-existent jobsite moisture management plans. A job site that is allowed to turn into a mud hole will have long-term negative impact on the soils that surround the below-grade construction and as a result, have a potentially negative impact on the moisture management of the below-grade construction. Job site moisture management, in the form of a jobsite drainage plan and the ongoing implementation of this plan, is critical. Allowing jobsite surface water to run toward and into below-grade construction excavation and details can have a permanent negative impact on a project. The inadvertent saturation of soils that surround and support footings and walls is not good (Images 4A and 4B). The list of potential violators of a job site drainage plan is long and includes plumbers, sewer and water utility personnel and electrical contractors. The standing jobsite rule on this should be that anyone who moves or adds fill to a jobsite should return it to the original jobsite elevation drawings and plans and compact

September 2011 | www.wconline.com |

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Moisture Management fill as to the specs. Construction specifications should clearly state excavation dimensions required to safely and efficiently construct the below-grade structure and minimize the size of open excavation, therefore minimizing the amount of water entering the excavation (Image 5). Upon completion of the excavation, form and pour the footings and walls or form and pour the footings and lay the block. There are two critical principals that must be followed at this stage of the construction process. First: Do not fool around! It is imperative that all parties involved adhere to a strict timeline and complete the project on schedule. The amount of excess time this excavation is left open invites moisture management disasters in the form of excavation cave-ins, flooded excavation, etc. Construct the basement and get it waterproofed, drained, and backfilled ASAP! Second: Don’t take shortcuts! Do not skip any of the important construction procedures. The foundation of the entire project is literally being fabricated. If any part of it is either hurried or omitted, the entire project is at risk. Working cohesively as a team is crucial. There are usually several subcontractors involved including plumbers, electricians, waterproofers, and excavators. The coordination necessary to keep these subcontractors on schedule is also crucial. Additionally, there is a real danger at this time that one or more subcontractors will, because of gross negligence, ignorance or other reasons, undo important

Image 3

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drainage or waterproofing details. Studies have shown that as much as 85 percent of all labor time conducted on or near waterproofing systems is conducted by labor that has no understanding of how these systems are supposed to function.

DECIDE WHAT WORKS: KEY PLAN ELEMENTS Establishing a moisture management plan results in a positive outcome for a below-grade construction project. Following these critical steps (the plan) leads to an optimal end product and good site preservation practices. Select a sound building site with good soil and good drainage. Finding the right location is the first step in the process. A location that is too low and soil that doesn’t drain invites moisture problems. Be sure construction details are structurally sound. The right details make or break any construction project. It is imperative that all design details work together. A poorly designed detail can invite moisture into the project. The exterior surface of the basement walls and footing should be waterproofed. There are many high-quality waterproofing systems to choose from. Some of these systems consist of two parts. There are systems that feature a waterproofing material that faces the weather and is backed with a drainage material and there are systems that are a sheet stock material with a pattern on the back that provides drainage. Both of these systems, when placed on the outside surface of the basement, provide waterproofing on the exterior surface and a predictable drainage plane behind it to move water from a high point to a low point. Drainage systems should be located at the lowest elevation of the basement construction detail. This system usually incorporates drain tile and a sump basket system. Choose a highquality rigid or flexible drain tile; the most common tile dimensions are 4, 6 and 8 inch. The drain tile should be installed along the interior and exterior sides of the exterior perimeter wall and footing with a connecting pipe of smaller dimension running through the footing at its base (Image 6).

Note: A structural engineer should do the required engineering to facilitate this detail. Connecting the exterior drain tile to the interior drain tile serves two important purposes. First, it provides a drainage pathway for water in an exterior drain tile of a full in-ground basement to have access to the sump pump and sump basket located in the interior of the basement. This facilitates it being pumped out and away from the

basement detail. Second, it provides immediate elimination of potential water pressure build up. Prevention of this phenomenon is a must in maintaining a below-grade moisture management system. Connection of the vertical drainage planes on the exterior of the perimeter wall systems to the drain tile system is very important. Any restriction of moisture flow at this point may cause water pressure build up. This transition from verti-

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cal to horizontal is accomplished in a number of ways. The two most common are: • Systems that actually have connecting components as part of the system (See Image 6) • Systems with a drain field consisting of stone (See Image 6) Vertical wall drainage systems that are installed on the interior surface of exterior perimeter walls. The systems provide a passageway for moisture (in its liquid state) to drain from a high point of entry to a drain tile and drain field system at the lowest point of the construction detail. They maintain a separation (barrier) between concrete or CMU basement walls and the material used to create the finished interior wall detailing (Image 7). Drain field systems that are installed below basement floors, around interior drain tile and around and over exterior tile and around and under sump baskets. When possible, these systems should be constructed out of hard river rock no smaller than 1¼-inch (never use sand or pea gravel). The larger dimension hard rock creates more voids between each unit resulting in more space for water to occupy. The larger voids also create more space for air that in turn insulates the various basement construction details from the surrounding soil temperature and allows the internal manmade heat supply to keep these details warmer (Image 6). The drain field sizing around and under the sump basket and the preparation of the sump basket is critical. The exca-

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| Walls & Ceilings | September 2011

vation around and under the sump basket should be oversized a minimum of 12 inches on all sides and at the bottom. This creates a larger capacity reservoir for water and as a result more productive pumping cycles for the sump pump. The sump basket must be a high quality, large capacity unit with a gas tight lid and well designed discharge ports. Before installation drill 1-inch holes approximately 2 inches off center starting 8 inches down from the top of the sump basket on all sides and on the bottom of the sump basket. The oversized drain field surrounding the sump basket allows water that is held in the reservoir prior to the sump pump being activated by the float to be readily available for the sump pump ensuring a productive pump cycle. A larger volume productive pump cycle reduces stress on the pump created by too frequent low volume on and off cycles. The larger, deeper sump basket with the oversized drain field also creates a reservoir that can accommodate water surges (Image 8).

