A L A B A M A CO NCR E TE I NDUS TRIES ASSOC IATION M AGAZ IN E | SU M M E R 2014
POLISHED CONCRETE FLOOTS | AUBURN, AL
SUMMER 2014
ConcreteWorks is a publication of the Alabama Concrete Industries Association and features articles and photographs pertaining to product applications, educational opportunities, as well as innovative construction techniques impacting the industry. Please email rlindsay@ alconcrete.org with any comments regarding featured articles in ConcreteWorks or to suggest a story idea for a future edition. Rebecca Lindsay,
2
TABLE OF CONTENTS
Unmovable
Just a few short years ago, plans were
16
Keep on Trucking
The Annual Truck Driver Championship
put in place to construct a new School
brings together some of Alabama’s best
of Kinesiology Building on the campus
concrete truck drivers, providing a family-
of Auburn University. The new building is
friendly event and a little lighthearted
receiving much attention, and is closer than
competition. Held at Barber Motorsports
ever to becoming the best in the nation.
Park, this is one of the industry’s favorite
6
events.
Pacific Protection
In April 2014, the new United States Naval
22
Technical Review
In this interesting article, Jason
Art Director & Editor
Hospital opened in Guam. With beautiful
Thompson with the National Concrete
John Sorrell, Editor
views of the Pacific Ocean, the new design
Masonry Association explains the
provides an attractive and functional
evolution of concrete masonry and the
answer to the healthcare requirements of
impacts it has in today’s market.
www.alconcrete.org www.mysaferoom.org
the military, and is constructed mostly of concrete. (ON THE COVER)
10
Architect Spotlight
In Les Tillery’s 17-year career, he has
27
2014 Calendar
New to ConcreteWorks, the 2014 summer
designed many notable projects, and
calendar will help you save all the
credits concrete as one of his favorite
important upcoming dates.
products to use. Read why he loves it, and how he is using it today to design some of Huntsville’s newest buildings.
PROJECT SPOTLIGHT
in the country is now closer than ever to
create and implement an invigorating
becoming a reality.
learning environment for undergraduate and graduate students, and improve the
The School of Kinesiology at Auburn is the
health and wellness of society through
center of research and study on human
research, outreach, and teaching.”
movement and physical activity, and offers
MOVABLE
Close collaboration between the design
Kinesiology
is
movement,
or
the
study
motion.
of And
building
School
of
for
Auburn
Kinesiology,
toward attaining the title of best of the best. After being housed in the AU Wellness & Student Activity Center for many years, it
space tailored to meet the needs of the
was decided that the school needed its on
when
School’s unique assortment of research
facility, and in 2010 Infinity Architecture in
and outreach endeavors.
Montgomery was chosen for the project,
University’s
the
the facility the opportunity for advancement
human
plans were put in motion to design a new
team and the faculty leadership allowed
and the design process began. Ground
outcome
The School mission is “to promote the
was broken in 2011, and the new building
exceeded expectations, and the goal of
creation and application of knowledge
was completely finished in February 2012.
becoming the best Kinesiology program
about physical activity and performance,
PROJECT SPOTLIGHT
Sited on Wire Road, adjacent to the tennis
organized based on the needs of different
there are recessed pits that have a special
courts and the Recreation and Wellness
areas within the school, as some needed
foundation, separate from the building
Center, the 58,000 square-foot facility,
access to the exterior, some needed to be
foundation, to assist with the intended
using concrete as the main component,
more private, things of that nature.”
function of those pits. The pits support
houses more than 20 faculty and staff
a lay in access floor that is level with
offices, as well as laboratories that conduct
Interior gathering spaces and multiple
the ground floor slab, and which works
a broad range of research relating to human
exterior porches provide opportunities
with special force plates used in different
movement, health and performance. It
for student and faculty collaboration,
experiments.
serves 650 students and offers much-
while extensive outdoor space provides
needed space to meet the needs of
a setting for research beyond dedicated
The recessed floors, where the force plates
the department’s unique assortment of
laboratories.
are located, had to be poured separately,
research and outreach endeavors.
and to a special specification in order for The entire ground floor of the East and
the readings from the force plates to be
“The building itself is very diverse, and
North side of the building is cast-in-place
most accurate. These force plates are
definitely not ‘cookie-cutter,’ says architect
(CIP) concrete, which was left exposed for
used in biomechanics research labs where
Nicole Truitt. “The design itself was
design purposes. In the ground floor labs,
they study anything from the minutiae of
EXTERIOR OF AU KINESIOLOGY BUILDING | AUBURN, AL
SUMMER 2014 3
PROJECT SPOTLIGHT
a persons step to larger scale running or
ability to provide strong walls, safety and
jumping type movements. The force plate
disaster resistance, mold, rot, mildew, and
areas are surrounded by special lights and
insect resistance, energy efficiency and to
cameras which use ‘stop-motion filming,’
block sound.
that the students and researchers can analyze to assist with their efforts.
