Masonry Magazine September 2016

September 2016

T Th he e V Vo o ii c ce e o o ff tt h he e M Ma as so on nr ry y II n nd du us s tt r ry y

Choosing the

Volume Volume 55, 55, Number Number 99

Right Anchor Also Inside: Jobsite Safety Flashing Installation Tips

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September 2016 | Volume 55, No.9

Contents Flashing and Drainage Installing Flashing in Non-Standard Conditions

16 to Luxury New York Condo Embellished 22 Entrance With Custom Terra Cotta Rainscreen System Case Study

Connectors, Anchors and Fasteners Selecting Anchors and Connectors for High-Wind Areas

24 30 Q&A: Brick Veneer Anchors 34 Resupporting Old Structural Masonry Case Study

Safety on the Jobsite Jobsite Safety Inspections

38 44 Common Myths About Active Fall Protection 46

Special Feature Women in Masonry: Building on a Strong Foundation

This Georgian Revival home was designed to transcend passing design fads and minimize long-term maintenance costs. Red clay brick was a natural choice for this home’s classic façades, which include a central pedimented entry, protruding one- and two-story bays and four soaring chimneys. The bricks were all handmade and oversized to represent the brick of the Georgian period.

The project won a 2016 Brick in Architecture Award. More details can be found on page 60.

Photography courtesy of Robert Benson Photography and Nicholas Rotondi Photography.

columns & departments 6 8 10 12 48 50 52 53 56

President’s Message Chairman’s Message Government Affairs New Products Full Contact Project Management Business Building Classified Advertising News MCAA Upcoming Education

MCAA Strategic Partner Program

MASONRY (ISSN 0025-4681) is published monthly. Subscription rate $29 per year; Canada and Mexico $47 (U.S. currency); all other countries $65. Single copies $8.50. Copyright 2016

by Mason Contractors Association of America. POSTMASTER: Send address changes to MASONRY, c/o Lionheart Publishing, Inc., 506 Roswell St., Ste. 220, Marietta, GA 30060. Canadian return address: Station A, PO Box 54 Windsor, Ontario N9A 615. SEND SUBSCRIPTIONS and business correspondence to: MASONRY, c/o Lionheart Publishing, Inc., 506 Roswell St., Ste. 220, Marietta, GA 30060 Phone: 770-431-0867 or 888-303-5639 www.masonrymagazine.com. Layout & Design © Lionheart Publishing, Inc.

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

PRESIDENT’S

The Voice of the Masonry Industry

MESSAGE

MASONRY Magazine Official Publication of the Mason Contractors Association of America and the Canadian Masonry Contractors Association The Mason Contractors Association of America is committed to preserving and promoting the masonry industry by providing continuing education, advocating fair codes and standards, fostering a safe work environment, recruiting future manpower, and marketing the benefits of masonry materials.ion of America is committed to preserving and promoting the masonry industry by providing continuing education, advocating fair codes and standards, fostering a safe work environment, recruiting future manpower, and marketing the benefits of masonry materials.

Jeff Buczkiewicz, President - jeffb@masoncontractors.org

Dear Masonry Magazine reader, I wanted to take a brief moment to inform you about some upcoming changes for Masonry Magazine. Masonry Magazine has been owned by the Mason Contractors Association of America (MCAA) since its inception.

For the last 15 years or so, MCAA has had a contract with Lionheart Publishing in Atlanta, Ga., to publish our magazine. We have appreciated the way Lionheart has managed and published our magazine over this period. Earlier this year, the MCAA board of directors decided to go a different direction with Masonry Magazine and voted unanimously to bring the magazine back inhouse to the MCAA. As a result, effective with the January 2017 issue of Masonry, the magazine will be published out of Chicago under the direction of MCAA. Lionheart will continue to publish Masonry in the same professional manner they have done throughout our contracted period. The MCAA hired a new editor for Masonry Magazine, Dan Kamys, who will be helping us through the transition of the magazine to the MCAA office. He will take over editorial responsibilities as of

Mason Contractors Association of America

the January 2017 issue. Until then, Lionheart will have Karen Hickey, the current editor, producing Masonry through the end of 2016.

We are very excited about the transition, and the MCAA board feels this will give us an opportunity to increase the focus of Masonry on many pressing industry issues. We plan to continue to deliver expanded educational reading and build up the topical industry news and information our readers value. In addition, you will see some changes in 2017 as a reader. We plan to develop interactive articles which will tie back to the Masonry Magazine website. New regular features will also be added, and many new surprises will be coming as we progress throughout 2017.