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Employ a gas-tight sump basket lid with designated outlet hole gaskets and brackets that facilitates proper installation of moisture and gas venting stacks. This sump basket configuration can be mechanically vented with an inline fan system. The mechanically fastened sump basket lid is a safety

device and code in most states. The venting of soil gases from the sump basket and the connecting drain tile/ drain field details has a number of positive aspects. One of the most beneficial aspects is that the venting of these gases creates a slight negative pressure in these details that discour-

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ages soil gases from entering the living space of the building envelope. Building professionals have been engaged in a long, ongoing struggle over two concepts: drainage vs. waterproofing and venting vs. sealing. Is it better to seal water out with waterproofing or drain it away? Should contaminated air be vented out or sealed out? It is only by combing waterproofing with drainage and venting with sealing that we truly have an acceptable answer to each question. For many years, manufacturers of waterproofing and sealant materials have controlled the market. They had the marketing dollars to influence the consumer, so they have held sway. There have been few manufacturers with either the money or a reason to dispute the efforts of the waterproofing and sealant manufacturers to push product. As a result of this imbalance of forces, waterproofing and sealant companies have won the day and instilled a sense of security with many building professionals. In many cases this sense of security is well-founded as many sealants and waterproofing products of today are nothing short of fantastic. How-

40

| Walls & Ceilings | September 2011

Image 8

ever, there is a caveat: While these materials have improved, the labor force that installs them has not. If we can accept (for the purpose of this discussion) that the labor force has declined, we must find a way to counteract it. That counteracting force is the inclusion of sound, proven drainage and venting practices. Another negative force that must be addressed is construction design detail conflicts. Sometimes, drainage and venting are in direct design conflicts with waterproofing and sealing. Construction details that have high quality drainage, waterproofing, venting and sealing components perform better and last longer than details that don’t have all four. So how does this pertain to belowgrade construction? One primary example is a construction detail where the basement floor comes in contact with the exterior perimeter wall and the footing that supports it (see Image 7). There are a number of moisture management concerns that need to be addressed at the intersection of the basement wall, structural footing and basement floor. • Temperature transfer • Condensation

• Water Infiltration • Soil gas/contaminated air infiltration The temperature transfer concerns start with a large mass of concrete like the structural footing. This cold sink excesses because the footing is located at the lower point of the basement construction and is in constant contact with the surrounding fill temperatures that hover around 54 degrees Fahrenheit. Another factor that affects the temperature of this detail is the fact that is away from any heat source and because the basement wall rests on the footing and is exposed to fill temperature around 54 degrees Fahrenheit. The bottom of the basement wall and the footing transmit the 54 degrees Fahrenheit temperature to the edge of the concrete floor. This results in the inside corner where the basement floor meets the basement wall being constantly cooled to 54 degrees Fahrenheit. This cooled surface temperature may represent a dew point temperature and the diminished airflow in the inside corner is a recipe for condensation (see Image 2). The voids that remain between the surfaces of these three construction details also represent entrance paths

for both air and water. What seems like the obvious remedy (caulk and seal these voids off) may not be the best long-term moisture management solution. Placing a bead of caulk over the void in the corner where the floor meets the wall is, in fact, a very poor caulk detail. It is a three-sided adhesion issue that has been historically proven to have a short life. A final issue with this detail is what happens if the interior surface of the basement wall gets wet from condensation or a leak? Where will the water go when it runs down the face of the wall and meets the floor? This is an example of the design conflict we mentioned earlier: sealing and waterproofing versus venting and drainage. Building professionals and building code tend to lean towards waterproofing and sealing alone. However, venting and drainage play a critical role in a total solution and they should not be omitted if a long term, low (or no) maintenance outcome is desired. If the drainage material and the mois-

ture management system are of the right design, drainage, venting and temperature can be successfully addressed with one system. The bonus is that little or no maintenance will be required (Image 6). Separate above-grade and belowgrade construction details. There is one last aspect of below-grade moisture management that should be considered in a holistic building design but rarely is. The interior living space above below grade construction needs very special heating and air conditioning considerations. The normal whole-house air circulation concept is not conducive for belowgrade air management. Below-grade construction and above-grade construction (specifically the interior living space) are very different. Most below-grade construction (basements) needs to be dehumidified and warmed. The concept of heating and dehumidifying the basement is hard for most building owners to understand. Above-grade construction and below-grade construc-

tion need to be addressed by construction details that separate them.

BUILD FOR THE FUTURE Those are the key elements of our 21st century moisture management plan. Most of us know change is needed. Too many of us have witnessed too many below-grade construction failures due to moisture issues. The great Spanish philosopher, George Santayana wrote, “Those who cannot remember the past are condemned to repeat it.” How long will we accept and repeat below-grade construction practices that lead to failures. There is too much evidence that traditional moisture management practices are not working with modern materials and the desired outcomes of sustainability and green building. It is time to embrace new ideas and employ better moisture management practices. W&C John Koester is CEO of Masonry Technology Inc. If you read this article, please circle number 279.

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41

The Time of

His Life F

or nearly 40 years, Bob Drury has served the wall and ceiling community proudly through his position as executive director with the Northwest Wall and Ceiling Bureau. What readers may or may not know is that he also has close ties to Walls & Ceilings—his fatherin-law ran the magazine decades ago. Now on the brink of retirement, Drury took time for an extensive interview with W&C to reflect on his time with the NWCB, its accomplishments, how the industry has changed and evolved and what his future plans are. All of us at W&C congratulate Drury for a remarkable career that has been not only been productive but exceptional. Bob, you were introduced to the industr y by your father-in-law? Or tell us the genesis of how you became involved? My wife Dorothy’s father Chuck Clay was executive director of the Lath and Plaster Bureau and owner of Walls & Ceilings magazine. After college, I worked part time for the magazine doing layout, while my full-time job was working as an engineer for the Boeing Co., designing the interiors of the airplanes and emergency features. How would you define your first position? I was asked by the Northwest Lath and Plaster Bureau to take the position of architectural consultant in

42

| Walls & Ceilings | September 2011

Longtime head of the NWCB reflects on the industry, his place in it and what he sees on the horizon for wall and ceiling contractors. By John Wyatt