“Concrete is a great material to use for sound-proofing, and in this case it was
Cast-in-place concrete walls are made with
necessary when there are so many different
ready-mix concrete placed into removable
activities going on inside of the building,
forms erected on site. Historically, this
especially things like aerobics classes,”
has been one of the most common forms
says Nicole. “It helps to minimize the
of building basement walls. The same
vibrations and create a much more quiet
techniques used below grade can be
working environment.”
repeated with above-grade walls to form the first floor and upper levels of buildings.
The School of Kinesiology is currently pursuing
LEED
Silver
certification,
“In the case of the Kinesiology building,
designed to provide inhabitants with
concrete was an integral component of
extensive
strength, keeping the building solid,”
opportunities, reducing a need for artificial
says Nicole. “If I had my choice, I find
lighting. Daylight harvesting is achieved
exposed concrete beautiful and would
through building controls and each room
use it all the time.”
includes exterior shading devices, interior
views
and
day
lighting
shading, automated lighting and HVAC The
benefits
of
CIP
concrete
are
controls that monitor occupancy. The
numerous, and it is generally used for its
interior finishes are low VOC, sustainable
PROJECT SPOTLIGHT
and/or recycled products. Energy recovery
says Mary Rudisill, distinguished professor
Rudisill says it best when she stated ‘our
is actively achieved in the HVAC design
and director of the School of Kinesiology.
building has already helped us to advance
and controls, as well.
“This past summer our Performance and
our mission at an accelerated pace.’
Health Optimization Center became the “The new facility has created a number
high performance training center for the
of exciting opportunities for the School of
USA Team Handball teams, and we hope
Kinesiology, and our collaborations with
to become an Olympic Training Center in
outside entities have dramatically increased,
the near future.”
I doubt anyone would disagree.
expanding our research and outreach,”
IF I HAD MY CHOICE, I FIND EXPOSED CONCRETE BEAUTIFUL AND WOULD USE IT ALL THE TIME.
AU KINESIOLOGY BUILDING | AUBURN, AL
SUMMER 2014 5
PROJECT SPOTLIGHT
PACIFIC PROTECTION
THE UNITED STATES NAVAL HOSPITAL | GUAM
PROJECT SPOTLIGHT
The United States Naval Hospital in
physical
therapy,
Dietician,
Health
Guam’s motto is ‘delivering readiness,
Promotions and social work services.
community and its beneficiaries,” says Parker.
quality care and health where America’s
providing
services
while
The
the
withstanding all potential calamities, both
replacement of the aging, but venerable
natural and man-made. And, the design
opportunity to design the new structure,
1950’s era Naval Hospital at Guam.
provides a cultural hub for continued
he met the challenge head-on. Opening
The new design provided an attractive
goodwill ambassadorship between the
in April of this year, the 281,000 square
and functional answer to the healthcare
United States and the Government of
foot medical facility offers a broad range of
requirements of the military and supported
Guam and its citizens on island.”
medical services including family practice,
dependents and retirees in order to serve
OB-GYN,
the mission of the United States in the
The U. S. Naval Hospital is distinct because
Pacific basin.
it serves as the essential healthcare facility
surgery,
anesthesia, internal medicine, psychiatry, psychology,
occupational
health
on
required
Sherlock, Smith and Adams was given the
general
concentrated
the
day begins,’ so when David Parker with
pediatrics,
project
“The facility is now capable of
and
for the Pacific Rim. As an important
preventive medicine, emergency medicine,
“The design outcome achieved a creative
interface between the U. S. military and the
dental surgery, urology, otolaryngology,
and flexible response to the functional
local population, the hospital is designed
ophthalmology, optometry, acute care,
demands
to meet the day-to-day needs of service
of
the
military
healthcare
SUMMER 2014 7
PROJECT SPOTLIGHT
members and the local population while
modified, and the project design was
the main public entrance area the arches
incorporating design contingencies for
restarted in 2008, and completed in 2010.
give way to site-cast vertical concrete sun
mass casualty potentialities. The project is
Construction began in early 2011 and has
and wind screens. These devices provide
distinct in location, because of the strategic
very recently been occupied.
protection from the sun which can be harsh
importance of Guam to the interests of the
on Guam, and they also provide protection
United States in the region, and different
It was always understood that the Naval
from wind-borne debris which may be
because of the design challenges that
Hospital would be a special project due
caused during the regularly occurring
were met to maintain continuing operation
to its critical mission and the rigors of
typhoon events on the island. All of the
following first order seismic and/or weather
responding effectively to its environment.
exterior concrete on the project is finished
events
geologic
How to build a bunker, and make it an
with a spray-applied synthetic stucco
activity (Marianas Trench) and climatic
which
attractive, modern major medical facility
coating which provide an evenly-textured
activity (typhoon force winds).
too? The solution is cast-in-place concrete.
and multi-colored finish to the facades.