We look forward to serving you in this new capacity and thank you for being a loyal Masonry Magazine reader.

Chairman Vice Chairman Treasurer Secretary

Robert V. Barnes, Jr. Glenn Hotmann John Jacob Gary Joyner Jed Olafson

Regional Vice Presidents

The Keelen Group Timothy W. O’Toole Todd Fredrick Angie Parisi Lorra Lein Rashod Johnson

Editorial Advisory Board David Jollay (Jollay Masonry Contractors), John Chrysler (MIA), John Melander (PCA), David Hill (Pettit Construction Co.), John J. Smith (John J. Smith Masonry Co.), Brian Grant (Grant/Jack’s Masonry), Jerry Painter (Painter Masonry, Inc.), Doug Nichols (Doug Nichols Enterprises), G. Alan Griffin (Griffin Contracting, Inc.), Tom Daniel (GBC Concrete and Masonry Construction, Inc.)

Executive Office 1481 Merchant Drive Algonquin, IL 60102 Phone: 224.678.9709 or 800.536.2225 Fax: 224.678.9714

President Mason Contractors Association of America MASONRY is the official publication of the Mason Contractors Association of America (MCAA) and the Canadian Masonry Contractors Association (CMCA).

The magazine acts as a sounding board without approving, disapproving or guaranteeing the validity or accuracy of any data, claim or opinion appearing under a byline or obtained or quoted from an acknowledged source. Opinions expressed by officers do not necessarily reflect the official views of MCAA or CMCA. The appearance of advertising or new product information doesn't constitute an endorsement by MCAA or CMCA of product featured.

SAWS AND SAW BLADES What’s new in saws, saw blades, hammers and grinders? Masonry will showcase the latest products in these categories.

PAVERS, THIN BRICK/STONE AND THIN VENEER Discover a new sub-surface system that collects solar thermal energy, cooling patios or melting snow, while also heating a pool, spa or domestic-use water.

HARDSCAPING CASE STUDIES From driveways and patios to commercial redevelopment areas, get a glimpse into how others have created beautiful hardscapes.

For advertising information, contact Marvin Diamond

770.431.0867, ext. 208 • Toll-free: 888.303.5639 • E-mail: marvin@lionhrtpub.com n

Jeff Buczkiewicz

Government Affairs

Representatives Director of Marketing, Education,

and Information Technology

Director of Development

Membership Coordinator

Administrative Assistant

Consultant

Jeff Buczkiewicz

Be sure to catch the October 2016 issue of Masonry, which will feature articles covering current trends and examining industry issues, including:

MASONRY

President/CEO

Michael Schmerbeck Rick Swanson Lynn Vasquez Dennis Withsosky

Executive Staff

Sincerely,

COMING IN OCTOBER 2016

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Michael Sutter Paul Odom Paul Oldham Larry Vacala

September 2016 • www.masoncontractors.org

Masonry Advertising and Editorial Office

Send all advertising and editorial submissions for Masonry to: Lionheart Publishing, Inc. 506 Roswell Street, Suite 220, Marietta, GA 30060 USA Tel: 888.303.5639 • Fax: 770.432.6969 • E-mail: lpi@lionhrtpub.com www.masonrymagazine.com Publisher John Llewellyn • llewellyn@lionhrtpub.com Editor Karen D. Hickey • karen@lionhrtpub.com Copy Editor Marty M. Hohmann • marty@redclayeditorial.com Art Director Alan Brubaker • albrubaker@lionhrtpub.com Online Projects Manager Patton McGinley • patton@lionhrtpub.com Assistant Online Projects Manager Leslie Proctor • leslie@lionhrtpub.com Advertising Sales Marvin Diamond • marvin@lionhrtpub.com Advertising Sales John Davis • jdavis@lionhrtpub.com Marketing Director and Audience Development Maria Bennett • bennett@lionhrtpub.com Reprints Kelly Millwood • kelly@lionhrtpub.com

The Voice of the Masonry Industry

CHAIRMAN’S

MESSAGE

Michael Sutter Chairman

Mason Contractors Association of America mike.sutter@suttermasonry.com

Who Moved My Cheese?