1972. So I left Boeing and started this job. About a year and half later, Charles Clay passed and I was appointed the executive director by the board of directors. What are your responsibilities within this position? How I view the responsibility is that, first of all, it is to be the visionary source for the industry in the Northwest. The other responsibility is to be the administrator and technical person for the daily operation for Northwest Wall and Ceiling Bureau. It is important in this job to enjoy working with people. I learned right away that there are a lot of people with different agendas. A person in this position has to bring everyone together for the common goals of the industry. When I first started the job, I spent much of my time in the field, often up on scaffolds, looking at how interior and exterior work was being performed. I made a point to communicate and relate well to those working the field as well as to management personnel and to understand their duties. I also worked with city officials and key people in the construction industry. I had to able to mingle and communicate with a lot of different types of people. As far as lobbying goes, our main goals with city and state government

were to influence building codes and to get uniformity from the building inspectors in the field. That was very challenging because there are so many different municipalities in the Northwest, and the city of Seattle has its own building code. The NWCB’s work with the building codes paid off. Eventually, I was on the advisory board for building code for the city of Seattle and active in construction-related organizations. To give us an historical perspective, tell us what the wall and ceiling community was like when you first began? Were the issues and concern different or much reflective of how it is today? At that time, there was the plastering industry and drywall industry—they weren’t under one uniform organization. I saw that there were a lot of the same manufacturers and contractors doing both scopes of work in drywall and plastering, and one industry organization was needed to achieve the goals of these two trades. At that time, in the late-70s, metal framing was really starting to take off and so were various drywall assemblies, such as shaftwalls and fire and sound rating (in commercial construction). Another major change that started to take place was prefab panels and

EIFS in the mid-80s. I felt this exterior work was really challenging and interesting. I saw a big future for this in the Northwest for all involved in our industry (contractors, manufacturers, distributors, etc.) The organization’s name changed to N or t hwe s t Wa l l a nd C ei l ing Bureau in the early ’80s. That became a great opportunity to work with architects, owners and general contractors to promote all scopes of work of the wall and ceiling industry. The construction community embraced and welcomed new building materials, such as EIFS and exterior claddings. Today, that effort and dedication to the exterior work of stucco and EIFS is still key to NWCB. During this time, N WCB was becoming more and more of a goto place for people that wanted to find out how to design, specify and build various wall and ceiling work, and with that came the opportunity to sell architects and owners more work. Once I became involved on a project, I could point out and find other products and systems, such as metal framing and drywall assemblies, that could be used in place of masonry. One of the biggest opportunities our industry presents to the project is the aesthetics that the products can create for the architect and owner. We are in the finishing business—there are numerous choices that owners and architects have and we explore those all the time. Metal studs and drywall assemblies, being relatively new in the architectural community, then also became a big part of our efforts for improving and expanding the industry in this region. Load bearing steel framing still has a tremendous opportunity in construction. What is the biggest change you have seen in your years of service? I would say the trend of general contractors is to do less self-performing of the work. The GCs are becoming more like managers and brokers, and that has been an advantage for contractors in our industry in that it offers more business to us. I think another change has been t he te ch nolog y. Cu r rent ly, t he

September 2011 | www.wconline.com |

43

The Time of

His Life advancement of electronic communication from office to field has taken away the enormous amount of paper work done. It’s a huge difference. There’s also been an impressive stream of new products to the market in the last five years. Having said that, there has been a big decline of interior plaster work being done and it is being replaced by new types of board products, systems and interior finishing, coatings, such as Venetian plasters and more specialty products. The new ceiling systems are also impressive in the incredible variety of products now offered. What threats should the wall and ceiling industry be vigilant of in the future? I think the threats are intangible things that the industry for the most part has no control over. But as an industry and a company in business we need to be aware and plan ahead for things such as economic downturn and construction slowdowns. Run your business smart and plan for change.

Another threat is the over abundance of state and federal regulations that make it difficult to do business. The nature of our scope of work re qu i re s a top - no t c h workforce. We need to have good apprentice programs and be aware that the labor force is extremely important. We need to surround ourselves with quality people. What do you feel have been your greatest accomplishments within the NWCB? One of my biggest accomplishm e n t s h a s b e e n e l e vat i n g t h e N WCB to be recognized in our region as an authority and expert on all phases of the wall and ceiling business. This has been accomplished by being responsive to what our members and the construction industry needs. We want to be an authority not for selfish reasons but because it serves the industry as a whole. We have a tremendous reputation within the building community as

Please Circle #121 On Reader Action Card 44

| Walls & Ceilings | September 2011

a single source to go to in the wall and ceiling industry. Almost all project construction documents in the Northwest reference the NWCB for performing wall and ceiling work. We have a library of technical documents our members rely on a daily basis for their jobs. In addition to the technical documents, we produced the “Stucco Resource Guide.” People buy that book all across North A merica now. A not her i mpor ta nt document that the Bureau published is the “Impacts to Labor Productivity in Steel Framing and the Installation and Finishing of Gypsum Wallboard” guide. Will the conventions continue? The Northwest Wall and Ceiling Industries Convention and Trade Show will continue. I’m proud of how our conventions have evolved and become one of the most important industry events available. This is something the whole staff at NWCB should be very proud of.

Were there any goals that you feel have gone incomplete? Any regrets? I regret we couldn’t broaden membership more in the various regions. We had requests to go to other parts of North America in the West. We could not do that with the funding we have and provide the same service that we offer our members. After so many years serving the industr y, are you truly ready to step back from it altogether or will you still be involved on some level? Please elaborate. I have been fortunate enough to have spent so much of my life doing what I did. I look forward to going to work. I’ve enjoyed what I’ve done. I will miss the issues and the challenges of solving problems and meeting people. As far as the future, there will be a transition period with the new executive director and I will be available as needed to help on current needs or special projects. W he n you l eave, who w ill be charged to take on the task to lead the NWCB? Mark Eisenmann. He is a graduate of construction management from Washington State University. He was a branch manager with a specialty construction company, has worked with the N WCB and knows the industry. I think Mark will do a wonderful job and he’s great with people.

tion and expansion of the recogni recognition of the NWCB. What closing comments would you like to share with our industry and NWCB members? I’d like to express my gratitude to all the members throughout the many years for their support. For allowing me to be in the position that I was in, to be able to be cre-

ative and feel proud of what I was doing—all the while helping the industry. I have been really fortunate to have wonderful people working with me for all the years I’ve been here. They are very dedicated individuals. Every day we have challenges and find solutions. W&C If you read this article, please circle number 280.