The process of designing the Naval
“The entire facility is cast concrete; ground
On the interior in the major public spaces
Hospital, Guam was challenging.
The
slabs, frame, elevated slabs, roof slabs,
concrete is on full display as well. The day-
Program for Design (PFD) for the project
and exterior walls. The plastic nature of
lighted, barrel-vaulted three-story atrium
had been completed a significant time
concrete is on full-display with the robust
space features curvilinear concrete beams
prior to the actual design of the project.
projecting overhang at the cornice, which
of intricate design and textural decoration.
As such, technologies and requirements
conceals a built-in cast-in-place concrete
The
had
changed
could
include
during
the
interim,
robustness
of
the
concrete
is
gutter,” says Chief Structural Engineer
juxtaposed with the delicacy of the glass
resulting in adjustments to the project’s
Chuck Singley.
partitions and custom signage and the
requirements during design. Additionally,
providing
changing requirements for supporting the
Spanish Heritage of the island, occur per
troops assigned to the geographic area
structural bay, with windows integral to
“The resulting building is a sophisticated
contributed to fluctuations in project’s
each arch. The arches which occur in the
use of cast-in-place concrete for the entire
requirements. After having been started in
bays surrounding the main entrance, are
structure and exterior closure,” Singley
2005, the project was paused for a time,
sculptural in nature, providing a significant
says.
the program requirements were significantly
relief to the face of the façade. Away from
the project were very demanding and well
Decorative twin arches,
historical
references
to
the
stainless steel cable railings.
“The formwork requirements for
EXPANDED AND RESTORED PUBLIC SAFETY BUILDING | MONTGOMERY, AL
PROJECT SPOTLIGHT
executed. The building will be a permanent
hour, would be “like blasting a fire hose” at
fixture in Guam for generations to come;
panel joints damaged by earthquake or the
this, in an environment that is one of the
harsh tropical environment.
toughest in the world – thanks in large part to concrete.”
So the solution was an entirely concrete structure seismically designed under the
During the conceptual design phase,
American Concrete Institute’s provisions
a
various
for special reinforced concrete shear walls
comparative
concrete
and
analysis
schemes
and framing. The resulting building proved
were performed. In addition to initial cost,
so stiff that little to no internal damage
weightings were assigned to such factors
to building elements is expected under a
as wind, seismic, blast, sound, vibration
design seismic event. After going through
TOP LEFT: Concrete roof being placed
and corrosion resistance, thermal inertia,
the design process, it came as no surprise
TOP RIGHT: Hospital atrium
long
requirements,
that the design solution essentially matched
BOTTOM RIGHT: Exterior construction
LEED, tradesman availability, use of local
that of the existing adjacent six decade
materials, and local custom.
old hospital to be demolished, which has
term
steel
of
framing
maintenance
performed so well through multiple serious For each of these factors, concrete was the
earthquakes even though not designed to
winner.
modern code requirements.
An interesting finding in the analysis was
When asked what the designers’ favorite
that while an economical solution could
design aspect is of the new hospital, their
have been had with a steel frame stabilized
answer was simple.
by diagonal braces with viscous dampers and clad with precast concrete panels,
The ability to bring form, rather intricate in
building motion during even low intensity
numerous places, to the building with one
seismic events, which are frequent, would
single, durable material, and that material
rupture the sealants between the panels.
is concrete. It provided a simple solution
One design team member pointed out that
to economically perform in a very harsh
wind driven rain during typhoons, that can
environment for generations to come.
have gusts well over two hundred miles per
SUMMER 2014 9
A R C H ITE CT S P O T L I G H T
DYNETICS SOLUTIONS COMPLEX | HUNTSVILLE, AL
AR CHI TE CT S P O T L I G H T
Les Tillery is a man of many talents, so it’s no surprise that he is a notable architect in Alabama. After graduating from Mississippi State University in 1997,
A FEW OF THE MANY REASONS WHY LES TILLERY USES CONCRETE:
Les began practicing architecture. And in 2003, he joined Fuqua & Partners
· Concrete is such a versatile material – it can be used for so many different things.
Architects in Huntsville, becoming a partner in 2010.