“Movement in new direction helps find new cheese.” This is a quote from Dr. Spencer Johnson, author of “Who Moved My Cheese?” a business fable about change and opportunities. We are moving some cheese/making a change at MCAA that excites us all. As you will read in the President’s Message, MCAA w ill beg in publishing Masonr y Magazine in Januar y 2017. We have always owned the magazine, b u t we p rov i d e d o n l y l i m i te d content. The editorial content and publishing were controlled by our publisher, Lionheart Publishing.

With our contract ending at the end of this year, and after a lot of discussion regarding the pros and cons of renewing our contract, we came to the decision that it is in the best interest of our members and industry to take back Masonry Magazine and control all aspects of it. Doing what is best for our members and industry is our top priority and focus when we make any decision at MCAA. We appreciate our relationship with Lionheart Publishing and our current editor, Karen Hickey. While we haven’t had the opportunity to work with Karen very long, we enjoyed the relationship we had with her and thank her for the work she has done for us. Karen worked very hard during her time with us to learn our industry and the people in it. I want to personally thank Karen for editing my article each month to make it readable! We also thank our 8 |

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previous editor, Jennifer Morrell, for her years of service as our editor and friend to our industry.

Of course, we also thank all of our contributors and advertisers for their support and contributions. We want to continue to strengthen our relationships going forward and will do whatever we can to make that happen while increasing the value of the magazine for our readers. We have a lot of ideas and look to begin rolling them out in the January 2017 issue.

Please keep an eye out for them, and if you have ideas/suggestions regarding Masonry Magazine that will bring more value to you the reader, let us know. We want to provide content that is rewarding yet challenging. If you are interested in writing an article about your experiences, tips or tricks, we want to hear from you!

I have just returned from Austin, Texas, from the Texas Masonry Council convention. The Texas mason contractors are always out in front, leading and promoting masonry in both their state and the country. My wife, Colleen, and I love visiting our MCAA chapters and the old friends we have made over the years, and also meeting new ones.

This is a trip Colleen has been looking forward to for a while. You see, she is a huge fan of the TV show “Fixer Upper,” which is filmed in Waco. Susie Odom volunteered to take her to Waco and spend the day seeing everything “Magnolia”!

With less than 30 days before the MCAA Midyear event, I would be

September 2016 • www.masoncontractors.org

Doing what is best for

our

members and industry is our top

priority and

focus when we make any decision at MCAA. remiss if I didn’t mention it one last time. Our event will be held in my home state, in Scottsdale, Ariz., at the Westin Kierland Resort. It is one of the finest resorts in Arizona, and I promise outstanding weather. There are awesome meeting rooms, Speed Dating rooms, restaurants and outdoor activities to fill your time while there. Please plan on bringing the family. I assure you they will not be bored while we are in our meetings.

The Midyear meetings are where we map out our agendas for the coming fiscal year. Our committee chairmen will reveal their plans, along with the executive officers, other committee chairs and members providing direction and focus to our members as we prioritize for the year ahead. I hope to see you there! yMAS

The Voice of the Masonry Industry

GOVERNMENT

AFFAIRS

By Stephen Borg

Stop the Federal Government Picking Winners and Losers As Congress returns from its August recess, I wanted to take this time to bring a new bill to your attention and ask that you share our concerns with your local members of Congress.

On April 28, 2016, Sen. Debbie Stabenow (D-MI) introduced S. 2892, the Timber Innovation Act (TIA). Then, on July 14, 2016, Rep. Suzan DelBene (D-WA) introduced the companion House legislation as H.R. 5628. Specifically, the legislation directs the U.S. Department of Agriculture (USDA) to establish a research and development program “advancing” the use of wood in tall buildings 10 floors and higher.

It also creates a grant program for state and local communities to promote the use of wood materials in construction of these buildings over other materials and establishes a competition for tall wood building design.

The Mason Contractors Association of America (MCAA) has many concerns with this legislation, but our main objections center on the safety and soundness of the built environment — including tall wood buildings — and the federal government providing an unfair advantage to one building material over all others. As a result of our concerns over this bill and the timber industry’s aggressive lobbying effort, MCAA has joined a coalition — a diverse group of stakeholders consisting not only of the construction and building materials sector but also insurance and firefighters’ organizations — in opposition to this bill and has been meeting with Congressional 10 |

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offices to raise our concerns.