How do you plan to spend retirement? I don’t have any specific plans, but I’d like to keep my hand in the industry. I’ll probably play more tennis, go fly fishing and spend more time on Lopez Island here in Washington. I would like to spend more time with my grandkids. W here do you want to see the Bureau go? Where I’d like to see the NWCB go is to elevate the industry and the contractor base so they are recognized as a bigger part of the team on a project. In other words, bring more attention to the wall and ceiling work in the eyes of the construction community to improve wall and ceiling contractors’ business. I would also like to see the continuaPlease Circle #130 On Reader Action Card September 2011 | www.wconline.com |

45

Forward, into

the Past T

he promotional literature on Goldfarb Properties’ apartments at 920 Riverside Drive reads like a J. Peterman catalog entry, “…Aim Higher in Upper Manhattan’s Gorgeous Washington Heights Neighborhood. 920 Riverside Drive offers Large, One to Three Bedroom Apartments, Many with Spectacular Views of the Majestic Hudson River and The George Washington Bridge.” Sound good? Sure. But just a year ago, the word “gorgeous” might not have been the first thing to come to mind when walking into the lobby. The pre-World War II apartment building was in need of a freshening up and the new owners contacted a local artist and interior remodeler to put the old building in a new light. That’s important for any apartment building, but especially so in a place where hardwood floors, two bedrooms and a view of the river can run around $2,999 a month.

FOR LOVE OF ART Jeanne Santomauro-Schnupp is the owner of Jeannie’s Designs Inc., an

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Jeanne Santomauro-Schnupp of Jeannie’s Designs Inc. uses fine detail plaster work and an artist’s approach to paint to restore an apartment building on Manhattan’s Upper West Side. By Alex Lundberg interior renovation company working in decorative painting, restoration and faux finishing. The Long Island, N.Y.,-based contractor has been in the business, in one way or another, for 35 years. “I got my start as an art teacher and did painting on the side,” Schnupp says. “I’ve always been interested in art.” While taking a break from school to raise a family, she did occasional work running a hand painted clothing business at home while picking up occasional work as a muralist. After several of her friends saw her work around the house and asked to do work on their homes, she started a new painting business that would cater to homes and businesses of all kinds. It was during this time that she started work

at her local Home Depot teaching people how to do their own work. This was an advantageous time to be working, she said, as it was 30 years ago and the very beginning of the DIY revolution. Schnupp was doing good work at the store, but her business, by then Jeannie’s Designs Inc., was starting to really take off. She continues to study; she’s already got some of her artistic education from artists in Europe and has built a business around making her customers happy by bringing their wishes to the walls, as it were, and meeting those needs while also meeting her clients’ budgets.

RESTORING A FADED JEWEL She was contacted by Goldfarb last year to work on the restoration of t he R iverside Dr ive apa r t ment

building near the George Washington Bridge. The grand old building had seen better days and its owners wanted to see those days returned. “The ceiling was plaster relief and they wanted to see what I could do,” Schnupp says. “There were cracks and the details in the plaster had faded under several layers of paint. There were other parts where the cracks were so extensive that entire pieces had come away and had to be reconstructed from fresh plaster.” The fine work on the plaster, originally done in 1939, had slowly been worked on over the years with different layers of paint in different color schemes. The upshot is that a lot of the ceiling had been filled in and what had once been intricate work had become nearly flat. The people at Goldfarb wanted it to stand out again. It wasn’t the first time the company had called her. “I actually found her on the Internet,” says Goldfarb Senior Vice-President Tim Ross. “I called her to work on a project on the East Side that was very much the same—beautiful reliefs and details that had faded over time.” The company had hired Schnupp as part of a general restoration of the Riverside Apartments, which they had purchased earlier that year. The company was hitting almost all of the building’s major systems (boilers, elevators, plumbing, intercoms and the front doors, amongst other projects) and the front lobby was of special concern if they were going to keep the building as an attractive place to live.

HARD WORK IN HOT WEATHER “We wanted to bring back the original look of the building,” Ross says. “There was some cleaning we had to do that hadn’t been done in 50 years.” O ver si x we ek s of eig ht- to 10-hour days, Schnupp and a crew of six workers labored to restore the building to its original grandeur. A few of the workers did plaster prep, filling the cracks and using fine tools to recreate what time and wear had destroyed. Later, she and another group of workers did the artistic painting. “Everything starts with a plan on paper,” she says.

September 2011 | www.wconline.com |

47

Forward, into

the Past “People would come by and get excited about what we were doing,” Schnupp says. “Even the residents were saying they never saw those details before. They were happy to be living in a beautiful place.” With their praise, she says, many brought cold drinks.

RIGHT ARTIST FOR THE RIGHT JOB

Schnupp said the hardest part was not the plaster work, or the detailed painting or even the task of matching old designs to new materials. The hard part was environmental. “It was really hard on our necks, those were 10 - and 14-foot ceilings,” she says. “There was a heat wave in the city when we were there, 100 degree-plus temperatures

the whole time. I had a fan in a bucket on my scaffold.” But while she and her employees were painting away in the heat, they got welcome respite in the form of many breaks (about every two hours) and the praise of the people from Goldfarb, the residents of the building and others who were amazed to see the transformation of the old building.