· It is a sustainable material – all of our LEED projects have received points for the use of concrete.
Les has many architectural designs in his 17- year career, with a few of his favorites
· It is extremely durable – works extremely well in environments that get a lot of abuse.
including none other than concrete. · Concrete is not limited to a certain number of manufactured shapes – the material The
Dynetics
Solutions
Complex,
which opened in Huntsville in 2012, is
a
226,500-square-foot
does have its limitations, but for the most part, if it can be drawn, it can be made out of concrete
prototyping
facility, incorporating the latest resources
· Concrete is typically a very high quality material. The concrete companies that we work with do an excellent job at delivering a product to the jobsite that is excellent quality and usually exceeds the design strength.
SUMMER 2014 11
...tilt up concrete is still the most cost effective way to build these buildings.
CAST IN PLACE EXTERIOR WALL OF RG7200 PROJECT
AR CHI TE CT S P O T L I G H T
available to produce quality products
Located
at
the
main
entrance
into
rapidly and affordably for both commercial
Redstone
and government customers.
building was designed as a 150,000
Arsenal
in
Huntsville,
the
square foot site that includes convenience It has 110,000 square feet of laboratories
retail, restaurants and hotels. The exterior
and manufacturing facilities and 116,500
of the building uses precast concrete and
square feet of office and conference
glass.
space. Features include 24 laboratories and five bays, with two labs and two
“The RG7200 Building also uses single-
bays meeting SCI-level requirements,
story tilt up concrete and LEED Certified
and 10K clean room, a vacuum chamber
Core and Shell,” says Tillery. “Concrete is
laboratory,
testing
an extremely affordable material, and the
laboratory, a PCB assembly laboratory,
an
environmental
main reason that the RG7200 project was
and an instrumentation laboratory.
done as tilt up construction is because of the cost – it was much more cost effective
“Concrete is the only material that I can
than other materials.
think of that can be both a boring utilitarian structural material and a beautiful interior
The design and construction process of
TOP: Interior hallway of Dynetics Solutions
finish material at the same time,” he says.
Redstone Gateway 7400 is about to begin,
Complex
“I like to use exposed concrete interior
and Tillery notes that it will also use tilt-up.
elements for this very reason.” “Even while the cost of concrete has gone The Dynetics Solutions Complex uses
up since 7200 was built, tilt up concrete
precast concrete exterior skin, as well
is still the most cost effective way to build
as polished concrete floors in prototype
these buildings.”
bays. In December 2013, RG7200 won the Another significant design of Les’ is the
North Alabama ABC Excellence Awards in
Redstone Gateway Building 7200.
Construction in three different categories,
SUMMER 2014 13
A R C H ITE CT S P O T L I G H T
GET TO K NOW LES TILLERY
including the Architectural Design Award
industry and is the only one of its kind in
of Merit.
North Alabama.
ABC Excellence in Construction (EIC) is
“It’s always proud and humbling moment
a nationwide awards program designed
to receive an award,” he says. “But my
to publicly recognize the quality and
favorite thing about being an architect is
innovation of Merit Shop construction. An
seeing the look on a client’s face when
EIC Award is one of the highest honors
they walk through their finished building
a contractor can receive, and is the only
and realize that the process to get the
construction competition that recognizes
building built, while challenging, was
the
absolutely worth it.”.
unique
partnership
between
all
members of a project team: contractors, owners, architects and engineers. ABC’s
What is the one tool you can’t
program
has
live without?
competition
become within
the
the
“premier”
construction
I have a leather pocket size flip notebook that I carry with me everywhere. An architect friend introduced me to this style
ABOUT FUQUA & PARTNERS ARCHITECTS
notebook, and looking back, I don’t know what I ever did without
Fuqua & Partners Architects, P.C. (FPA) was founded in 1982 to provide architectural
it. It’s great for sketching ideas,
and planning services. To offer clients a complete end product, the firm expanded its
taking quick notes, and it’s easy to
services to include Interior Design. With these complete services, Fuqua & Partners is
carry in my back pocket.
able to offer thoroughly integrated design solutions.
What’s the last book you read?
Fuqua & Partners has extensive experience in architectural, and interior design for
Knuffle Bunny: A Cautionary Tale
projects involving new structures, additions, renovations, alteration/modifications,
by Mo Willems. Don’t laugh, my 3
Historic Preservation, adaptive reuse and system upgrades.
year old, Bea, is really into Knuffle Bunny bedtime stories right now.
The firm has completed over 3600 projects, providing services for clients in Alabama, Tennessee, Mississippi, Georgia, Florida, Indiana, Oklahoma, South
What’s your favorite food?