Our main argument against this legislation is that we believe it is inappropriate for the federal government to pick winners and losers for building materials in the construction industry, especially at U.S. taxpayers’ expense. The wood industry already benefits from an industryfunded federal check-off program, which is entirely appropriate. Putting the federal government in the position of promoting one industry at the expense of others would be inappropriate and counterproductive for job growth. The federal government should instead be promoting fair competition in the marketplace. It is critically important to allow the engineers, architects, general contractors, material suppliers, and other interested and affected parties to determine the best practices for designing and constructing buildings based on sound science and engineering standards.

Our coalition also has serious concerns about the safety of extensive wood use in tall building construction and has been raising this issue in many of our meetings. Model building codes, including the International Building Code (IBC), classify mass timber as a combustible construction material with longstanding limitations on building height and area in order to mitigate the inherent risk to firefighters, first responders and building occupants. Recent code proposals, sponsored by the wood industry seeking to amend these limitations, have

September 2016 • www.masoncontractors.org

We believe it is inappropriate for the federal government to pick winners

and losers

for building materials in the construction

industry,

especially at U.S. taxpayers’

expense. been considered and rejected. The code development process provides the appropriate consensus mechanism for interested parties and building science experts to evaluate changes in the interest of public safety. We encourage the federal government to allow the code development process to continue to evaluate the risk associated with timber construction in a comprehensive manner, without the appearance of a preference for any one construction material, as suggested by the TIA legislation.

As members of Congress return to Washington, D.C., the MCAA and our coalition partners will continue to sound the alarm in regards to this legislation, but we are asking for your help as well. Take the time to educate your local member of Congress on the Timber Innovation Act, and ask him/her to oppose this dangerous legislation. yMAS The Voice of the Masonry Industry

EZG

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The Hoist Hog and Hog Cart are available in both block and brick.

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With the new OSHA standard for silica dust, the Mud Hog Mixer solid grate cover provides your employees less exposure to silica dust. There are also two separate openings on the grate. One for mixing materials and one for water intake to make the job more efficient and safe.

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NEW

Product & Service Information

PRODUCTS To submit a new product, contact: Karen Hickey • Email: karen@lionhrtpub.com

W. R. MEADOWS, Inc. Hampshire, Ill.

www.masonrymagazine.com • 888-303-5639, Ext. 230

We’ve made it fast, easy and convenient to request FREE information about any product or service in this issue.

To request information online, go to: www.masonrymagazine.com. Click on ‘FREE Product Information’ (right top corner), then…

1. Select the issue of the magazine you are reading 2. Check the box next to the advertiser you are interested in 3. Provide your name, address and business information 4. Click submit.

Ruwac USA

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Protect Your Structure With AIR-SHIELD LM

Industrial Vacuum Helps Remove Silica Dust

Advanced Layout Is Simplified With Hilti’s PLT 300 Layout System

AIR-SHIELD LM by W. R. MEADOWS is a singlecomponent, liquid-applied, water-based, polymermodified air/vapor and liquid moisture barrier, formulated to prevent the transmission of air and inhibit vapor and moisture from passing through porous building materials. The liquid-applied characteristic of AIR-SHIELD LM makes for a simple application, while it is also a sprayable product. It is suitable for both new construction and restoration projects. Installation instructions are available on the company’s website and can be printed or downloaded.

Ruwac USA’s WS2320-HD, a heavy-duty intermittent-duty vacuum that features 11 Hg” of negative vacuum pressure, doesn’t give hazardous silica dust a chance. Available with an outstanding 300 CFM, the WS2320-HD heavy-duty vacuum is equipped with absolute HEPA filtration that is 99.997 percent efficient at 0.3 microns, as well as 28 ft2 of industry-leading MicroClean primary filtration. The vacuum’s modular housing is fully grounded and sealed for dust-free operation, and made from a dent- and rust-free compression cast composite housing that is guaranteed for life.

Contractors will find advanced layout simple with the new Hilti Layout system PLT 300. Layout jobs can be completed quickly and efficiently by just one person, and no leveling is required. Hilti AutoStationing technology allows for easy automatic station setup. The PLT 300 comes with the PLC 300 controller, a tablet with a 7-inch display that has permanent wireless contact with the total station. Building Information Modeling (BIM) and “jobsite to BIM” data flow are now at your fingertips.

www.wrmeadows.com

www.ruwac.com

www.us.hilti.com

Dodge Data & Analytics DEWALT

Milwaukee Tool

New Britain, Conn.

Milwaukee, Wis.

New York, N.Y.