Please Circle #323 On Reader Action Card 48

| Walls & Ceilings | September 2011

“She did an incredible job on the plaster relief,” Ross says. “You can see more of the urns, cherubs and fruit than you probably could when the building was new. It was very artistic work. She took plaster reliefs and made them look three-dimensional.” The company has a lot of properties in Manhattan and employs a lot of workers to keep them up and running for renters. He says that while there are many plasterers and painters around the area, there aren’t many who can do what Schnupp does. “People who do this kind of work, this kind of detail are not a dime a dozen in the profession,” Ross says. “In the future, if I have plaster work, I would not call anyone else.” S ch nupp is a memb er of t he Professional Decorative Painters’ Association and the International Decorative Artisan’s League. Jeannie’s Designs is registered with the state of New York as a minorityowned business. W&C If you read this article, please circle number 281.

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the

FINISH LINE BY ROBERT THOMAS

God knows what weird sort of odd behavior by the local kids goes on at Foamhenge, especially during the equinox and Halloween. When we were there, there was an old political-sticker-encrusted VW van parked next to us and some aging hippies were sitting up on the knoll. For the curious, the term “henge” comes from a type of circular ring of earth (a sort of reverse moat) used as a form of fortification during the Iron Age. Camera in hand, I struggled to get up the hillside to see this henge. It was steep. There were more bugs than troops in the Chinese Army and I was nearly eaten alive. I got soaked by the storm but made it. The storm passed, and the bugs returned.

A (Faux)

THE REAL STONEHENGE

Monument for the Ages Everyone’s heard of Stonehenge in England—the weird stone blocks in the middle of a field. But who has heard of Foamhenge in Virginia? It is a full size replica of the real Stonehenge made of EIFS. Who could dream up a cooler name? HOW THIS TALE EVOLVED A friend and I take a road trip every year to see the various beautiful areas of America. Whenever we go on a road trip, one of our criteria is always go to someplace quirky or full of strange people—like Roswell, N.M., Area 51 in Nevada or Washington D.C. I had never heard of Foamhenge but she spotted it in some travel magazine and it was located en route to where we were headed in the Blue Ridge Mountains. We had to go see it. Blessed by GPS, we found it out in the boondocks.

Salisbury Plain. To say the least, the first modern people that stumbled upon it probably wondered, “What the devil is this?” It is about 2,500 years old. Foamhenge is on unoccupied farm land on a small hilltop. There is no admission fee or security. The place has an odd vibe, especially when we were there (a summer thunderstorm was approaching). It was eerie. It’s a great place to take a break while driving on the boring nearby interstate highway.

THE DAY OF THE VISIT WHERE IS STONEHENGE AND FOAMHENGE? The real Stonehenge is in southern England on a flat area known as the

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| Walls & Ceilings | September 2011

Foamhenge is just off of I nterstate 81 near a town called Natural Bridge. It is in the middle of nowhere in Virginia, on a knoll.

The real archeological treasure of Stonehenge has been the source of much study regarding its purpose and how it was built—how do you move and then tilt up these massive stone slabs without heavy machinery? It appears to have been built by an odd group, known as Druids. The Druids apparently had strange tendencies and curious ceremonies—such a human sacrifice and fun times without clothing. The Romans, when they first came upon Stonehenge, pronounced the Druids weird and suppressed them. The American who designed and built this replica, Mark Cline, is—by all accounts—eccentric and has done many curious and creative works of art. As evidence, he was really into those post World War II Japanese monster sci-/fi movies—the ones with some guy in a wetsuit and a blow torch in his mouth—tromping around a model train layout. Godzilla is the classic example.

HOW WAS FOAMHENGE MADE? Foamhenge is made of huge blocks of EPS and is coated with EIFS coatings and then painted to look like stone. It was built in six weeks by the designer and a team of plasterers. My friend made the astute comment that she didn’t realize that EPS blocks could be made so big. This

made me think that perhaps smaller blocks were spliced together. Looking at the photos of yours truly, do any readers know how big EPS blocks can be made? A plaque at the site said the foam blocks came from a molder in eastern Virginia.

WHAT CAN YOU NOT DO WITH EIFS? EIFS is amazingly versatile and is often used to mimic other materials, such as statues and pottery and all manner of stone-like things. But Foamhenge takes the cake for weird uses of an architectural material. Just for the record, there are numerous Stonehenge-like attractions scattered around the Earth but this is the only EIFS one I’ve found. No joke: there are henges made of old cars, abandoned refrigerators, ice sculptures and so on. You will note in the photos that the Foamhenge slabs are sculpted to look like real stone (with imperfections, etc.). Apparently, the designer went to the United Kingdom and photographed the real slabs from many angles, and then had the foam slabs in the U.S. sculpted to look the same.

THE FOAM FINISH LINE If you are passing through this area, this place is really worth a stop. Foamhenge is a good example of what can be done with EIFS and imagination. If you are handy with a trowel and want cars to stop in front of your home at Christmas to look at your decorations, make yourself a Foamhenge II. Your neighbors will no doubt talk about you. I am not sure if your local perplexed building department will require some permit. W&C Robert Thomas is a nationally recognized EIFS consultant, based in Jacksonville, Fla. He was the manager of technical services for a major EIFS producer, is the author of several books about EIFS and chairs the ASTM committee on EIFS. If you read this article, please circle number 282.

THE EIFS ASPECTS OF FOAMHENGE The coatings are like standard EIFS finish coatings in some places and then in some places not. In some areas you can see the reinforcing mesh but in other places the coatings are a weird, soft-spongy material. In any event, this piece of work has been out in the weather for more than 10 years and appears to be holding up fine. Strangely, I didn’t even spot any graffiti. I looked carefully at the base of the slabs and could not tell how they were anchored to the earth. Given the exposed location of Foamhenge (on a knoll, windy, etc.), I suspect there’s a slab just below grade and rebar that anchor the faux stone (EPS) blocks to the slab. I thought of writing to the designer, Mark Cline, and asking him how it was built but the hippies told me he‘d died. (EDITOR’S NOTE: Mark Cline, owner of Enchanted Castle Studios, is alive and well, living in Virginia).