Carolina, Kentucky and Louisiana. In addition to Fuqua & Partner’s experience and
Quail - marinated and sprinkled
technical skills, FPA is among the most respected firms in northern Alabama and the
with fresh herbs, wrapped in
surrounding states for its design ability and creativity, having received more than 20
bacon, and grilled in my backyard.
significant design awards in the past two decades.
It’s delicious. Such recognition is demonstrated by FPA’s receipt of the North Alabama Chapter of What is an interesting fact
the ABC 2008 Award of Excellence for 4 projects and also a 2008 Award of Merit,
that most people don’t know
the ABC Middle Tennessee Chapter 2008 Construction Award of Excellence, the
about you?
AIA North Alabama Chapter 2008 Merit Award, the ABC North Alabama Chapter
I can change the alternator in my
2007 Award of Excellence and the Alabama AGC 2004 Outstanding Architect of the
truck on the side of the highway in
Year. In 2009, Randolph School received an Award for Excellence in architectural
about 15 minutes. I found that out
design. Decatur Heritage Christian Academy, a private school in Decatur Alabama
the hard way.
was awarded an Award for Design Excellence in 2010.
Concrete...can be both a boring utilitarian structural material and a beautiful interior finish material
LOBBY OF DYNETICS SOLUTIONS COMPLEX | HUNTSVILLE, AL
SUMMER 2014 15
F E AT U R E
KEEP
ON TRUCKing
On a beautiful Saturday in April, some of
them on. The rodeo gives the drivers an
the state and industry’s best concrete truck
opportunity to show-off their skills with
drivers gathered at Barber Motorsports Park
a chance to win a cash prize and an all-
in Birmingham to compete in the Alabama
expenses paid trip to compete in the
Concrete Association’s 2014 Truck Driver
national competition in Indianapolis in
Championship, more commonly known as
August.
the “Truckin’ Rodeo.” This
year,
25
drivers
from
member
The annual event is held each spring,
companies including Ready Mix USA,
and the drivers are encouraged to bring
Webb Concrete, Sherman International,
their family members and friends to cheer
Kirkpatrick Concrete, Gulf States Ready
READY MIX USA CONCRETE TUCK | BARKER MOTOSPORTS PARK
SUMMER 2014 17
F E AT U R E
TOP: Participants in the 2014 Truck Driver Championships BAMA Concrete: Frederick Jones, Robert Slaughter / Gulf States Ready Mix: Isaac Johnson / Kirkpatrick Concrete: James Adams, Michael Adams, Terrell Bonner, Maurice Carr, William Flippo, Jim Hechler, Kevin Trammell / Ready Mix USA: Willie Benson, Paul Hatcher, Gaylon Lovelace, Roderick Parker, Todd McWhorter / Reed Construction: David Bradford,
Mix,
Bama
and a Game N’ Ride video game truck as
Jason Edwards / Sherman Industries:
Concrete participated in the contest. To
well as a remote control concrete truck
Buddy Batson, Ken Edwards, Charles
further challenge the drivers a written test
race kept the children entertained.
Grant, Billy Keith, Tony Peoples, Ronald
had to be completed before the driving
Ramsey / Webb Concrete: Tim Bryant
portion, which included various obstacles
As always, these events wouldn’t be
and maneuvers, began. To keep things fair,
possible without the help of our generous
Alabama State Troopers judged the event.
sponsors. A special thanks to Beck
Winner- Tony Peoples, Sherman Industries
Reed
Construction,
and
Team Winner- Ready Mix USA
Industrial, Nextran Mack and Volvo, Stan More than 115 family members and friends
BOTTOM RIGHT: AL State Trooper ready to judge competition
came out to support their favorite drivers,
Pate, and Truckworx
The rodeo gives the drivers an opportunity to show-off their skills with a chance to win a cash prize
THE 2014 TRUCK RODEO | BARKER MOTOSPORTS PARK
SUMMER 2014 19
The chute technology was designed for jobs requiring extreme precision.
F E AT U R E
Product Specs Function: fully-足 hydraulic Length: Max 9m / 30 ft. Weight approx: 700 kg / 1550 pounds The Ezextenz Concrete Chute is over
Swivel range: 180 degree
30 ft. long, fully-足 hydraulic and remote
Control: Remote-足c ontrolled, wireless
controllable telescopic concrete chute.
via radio
This highly innovative chute is a product
Drive unit: Hydraulic pump
of Mansarps Svets & Maskin (MSM), a Swedish construction, equipment and
MSM
security manufacturing company. The
Masarps Svets & Maskin (MSM) is a
chute technology was designed for jobs
privately owned Swedish construction,
requiring extreme precision. The chute
equipment and security manufacturing
In addition to the driving contest,
can swing 180 degree making any
company established in 1967. Today,
drivers took part in a skills
inaccessible area now reachable. With
it is run by the Niclas Hakansson, a
contest that required them to
its radio control unit, pouring is easy and
second generation of the Hakansson
position the Ezextenz chute
more importantly highly efficient.