DEWALT Introduces Premium Utility Knives

M18 REDLITHIUM HIGH DEMAND 9.0 Battery Pack

PlanRoom Service for Construction Contractors and Subcontractors

DEWALT has launched two new utility cutting tools for the toughest worksite conditions. Premium Utility Knives add reinforced strength through their new blade change mechanism and bi-material grip, offering professional users durability, stability and control. Traditional retractable knife users will have confidence in blade security during cutting with a 3x blade-life retention (compared to traditional utility knives). The 10295 knife has an IP54 rating on blade storage. Available in retractable and folding retractable models.

The new M18 REDLITHIUM HIGH DEMAND 9.0 Battery Pack from Milwaukee delivers up to 5X more runtime and 35 percent more power, and runs 60 percent cooler than standard lithiumion batteries. This new battery technology is fully compatible with the entire M18 system. The HIGH DEMAND 9.0 pack is optimized for highdraw M18 FUEL tools and solutions that need sustained power and runtime for applications such as high-demand drilling, chipping, cutting and grinding.

Dodge Data & Analytics has launched Dodge PlanRoom, an online service for storing, managing and sharing plans, specifications, and other construction documentation. Dodge PlanRoom is designed to support construction-specific workflows such as evaluating potential projects by quickly reviewing linked plans, sections and elevations. Optionally, contractors can quickly search projects to find the ones most suitable for them. Users can also add their own projects or participate in private projects they are invited to by owners and other contractors.

www.dewalt.com

www.milwaukeetool.com

www.construction.com/dodge/planroom.asp

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

H2Oh! No...

Cracks. Spalling. Corrosion. Mold.

Mortar Net Solutions helps prevent the pain of water damage in masonry walls with a full line of tried-and-true moisture management solutions that are field proven, easy to install and let you take pride in your work for years to come. No other company is totally focused on moisture management for masonry. No other company can turn H20h into H2Ahhhh.

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MCAA MASON CONTRACTORS ASSOCIATION OF AMERICA

www.masoncontractors.org

Installing Flashing in Various Conditions

By Steven Fechino MANY TECHNICAL QUESTIONS REGARDING FLASHING ARE BASED ON CONDITIONS THAT DIDN’T EXIST A SHORT TIME AGO. Grade differentials, bed depths or brick shelf dimensions, arches and piers are just a few details that can add significant time to your project if they are not properly evaluated and considered during the estimating or buyout phase.

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

Because different conditions can affect the installation of flashing components, we should be aware of details that can add material and labor costs.

Most contractors realize that flashing installations are not always routine; in some cases, they can be downright tough. Many different conditions can affect the installation of the components. As we estimate our work, we should be on the lookout for a few details that can add material and labor costs.

Cavity walls today are constructed over various grade differentials, with step-downs and all different bed depths or brick shelf dimensions. Arches can pose challenges, brick returns at door jambs are always frustrating, and piers and pier corners can add time to a project that in some cases was not considered at earlier stages.

Piers or column wraps have become very common on larger commercial buildings over the past few years. The piers can be hollow, where a larger cavity creates an architectural feature, or they can surround a structural element, such as a column of steel or concrete. In both conditions, the flashings must be constructed for effective and economical functionality.

On columns where the cavity is filled with a structural element, the challenge is greater for economical flashing installation, as components can become expensive when multiple corners are involved.

Fast Lightweight Safe Easy to Clean

www.groutgrunt.com 1-800-659-4731

Elevation of the Flashing The first item to address is the elevation of the flashing.

Many manufacturers’ recommendations are the same: flashings should be placed above grade and below the finished floor — which is common sense. However, this is becoming difficult to achieve for many projects because the flashing level is shown on the finished floor with the exterior grade at nearly the same elevation. As a contractor, you find yourself caught between what is best practice and the limited options you have for this condition.

Even if you write a letter or a request for information (RFI), you may end up no better Brick Shelf 1: Install the prefabricated for trying. So what can stainless steel drip edge corner in a bead of sealant. you do? www.masonrymagazine.com

September 2016

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FLASHING AND DRAINAGE

The installer’s best option is to use butyl sealant.

Developed in 1937, butyl has been around a long time and has a proven track record. It’s ideal when flashings need to be installed in a location where water is assumed to travel under the membrane either by capillary action or by an excessive water event. Place several beads of butyl parallel with the face of the veneer, approximately 1 inch from the face of the veneer and several inches deep within the wall. Here is where common sense is needed. Consider the site conditions to make sure you do not have excess material that might be exposed after your work is completed. Butyl is a non-curing product that will remain sticky forever. It is forgiving and can be pulled apart many days after Brick Shelf 2: Install two boot extensions installation without with a perimeter bead of sealant that oozes at the joint on each side of the destroying the flashing corner, extending approximately 1/2 inch or sealant in case a re-

Greater bed depths create larger corner gaps, and standard components will need adjustments no matter who manufactures them.

from the drip edge bend.