RAISING THE SLABS At Foamhenge, there’s a small plaque explaining how scholars theorize that the real solid stone slabs were raised. It shows timbers and other props. The theory is that a series of wedges and levers were used to stand up the huge slabs—very slowly and in tiny increments— without the use of then non-existent cranes and forklifts. It begs the question: How did they get the horizontal slabs on top? Scholars say that cranes were not in the budget and the French refused to loan theirs. Please Circle #125 On Reader Action Card September 2011 | www.wconline.com |

51

straight

GREEN BY CHRIS DIXON

SERF A Green Building Rating System for the Rest of Us?

I like choices. Who doesn’t? When I was in college on a study abroad program for a semester, I visited then communist-ruled East Berlin and got a little taste of what it was like to live life with very few choices. Entering an East Berlin department store, I was moved with the rest of the people in the store like cattle, single file, between roped off islands of new, ’50s-looking merchandise. In all cases there was one item to choose from among the merchandise displayed; one style of blue jeans, one clock radio, one coffee maker, etc. No touching allowed, no fitting rooms and no helpful salesperson answering questions. And why would it need to be any other way, with only one of each item to choose from? My brief visit to East Berlin was eye-opening, to say the least and made me appreciate so much more the choices that I was accustomed to having. Years later in my life, after serving two years in the Peace Corps, one of the fi rst things I did when I returned home was to hit the grocery store for some comfort food. In the country I served there were no grocery stores, just mom and pop shops that sold only the bare necessities—rice, bar soap, sugar, Spam, Navy biscuits and Ovaltine among them. I could not wait to get back home and eat all of the food I missed so much. The fi rst thing on my list was pickles (I have no idea why). In the mega grocery store I was presented with a glut of pickle choices. There were sweet, dill, spicy, bread and butter, baby,

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gherkin, Kosher, candied, chipped, waffle-cut, spears, halved, etc. An entire aisle’s worth. It was overwhelming. I stood there for quite a few minutes, the number and variety of choices put me into a daze. So why is it, in this great country of ours, filled with choices upon choices from everything from jeans to clock radios to even pickles, that we have so few green building rating systems to choose from? That’s exactly what Joe Maguire wondered and what drove him to develop the Society of Environmentally Responsible Facilities, a green building rating system for anyone looking for an alternative to LEED (but not Green Globes*). Maguire is a property developer with a BA in economics from Northwestern University and a MS from the Columbia University Graduate School of Architecture, Planning and Preservation. As a third generation property developer, Maguire rubs shoulders on a daily basis with other developers that, like him, were desperate to become engaged in building green but frustrated with the single certification choice available to them (LEED) with its associated complexity, expense, and time consuming process. In April 2010 Maguire began a discussion with his peers about creating a new, inclusive g reen

building rating system similar to LEED, but without all the headaches. A rating system that focuses on advancing the concept of what Maguire calls Practical Environment a l S tewa rd sh ip. A f ter si x months of hard work, SERF was rolled out in October of 2010 and now boasts 32 certifi ed buildings, with 14 more in the process of becoming certified. This far exceeds Maguire’s initial expectation that 24 buildings would be certified under the fl edgling system by this date. He hopes for a total of 75 SERF certifications by the end of the year and 200 by the end of next year. At this rate, it won’t take too long for SERF to make a noticeable dent in LEED’s commanding 9,000plus building certifications.

SERF: A CLOSER LOOK Maguire’s promise to people that decide to use SER F over LEED is that it will be far less expensive (between $4,000 to $12,000 depending on square footage), will be far easier to submit (using a simple fi ll-in-the-blank form fi lled out by one person) and much quicker (from four to six weeks from receipt of application to cer tification). Compare this to LEED’s $8,000 to $70,0 0 0 documentation cost (according to the study “Analyzing the Cost of Obtaining LEED Certification” by Northbridge Environmental Management Consultants), its multiple credit template forms required to be fi lled out and signed by multiple project team members and an average 18 month time period from receipt of project application to certification (according to Maguire), and SERF comes out a very clear winner. SER F has cer tification applications for several building types including residential (single and multi-family), office, distribution and manufacturing, retail /commercial and institutional /other. Each application has a unique set of point categories and total number of points. Certification requires that a building achieve a percentage of

the total available points (roughly 40 percent for new buildings and 30 percent for existing buildings). Requirements for earning points are largely prescriptive and include the following categories: • EnergyStar-rated HVAC equipment • Building automation systems • Enclosure R values • Interior and exterior lighting efficiency • Storm water management • Appliance efficiency • Landscaping • Water use • Air quality • Renewable energy To maintain certification, SER F requires that buildings recertify on an annual basis for a nominal fee ($195 for single family residential and $295 to $495 for all other building types). Recertification is granted as long as there have been no “material changes” to the building in the intervening time period between certifications. The certification process involves on-site verification of the claimed p oi nt s by a n a rc h it e c t , e n g i neer, builder or building inspector licensed in the state of the subject facility as well as a random audit by SERF for an unspecified number of points being pursued.

ROOM FOR IMPROVEMENT There is a lot to like about SERF, primarily its simplicity and ease of use. It will appeal to anyone who has banged their head against a wall after dealing with the bureaucratic morass that the LEED documentation and certification process has become. The challenge for Maguire, which he freely admits, is to carefully balance the rigor of the system against ease of use. Too much rigor kills incentive for use, and not enough rigor results in a credential with little meaning. Maguire has done a good job of balancing both and takes SERF building certifi cation very seriously. This is not a rubber stamp certification.

There are, however, some very simple changes that could be made to the rating system to make it even better without compromising its simple elegance. My wish list of improvements includes: • Minimum Point Requirement per Category: Most people will readily agree that energy performance of a building is by far the most important environmental consideration for building green. Requiring a minimum number of points be achieved in the most important point categories, such as energy conservation, will result in a more environmentally friendly building. SERF currently allows a building to be certified without employing ANY of its energy conservation points, which is an oversight that must be immediately corrected for the system to be truly credible. • Point Scaling: Instead of an all or nothing whole point reward, I recommend that teams be allowed to scale available points based on actual percentage achieved. For example, instead of offering two points for installing pervious paving for 80 percent of total paving, allow a percentage of the available two points based on actual percentage of pervious paving installed. If only 40 percent pervious paving is installed, allow one point to be awarded. Arbitrary bench ma rk requ i rement s k i l l incentive to do anything. • Tie Recertification to Building Performance: Recertification of a green building rating should be about how the building performs. SERF provides annual recertification based solely on the requirement that nothing has materially changed, which means, according to Maguire, that no space was added to the facility or substantially renovated. To be regarded with any credibility, a recertification should be recognition that a building is performing as intended. A building that touts itself as green but consumes more resources than predicted, with systems that do not function as intended,

should not be further rewarded with a bogus recertification.