Family. For over 45 years MSM has
into five buckets. The contest
had a stronghold on the construction
replicated situations a driver
The Ezextenz Concrete Chute, which has
industry in Europe and is focused on
might encounter in the field.
become the standard through Northern
quality, innovation and service. Ezextenz
Ezextenz provided $3,000 in
Europe, is now being introduced to the
Concrete Chute is one of many highly
prize money for the contest.
US market with official product launch in
innovative product solutions designed
May 2014.
and produced by MSM..
SUMMER 2014 21
TECHNICAL REVIEW
THE EVOLUTION OF CONCRETE MASONRY BY JASON THOMPSON It isn’t often that I recommend a book to read, and even less frequently on such topics as the history of concrete masonry. But if you are reading this article you will likely find From the Carriage Age…to the Space Age, The Birth and Growth of the Concrete Masonry Industry (Ref. 1) fascinating. Not because it is well written (it isn’t), or because it presents an otherwise dry topic in an entertaining light (it doesn’t). What From the Carriage Age…to the Space Age does do very well is provide background, insight, and reasoning behind the culture and products that define the concrete masonry industry as we know and understand it today. One passage in particular is noteworthy and relevant: In the early 1920s, the concrete block industry was in a chaotic state with respect to the sizes of concrete block. In that year, block were manufactured in 30 different lengths, 20 different widths, and 26 different heights. Architects were severely handicapped because they had no way of knowing what sizes would be delivered to the job until the block actually arrived. They
were,
therefore,
unable
to
dimension their buildings with any assurance that the units actually delivered would correspond to the dimensions. The book goes on to say that by 1924 block sizes were standardized and by 1927
SUMMER 2014 23
TECHNICAL REVIEW
“ninety-five percent of all concrete block were
to supply more sustainable products to the
direct means of transferring heat through
produced in conformity with this standards”.
marketplace by using less raw materials
a masonry unit as shown in Figure 1,
Shortly thereafter, the first version of ASTM
and energy during production.
Others
changing the configuration or size of the
C90, Standard Specification for Hollow
will see the ability to reduce unit weight
webs can have a significant and direct
Load-Bearing Concrete Masonry Units, was
and thereby increase mason productivity
impact on the resulting thermal properties
published in 1931.
and reduce injury and fatigue.
of an unfinished, single wythe concrete
Perhaps
the greatest opportunity these revisions
masonry assembly.
Little did these early pioneers know at
offer is the chance to increase the energy
assembly is to be solid grouted, in which
the time that these monumental efforts
efficiency of concrete masonry construction
case the web configuration is irrelevant
would come under scrutiny in 2011 as the
– particularly single wythe construction. In
regarding thermal efficiency, the modeling
concrete masonry industry contemplated,
my personal opinion, however, the market
results are simple: smaller webs equals
debated, and ultimately approved revisions
that can capture all of the nuances, as well
higher R-values.
to the prescriptive web configuration
as others related to production efficiency,
requirements that have been a part of ASTM
fire resistance, and other intrinsic properties
The relationship between web configuration
C90 for nearly a century. These changes,
of concrete masonry construction has the
and assembly R-value is illustrated in Table
which appear in the 2011b version of
greatest chance of success.
2 for 8-inch concrete masonry assemblies;
ASTM C90, Standard Specification for Loadbearing Concrete Masonry Units (Ref. 2), are shown in Table 1 and summarized
Unless the resulting
and again in Table 3 for 12-inch concrete
THE IMPACT OF WEB CONFIGURATION
masonry assemblies.
The middle two
columns of each of these tables compares
as follows:
the steady-state R-values of a conventional While
and
three-web, two core concrete masonry
ASTM
unit manufactured to comply with historical
sum of the individual web thicknesses per
C90 offers that are worthy of review,
ASTM C90 requirements to the R-values
foot of block length, has been removed.
this
on
that would result if this same assembly
those related to energy efficiency of the
were constructed using units manufactured
finished assembly.
to comply with the new ASTM C90-11b
• The equivalent web thickness, which is the
• The minimum thickness of each web cannot be less than ¾ inch (19 mm). • The total minimum cross-sectional area
there
opportunities
are
many
this
discussion
aspects
change
focuses
to
primarily
Other topics, such
as fire resistance, sound abatement, and
minimum web requirements.
structural design, will continue to be visited
differences between the R-values for these
in future articles and discussions.
assemblies are impressive; increasing the
of the webs connecting the face shells of
The relative
steady-state R-value by an average multiple
the unit cannot be less than 6.5 in.2/ft2
The modeling of the thermal properties
of 2.7 for the 8-inch assembly and 3.2 for
(45,140 mm2/m2), which translates to
of concrete masonry units is done using
the 12-inch assembly.
