Synthetics rising in exterior tnillwork

HEN IT coMES to exterior trim and millwork, how much do homeowners care about "authentic" or "natural" products? According to the residential builders we queried at this year's International Builders Show, what's most important is getting the right look and eliminating as much maintenance as possible.

Even in high-end houses and historical renovation projects, mainternance concerns are starting to outweigh insistence on "authentic" materials. Or, as one builder put it, "Nobody likes to do maintenance."

Another of the builders agreed: "With traditional materials, there's a traditional solution: maintenance. So when traditional pine rots or fingerjoint glue doesn't hold, the answers all involve more labor and more materials."

While everyone expressed respect for historical accuracy and aesthetics, most said they often urge their clients to consider modern, manufactured substitutes. A common rule of thumb: If it fits the look and feel of the house-and will require less maintenance-go with the substitute.

"For exterior trim, five or 10 years ago there was quite a bit of resistance," said one builder. "But now, when I show customers how their original trim has rotted out, they want to go with something like PVC. Once they learn that it's an option, people overall are trending toward not wanting to spend time or money on maintenance."

Coincidentally, regions where tradition runs deep-such as New

England and the South-have climates that reinforce the argument for synthetic components and materials, the builders said. Brutal winters in the north and hot, humid summers in the south take their toll on features such as exterior trim.

"High-end clients start out really wanting traditional materials because that's what they see themselves paying for," said another builder.

"Unfortunately, we're in the Northeast, right on the water. There's a four or five month window when it's the greatest place in the world to live. But then you come here in

January and it's brutal."

Builders also noted that the case for low-maintenance substitutes has gained support in recent years. Today's homeowners tend to do much more research than earlier generations, and so many of them bring to the project some awareness of material properties.

"Luckily, most of our clients are being educated by their architects," said one builder. "Eventually, they see that we can get a historical effect with materials like PVC trim and bring the level of maintenance a lot closer to zero."

Manmade materials have also become more convincing, as well as more reliable. "I'm not recommending synthetic materials everywhere," admitted one builder. "but I have to tell my clients that some of the old materials just aren't working anymore. And some of them never did."

- Rick Kapres is vice president of sales at Versatex Trimboard, Aliquippa, Pa. A division of Wolfpac Technolog,ies, the company manufactures cellular PVC extrusion products such as trimboards, sheet, bead board, mouldings, and columns. Contact him at (724) 857-1111 or rkapre s@ ver satex.com,

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For us, using software technology is a continuation of a spirit of innovation started by our founder, William Frogale, 60 years ago. He was the first LBM professional in the Washington, D.C., metro area to develop and distribute pre-hung door units. By providing an easier way to build homes, and helping improve quality, save time, and reduce costs, he became a valued partner to builder customers. Today, the same types of benefits are possible with structural frames.

Framing Software

Structural frame product manufacturers have developed a host of software tools. As with anything, capabilities vary.

We evaluated a number of packages and selected Weyerhaeuser software as the best for our business. Their NextPhase Site Solutions include multiple programs for design, specification, and fabrication. For example, Forte software provides a fast and simple way to size joists, beams and columns. We use Javelin software for designing and specifying home structural frame members top to bottom. Stellar software then converts the design data into instructions for our computer-controlled saw.

With these tools we're able to offer builders precision end trimmed (PET) frame members to within 1/16" tolerances, pre-cut holes in joists for mechanical systems, and members with intersection marks. Each JobPack is delivered to the job site with a set of color-coded sheets corresponding to the pre-cut floor framing system. Builders can thus reduce cycle time, improve site safety, and minimize theft because fewer materials are left on site durine down times.

Business Benefits

As it has become increasingly difficult for builders to earn a profit, dealers that provide them with ways to build better, faster, and with less waste have a clear competitive advantage.

For example, with PET framing, builders save time by not needing to cut numerous individual pieces to size. Plus, the frame members all fit together precisely, which helps reduce framing errors and costly callbacks. Pre-cut framing also reduces waste and associated disposal fees.

Many framers really like PET because it saves them time and money from cutting materials on site, helps reduce their liability since they're not running saws on the job, and lowers waste and associated disposal fees. Pre-cut framing materials also provide dealers a way to help builders meet new code requirements more easily. For example, as more jurisdictions adopt energy efficiency codes that require HVAC ducts to be located within conditioned spaces, this often means in practice that the mechanicals must run through the floor system.

There seems to be a lot of confusion about the new energy code requirements. The solution we provide is to the builder and their trades (specifically the mechanical company). Once they show us how their system is designed, we can collaborate with them to make sure the holes are in acceptable locations, precut them, and provide the framers and mechanical installers with tools that improve the assembly and installation of the structural and mechanical systems.

Our customers have been really impressed with the NextPhase system. The range of structural frame materials and services we offer-powered by software-was key to us retaining the business of D.R. Horton in Maryland. Another customer, Advantage Homes, is a smaller builder that wants to be on the forefront of new technologies. For such builders, our software offerings provide them an improved way to build that they in turn can highlight with their homebuyers.

In addition to providing direct benefits to builder customers, today's structural frame software also can help dealers and fabricators enhance their own operations, including processing materials faster and managing inven-

BuiHing-hoducts.om tory better-both of which help control costs.

For example, the various software programs we use allow us to produce pre-cut framing packages much faster than is possible by hand. Just-in time ordering is a critical part of our business service to builders, and Javelin design software and Stellar fabrication software really help with this. We pride ourselves on fast turn-around-only two weeks from when a builder walks in with a rough sketch of the floor system until we deliver the JobPack of joists and other materials. This includes design of the floor and production of all the components. As a lean manufacturer, software helps us decrease production costs while improving quality.

Fabrication software also helps us better keep track of inventory and manage drops. We can now account for every cut, and use leftover pieces for blocking, etc., to optimize materials use and help eliminate costly scrap. The software is substantially more accurate even than our point-of-sale inventory tracking system, and helps us be accurate to within l%o to 27o every week.

Getting Started

Structural frame manufacturers can help you launch a range of design and fabrication software and services. In our case, Weyerhaeuser really helped us get off the ground and trained us to be self-supporting after the launch, and they've been responsive to get our saw back up and running as quickly as possible, if any issues arise.

When it comes to picking a software provider, here are some key questions to ask:

What are the specific programs you offer?

. What measurable benefits have other dealers achieved using these tools?

What training do you offer in software and fabrication operations?

What do you do to help fabrication crews solve problems themselves without having to rely on you?

. What support do you offer to help get framers on board with using PET framing materials?

. What types of marketing support do you offer?

Additionally, it's very helpful to visit other dealers using structural frame software to see how their operations work. This can provide great insights on what's possible and on how to set up your own operations. As Ziglar says, "It's not what you've got, it's what you use that makes a difference."