CONCLUSION SERF could very well be the green building rating system that I had hoped Green Globes would be—a rating system for the rest of us, those that cannot bear the burden of a complicated and expensive LEED certification process. SERF, in contrast to LEED, is simple to use, simple to understand, inexpensive and takes very little time to achieve from application to certifi cation. With a few simple improvements to SERF, I believe that it could be a system the majority of builders could use for green certification and engage more of them in those practices rather than just the elite few who can pursue LEED certification. We certainly don’t need the equivalent of pickles in a supermarket, but it is nice to know that we are no longer stuck with a single 1950s clock radio.

REFERENCE *As a Green Globes Technical Committee member, it pains me greatly that nothing has happened with Green Globes, the first ANSI green building Standard, since its development. I recently called the Green Building Initiative (The GBI, which administers Green Globes) office number and spoke with a gentleman on the telephone that did not even know there was a Technical Committee, did not know the status of the newly minted Green Globes ANSI standard and made an unfulfilled promise that someone would to get back to me soon with information on Green Globes availability. I have no idea what is happening with Green Globes but since it remains unavailable, it cannot be included in the list of possible choices. W&C Chris Dixon is a registered architect, Certified Construction Specifier, and LEED AP. He serves on GBI’s Green Globes Technical Committee and is a former USGBC Materials and Resources Technical Advisory Group member. If you read this article, please circle number 283.

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NEW PRODUCT BUZZ GUIDE E EASY, ACCURATE CEILING TTRANSITIONS A ARMSTRONG CEILINGS N ew t r a n s i t i o n m o l d i n g f r o m AArmstrong is a simple solution for cclean transitions from a suspended cceiling—including mineral fiber, wood aand metal—to a drywall surround. Compatible with all Ar mstrong C ssuspension systems and drywall grid ssystems, the hot dipped, galvanized transition molding eliminates the need for a vertical drywall return at the transition, return framing to support a drywall return, and corner bead and vertical taping. For more information, visit armstrong.com/transitions9wcpb.

B BASECOAT STUCCO - PUMP GRADE G Q QUIKRETE QUIKRETE Basecoat Stucco - Pump Q Grade is a fiber-reinforced, Portland G ccement-based stucco designed for uuse as the scratch and brown coat iin three-coat and two-coat stucco aapplications. It is specifically formulated to be highly flowable and has very low sag characteristics. The product is available in 80-pound bags and 3,000-pound bulk bags with a silo delivery system. For details, visit QUIKRETE.com. If you read this article, please circle number 205.

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e2XP TILE BACKER N NATIONAL GYPSUM National Gypsum has introduced N Gold Bond brand e 2XP Tile Backer, G a fiberglass-faced gypsum panel for iinterior tile applications in both wet aand non-wet areas. e2XP Tile Backer is i comprised of an acrylic-coated fiberglass front facer, which provides a water barrier for superior moisture resistance capabilities. This makes it ideal for use in interior residential and commercial applications such as shower and tub enclosures, walls and ceilings, countertops, backsplashes, locker rooms and more. For more information, visit http://purplechoice.info.

A ACCESS DOORS, FLOOR DOORS & ROOF HATCHES D D DEMAND PRODUCTS INC. TThe company’s access doors, floor ddoors and roof hatches are steel, sstainless, aluminum, galvanized llath, glass fiber reinforced and fire rrated. These have multiple uses and ssizes, and can blend into surroundiing drywall. • Multiple materials for all jobs • Wide variety of sizes • Many fire-rated styles • Styles for all applications • Meets most building codes

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For more information and for a free catalog, ask your distributor or manufacturer rep. Visit us at www.demandproducts.com. If you read this article, please circle number 207.

BONUS WITH SET OF TOOLS B AL’S TAPING TOOLS A AAl’s Taping Tools is running a Special oon One Set of Tools. Get 1 Free Bazooka and 2 Free Pumps G with set of tools!! w TThis is Crazy!! For more information, visit www.drywalltools.com and Call us regarding the Set of Tools Special Offer! If you read this article, please circle number 208.

S STAINLESS STEEL LATH AND ACCESSORIES A A AMICO FFrom AMICO, Stainless Steel T304 TTrims are now available in addition tto T304 and T316 Stainless Steel LLath. The products provide excellent ccorrosive resistance for specialty llath applications. The cornerbead, casing bead and control joints meet ASTM Specifications C1063 and C841. The lath meets ASTM C847-95. AMICO is proud to be the first company to offer these outstanding products as standard items in our comprehensive line of lath products. For more information, visit www.amico-lath.com. AMICO is a Gibraltar Industries Company. If you read this article, please circle number 209.

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| Walls & Ceilings | September 2011

NEW PRODUCT BUZZ GUIDE F FASTER INSTALLS WITH HYDROTRIM H

QUALITY BASE COAT STUCCO Q

For information, visit www.no-coat.com.

S SPEC MIX FFiber Base Coat stucco is formulated ffor optimum workability, reduced sshrinkage and maximum coverage oon every project. There is no sand to sshovel, eliminating the expense of wasted labor and material. On top w oof complete quality assurance, SPEC MIX FBC is more cost effective. It yields up to 30 percent more stucco compared to the same amount of bagged products and damp, loose sand shoveled into a mixer. Available in 80-pound bags or 3,000-pound bulk bags, FBC stucco increases productivity and profitability—every time. For more information, visit www. specmix.com.

If you read this article, please circle number 210.