5.8 in.2 (40,280 mm2) for a unit with 8
the series-parallel (also called isothermal-
by 16 inch (203 by 406 mm) nominal face
planes) method as described in ACI 122R-
While illustrative of the concept, the R-value
dimensions..
02, Guide to Thermal Properties of Concrete
increases shown in Tables 2 and 3 do
and Masonry Systems (ref. 4) and ASHRAE
not, however, capture the entire array of
90.1-10, Energy Standard for Buildings
production,
Except Low-Rise Residential Buildings (Ref.
variables that must be factored into each
WHY CHANGE? Probably
most
importantly,
the
construction,
and
design
web
5). Using this code-recognized modeling
project. For example, manufacturing units
configuration changes recently introduced
procedure, the thermal properties (R-value
with the minimum web area permitted
into ASTM C90 require no change to web
and U-factor) of a concrete masonry
under ASTM C90-11b can be challenging
configurations or unit properties.
They
assembly are influenced by the presence
while ensuring the resulting product is of
do, however, permit the webs of units to
and placement of insulation, grouting, unit
consistent quality and can be handled
be configured differently to meet evolving
density, and configuration of the webs and
without
market needs. Some regions will view these
face shells.
architectural finishes such as split surfaces
changes to ASTM C90 as an opportunity
importantly, because the webs provide the
Further, and possibly most
damage,
are desired.
particularly
when
When incorporated into the
TECHNICAL REVIEW
Table 2 – Comparison of 8-inch Concrete Masonry Assembly R-Values (hr-ft2-°F/BTU)1 Unit Density
Conventional Three-Web, Two Core Unit
2,3
Minimum Web Permitted
ASTM C90-11b CMU
by ASTM C90-11b
Grouted at 48 in. o.c.3,4
3
85 lb/ft3
7.9
18.0
7.9
95 lb/ft3
6.7
16.3
7.4
105 lb/ft3
5.6
14.7
6.8
115 lb/ft3
4.7
13.1
6.4
125 lb/ft3
4.0
11.6
5.9
135 lb/ft3
3.4
10.2
5.4
1Single wythe assembly without finishes. 2See Reference 3, Thermal Catalog of Concrete Masonry Assemblies, for modeling procedure and design assumptions. 3Values assume ungrouted cells contain foam-in-place insulation and moisture-corrected values for thermal conductivity. 4Assembly constructed using two-web A-block at grout locations to confine grout.
Table 3 – Comparison of 12-inch Concrete Masonry Assembly R-Values (hr-ft2-°F/BTU) 1 Unit Density
Conventional Three-Web,
Minimum Web Permitted
ASTM C90-11b CMU
Two Core Unit2,3
by ASTM C90-11b3
Grouted at 48 in. o.c.3,4
85 lb/ft3
11.9
30.9
10.7
95 lb/ft3
9.9
28.0
10.1
105 lb/ft3
8.2
25.1
9.5
115 lb/ft3
6.8
22.3
8.9
125 lb/ft3
5.7
19.7
8.3
135 lb/ft3
4.7
17.3
7.7
1Single wythe assembly without finishes. 2See Reference 3, Thermal Catalog of Concrete Masonry Assemblies, for modeling procedure and design assumptions. 3Values assume ungrouted cells contain foam-in-place insulation and moisture-corrected values for thermal conductivity. 4Assembly constructed using two-web A-block at grout locations to confine grout.
exterior envelope of a building, single-wythe
reinforced cells of an assembly increase
grouted construction as there is no means
concrete masonry construction serves the
the strength of the system, the presence of
of confining grout discrete cells within the
dual role of providing both enclosure as
grout provides for a larger area for heat to
assembly. The net result is a decrease in
well as structural strength to the system.
pass; creating a larger ‘thermal short’ within
the steady-state R-values as shown in the
As such, these assemblies almost always
the assembly. A further complication is that
last column of Tables 2 and 3 whereby grout
contain reinforcement and grout. While the
single web units cannot be used in partially
is assumed to be spaced at 48 inches on
SUMMER 2014 25
TECHNICAL REVIEW
REFERENCES
center. Although not shown in the Tables 2
configurations and associated technologies
and 3, using less grout in the assembly would
will likely be a slow transition driven by local
increase the resulting R-value, while using
market demands and the needs of producers,
1. From the Carriage Age…to the Space
more grout would have the opposite effect.
contractors, designers, and owners – a
Age, The Birth and Growth of the Concrete
process that may take years, if not decades.