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pair is needed. Butyl will bond directly to itself even many months later, regaining full integrity as a sealed lap.

Cavity Depth Once the placement of the flashing elevation has been established, the depth of the cavity needs to be addressed. Until recently, we did not see bed depths greater than about 7 or 8 inches. Though these larger bed depths are greater than a few years ago, we could easily manage the additional dimensions. Now we are seeing depths of 10 and 11 inches at many building bases where stone is featured. This is a bit of a game changer because the added bed depths create larger corner gaps, and standard components will need adjustments no matter who manufactures them. The process I will discuss encompasses standard flashing components used in the industry.

This is another area where common sense kicks in. When dry fitting the column where a bed depth is very large, say 11 inches, the first step is to install the stainless steel prefabricated Brick Shelf 3: Install a membrane patch corner. In this situation, with a perimeter bead of sealant that oozes at the joint with a small, 2-inch the corner components cut placed directly at the corner and commonly stocked by extending within 1/2 inch of the drip most distributors will edge bend. not allow you to install flashing without cutting it. The easiest alternative is to extend the prefabricated stainless steel corner from 7.5 to 12 inches in both directions.

With the drip edge in place, the next steps can begin. Before installing the corner boot, cut two pieces of membrane and install them Brick Shelf 4: Install the preformed so they are above the corner boot with a perimeter bead of corner boot in height sealant that oozes at the joint, as shown.

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

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That’s why Owens Corning Enclosure Solutions are designed for optimum durability and energy performance that meet today’s standards and anticipate tomorrow’s. ®

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FLASHING AND DRAINAGE

on the substrate, so that a small term bar can be installed on each side without interfering with the term bar on the base flashing panels. Extend the membrane sections approximately 9 inches in each direction from the corner and all the way to the front edge of the stainless steel drip edge where it bends down. This additional membrane will be under the corner boot and placed on top of the drip edge.

Keep in mind that, in this case, the corner boot will be short of meeting the drip edge by about 4 inches if you include the proper lap.

Here is what we have found to work well.

Simply cut a piece of patch membrane that is approximately 3 inches larger than the void on both sides. Place about Brick Shelf 5: Begin installing your base a 2-inch cut in the corflashing, aligning the drip edge with the prefabricated corner piece. Follow ner of the patch that will all standard base flashing installation rest in the seam of the procedures. corner.

This patch is placed with a full bead of sealant around the perimeter and, when placed, will create an ooze around the perimeter that assures you that water will not find its way underneath the patch. Once the corner flashing patch has been installed, there is no cutting or folding of flashings around the corner, thereby preventing any possible leaks that can occur with voids in flashing sealants or cutting of membranes. Another advantage of doing it this way is that the installer can pre-cut what he needs and stock it in front of the bricklayers. A specialty crew is not needed to install the flashings.

Wi t h t h e p a tch i n p l a ce , s i m p l y i n s t a l l t h e prefabricated corner boot with a bead of sealant around the perimeter of the setting area and allow it to create another ooze joint around the boot. Then place the flashing down the wall.

This technique will work for both inside and outside corners with large brick shelf dimensions. The entire corner should only take a few minutes, reducing the opportunity of flashing errors or leaks and keeping your bricklayers productive. yMAS Steven Fechino is engineering and construction manager with Mortar Net Solutions, makers of TotalFlash and BlockFlash. For more information, call (800) 664-6638, or visit www.mortarnet.com.

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Hyload, Inc.

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5020 Panther Parkway, Seville, Ohio 44273 info@hyload.com • 800-457-4056 www.hyload.com

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4/13/16 12:19 PM

The Voice of the Masonry Industry

Advanced Moisture Management Solutions The Advanced Building Products integrated system of moisture management solutions features

Copper Sealtite 2000® • Premium quality laminated copper through-wall flashing.

products specifically designed to protect your

• Superior tensile and shear strength.

investment for years to come.

• Compatible with most air barrier systems & sealants.

• Non-asphaltic and lightweight.

More lineal footage on each roll means fewer lap joints.