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S STRUCTUS BUILDING TECHNOLOGIES N HYDROTRIM corners are a faster, H ssimpler alternative to metal and pplastic bead. Combining durability with the convenience of a waterw aactivated adhesive, HYDROTRIM will not bubble, blister, crack or w ddent. Once wet, HYDROTRIM can be adjusted during installation, drying within 5-10 minutes for rapid finishing. Available in both Outside 90 and Bullnose profiles.

ADJUSTABLE MATERIALS CART A A ADAPA INC. TThe Tree Cart helps keep a floor uuncluttered and the job site more ssafety compliant. The cart makes the moving of multiple long and narrow m cconstruction materials a snap—a featture that is useful for a warehouse ssetting. At a job site, it can carry ddrywall metal, grid metals and many oother long items. Reset the “branches” 90 degrees and the cart can carry sheet-like pieces. Its telescoping assembly feature allows it to accommodate a variety of long materials being handled or stored. Rolling on 5-inch swivel casters, this 65-pound cart is a real mover. Visit www.adapausa.com for more information and see our complete line of products for the drywall industry.

DEFLECTION CLIP D F FLEX-ABILITY CONCEPTS TThe Three Legged Dog deflection clip bby Flex-Ability Concepts eliminates ffumbling or dropped clips. Slide the cclip onto the top end of the stud. With the clip attached, raise the W sstud into the deep-leg track and ssnap into place. Then, secure the cclip using conventional fasteners. TThe Three Legged Dog allows for 17⁄8 -inch of total deflection. www.flexabilityconcepts.com If you read this article, please circle number 213.

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T TONGUE AND GROOVE WALL AND CEILING PANELS A E EXTRUTECH PLASTICS INC. TThe company is an ISO 9001-2008 Certified manufacturer of bright white C ttongue and groove wall and ceiling ppanels that are perfect for incidenttal food contact applications. Panels install quickly with no exposed fasteners, providing a smooth, easy to clean surface. With suspended ceiling panels and corrosionproof doors also available, Extrutech Plastics can cover all your wall and ceiling needs. For more information, visit www.epiplastics04.com. If you read this article, please circle number 214.

4,000 CAPACITY SELF-DUMPING HOPPER 4 J JESCRAFT TThe self-dumping Hopper model# DH-20BR fits oon forklifts and telescopic handlers, which makes material removal from the job site easy and effim cient. It is secured to the forklift blades, raised from its loading position on the ground and dumps into a larger debris box. Once unlatched, the Hopper automatically rolls forward to dump, returning to its upright locked position when empty. A key feature is the front release bumper, which by coming into contact against the receiving debris container, automatically releases the spring loaded latch and dumps the debris. Additional features include a safety chain: a 50-inch long release pull cable allowing the operator to manually dump loads from the seated position. Optional caster sets can also be ordered making it perfect for indoor use as well. Its capacity is 4,000 pounds or 2 cubic yards with other sizes also available. Visit www.jescraft.com for information. If you read this article, please circle number 215.

September 2011 | www.wconline.com |

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NEW PRODUCT BUZZ GUIDE R RUSTFREE ULTRA-LATH NOW COMES PAPER-BACKED! C P PLASTIC COMPONENTS, INC. PPlastic Components’ Ultra-Lath plastic llath is better and easier to use than metal and it’s rustproof. The product is m eeasy to handle and now comes backed with asphalt-impregnated paper for w ssuperior moisture control. The selfffurred Ultra-Lath PB improves the keyiing of stucco/plaster. Combining paper aand lath applications into one process saves time and eliminates upside down lath installations. • It has no effect on cellphones or wireless transmissions • 27-inch-by-96-inch sheets

WEATHER DEFENSE PLATINUM W L LAFARGE NORTH AMERICA INC. LLafarge Weather Defense Platinum is a moisture- and mold-resistant exterioor wall sheathing designed to be coveered by an exterior-finish cladding. It iis lightweight, scores, cuts and fastens eeasily, and provides irritation-resistant handling. It also provides protection in most applications, under normal weather conditions, from exposure to the elements for up to 12 months. For more information, please contact your area sales manager or the Lafarge Customer Value Department. Visit www.lafarge-na.com for further information. If you read this article, please circle number 217.

For more information, visit www.plasticomponents.com. If you read this article, please circle number 216.

M MORE THAN CONSTRUCTION SOFTWARE S O CENTER SOFTWARE ON TThe company offers more than biddding, estimating and project-trackiing software. We are a fully in-house ooperation, putting everything from development to technical support and hi-tech training facilities under one roof. We offer training and software support packages that are all aimed at a singular goal—to win our clients bids and grow their profits. For more information, visit www.oncenter.com. If you read this article, please circle number 218.

A ECONOMICAL AND ULTRA AN DURABLE COATING FOR D BEAUTIFYING PAINTED CMU! B T TOTAL WALL TTuff II is a ready-to-use, all acrylic syntthetic plaster that will transform any ppainted masonry into a fresh natural sstucco look. Tuff II is durable, crack rresistant and mold- and mildewresistant with proven performance on thousands of projects in all climates over a 12-year history. The product is being used by the United States Military to transform their painted masonry structures into durable attractive stucco clad structures. Join the growing list of success stories today! Please contact Total Wall for a free sample! For more information, visit www.totalwall.com. If you read this article, please circle number 219.

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PLATINUM EXTERIOR SHEATHING

Platinum Protection for serious professionals

Jeanne McGrath, President Holmes Drywall Supply, Inc. One of the Midwest’s largest drywall distributors

“ We are very serious about meeting the needs of today’s construction professional, and for our customers nothing but the best will do.” – Jeanne McGrath Introducing Weather Defense Platinum™, Lafarge’s newest exterior gypsum sheathing offering superior mold and mildew resistance backed by a 12-month exposure warranty. Weather Defense Platinum is easier to handle and cut than traditional fiberglass-faced boards and has the industry’s highest percentage of recycled content (over 90%) for higher LEED® credit contributions.* Get covered with Platinum Performance. *For specific LEED credit information visit certguide.lafarge-na.com

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