Masonry Industry, National Concrete Masonry
NOT THE WHOLE STORY
Association, Herndon, VA, 1969, Edited by Looking ahead, the real challenges facing
Joseph
Everyone understands that higher R-values
the industry will be to offer cost effective
AboutNCMA.aspx).
equate
to
higher
energy
efficiency,
Bell,
(http://www.ncma.org/Pages/
but
solutions to meet continuously increasing
ending the comparison there can lead to
energy efficiency requirements imposed by
2. ASTM C90-11b, Standard Specification for
gross misconceptions regarding the true
building codes. This is where the flexibility in
Loadbearing Concrete Masonry Units, ASTM
energy efficiency and energy use of a given
unit configurations available under the new
International, West Conshohocken, PA, 2011,
building. Focusing solely on the R-value of the
ASTM C90 requirements can be the most
(www.astm.org).
opaque portion of the building envelope only
beneficial when coupled with innovation and
provides a very narrow view of a building’s
creativity. The specifics of how the industry
3. Thermal Catalog of Concrete Masonry
energy use. In reality, masonry construction
moves forward with these options is yet to be
Assemblies,
goes beyond simply providing steady-state
determined, but will continue to be a central
Association, Herndon, VA, 2010, (http://www.
thermal resistance by enhancing the less
theme of discussion for years as the entire
ncma.org/resources/design/Pages/default.
quantifiable user-comfort characteristics of
industry contemplates ways to successfully
aspx).
energy efficiency. This includes such attributes
manufacture, install, test, and design using
as dampening temperature swings through
unit configurations that may not yet exist
4. ACI 122R-02, Guide to Thermal Properties
thermal mass and providing a draft-free
in the marketplace; while meeting evolving
of Concrete and Masonry Systems, American
environment with an air-tight enclosure. These
market-driven needs to use less material, be
Concrete Institute, Farmington Hills, MI, 2002.
topics, however, have been thoroughly covered
more energy efficient, and maintain its inherent
elsewhere.
structural, fire safety, sound abatement, and
5. ASHRAE 90.1-10, Energy Standard for
durable characteristics.
Buildings
Except
Buildings,
American
WHAT DOES THE FUTURE HOLD?
National
Concrete
Low-Rise Society
Masonry
Residential of
Heating,
I invite everyone to share their thoughts and
Refrigeration and Air-Conditioning Engineers,
We all recognize that the entire industry is not
insights with me as to what your crystal ball tells
Atlanta, GA, 2010.
going to immediately retool and begin producing
you the future holds for the concrete masonry
units of alternative or unique configurations
industry.
in response to the revisions incorporated into
ncma.org or 703-713-1900..
ASTM C90. Instead, the use of alternative unit
I can be reached at jthompson@
2014 CALENDAR
MARK IT
DOWN
2014 JUNE
ACI Strength
04
Concrete Strength Testing Level I is an eight hour course which covers the following ASTM standards: C39, C78, C617, and C123.
AUG.
12 -15
ACI/CT Certification
ACI Level 1 is a two-day only program that will consist of classroom review followed by a written test and hands on performance test. Concrete Technology (CT) is a one and a half day course addressing regulations of concrete as required by the state. After successful completion of this class, state employees will be qualified to run testing procedures to determine the quality of the concrete. There is a written exam for this certification. To register, visit www. alconcrete.org/classes.
SUMMER 2014 27
2014 CALENDAR
SEPT.
09
SEPT.
-12
17
OCT.
22 23/29/30
ACI/CT Certification
ACI Strength
ACI Level 1 is a two-day only program that
Concrete Strength Testing Level I is an eight
A Day of Concrete Knowledge
A Day of Concrete Knowledge is designed
will consist of classroom review followed by
hour course which covers the following
to provide valuable education programs
a written test and hands on performance
ASTM standards: C39, C78, C617, and
on concrete and masonry concrete topics.
test. Concrete Technology (CT) is a one and
C123.
This full-day seminar provides 8 hours of
a half day course addressing regulations
AIA approved HSW credits. Certificates will
of concrete as required by the state. After
be issued to both architects and engineers.
successful completion of this class, state
Additional information to follow.
employees will be qualified to run testing procedures to determine the quality of the concrete. There is a written exam for this certification. To register, visit www. alconcrete.org/classes.
AL Concrete 6-17-14.pdf 1 6/17/2014 12:46:39 PM
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