Mortairvent®CW • Full-wall mortar deflection and rainscreen

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Mortar Deflection, Drainage, and Ventilation

system for cavity walls.

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• Minimizes thermal bridging.

• 16 inch width allows the product to be easily installed between the brick anchors.

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>>> CASE STUDY

FLASHING AND DRAINAGE

Entrance to Luxury New York Condo Embellished With Custom Terra Cotta Rainscreen System The Wester n Specialty Contractors Facades Division (Ridgefield, N.J.) has helped to transform the discreet entrance to one of Manhattan’s most luxurious condominium high-rise buildings into a functional work of art.

Located at E22nd Street in the Flatiron District is the entrance to an award-winning, modern highrise featuring some of Manhattan’s most luxurious condominiums (prices start at $10.5 million for a 3-bedroom apartment and $72 million for the penthouse). Its private entrance was made up of concrete columns and spandrels with large windows covering the majority of the south elevation. Its lobby often features commissioned artwork.

Western Specialty Contractors was hired by Lend Lease Project Management and Construction to install a terra cotta rainscreen system on the entrance’s façade at a total cost of $1 million.

Work began with a laser survey of the concrete structure. Boston Valley Terra Cotta would use the survey to customdesign a terra cotta façade for the building.

Multiple trips were required by Western crews to Boston Valley’s manufacturing plant in Buffalo, N.Y., for dimension verification and revisions to the shop drawings to ensure that the system would fit a variety of conditions.

Once the terra cotta rainscreen system design was finalized and its fabrication complete, Western crews began waterproofing/insulating 22 |

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the building’s entrance using a Sika Air-Vapor Barrier and Roxul mineral wood insulation, hung with aluminum pins. Western then installed the rainscreen metal girt and track support system to carry the terra cotta façade, then sealed the window mullions at the perimeters.

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The challenging work for Western began with installation of the decorative, vertical terra cotta fins, which were supported with a steel tube spine system outboard of the wall tiles, some of which spanned over windows from floor to floor to create a “floating fin” effect. The terra cotta tiles were then set on the support system at columns, spandrels, window returns, soffits, floating fins and the entrance return. The runs spanned from the sidewalk level to the top of the structure, which is approximately 65 feet tall. Lastly, Western crews installed colored aluminum sills to complete the system.

Each terra cotta tile, which had a natural color finish, had to be meticulously installed by Western crews based on the architect’s specified color pattern. Multiple site visits with the architect were required to confirm the colors and final tile placement. yMAS www.masonrymagazine.com

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Selecting Anchors and Connectors for High-Wind Areas

By Randy Shackelford, P.E., and Karen D. Hickey

WHEN BUILDING WITH HOLLOW AND GROUT-FILLED MASONRY BLOCK, it is often the case that some other material will need to be fastened to it. Besides having to anchor something into the top of a wall (such as roof framing), you frequently have to anchor material to the face of a masonry wall. This connection likely has to be able to resist vertical gravity loads, and in some cases, it has to resist sideways wind or seismic lateral loads, or even uplift loads. The loads on these connections can depend on the local building code and the region’s weather patterns. In high-wind areas like Florida, for example, a lot of residential construction is comprised of masonry walls with a wood or steel trussed roof. Tie-downs are especially needed in order to keep roofs on the buildings.

So, how do you determine the right anchor for the job?

First, it’s important to know what anchoring and connecting products are on the market.

Anchors are heavy-duty fasteners that can be installed into masonry either after construction and curing 24 |

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(post-installed anchors) or during construction (cast-inplace). Common post-installed anchors include mechanical anchors, which screw in or expand in to engage the surrounding material, and adhesive anchors, which form a chemical bond with the surrounding material. While

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

each type will require its own installation process, it is important to note that adhesive anchors w ill require thorough cleaning of the hole and a dispensing tool specific to the adhesive type and packaging.

To help you navigate the Hollow drop-in anchors. available products, Simpson Strong-Tie has created an Anchor Product Selection Guide that includes recommendations for masonry. Those anchors include: Hollow Drop-In Anchor: A light-duty anchor designed to be installed into the face of either grout-filled masonry or hollow masonry. It comes with the tools to install into either material.

Titen Screw: A threaded, smaller-diameter anchor designed to be installed into either grout-filled or hollow masonry. Drill the hole with the included drill bit and install. The The hex-head screw cuts its own threads into the base mateTiten screw. rial. It is available in either a zinc-plated with baked-on ceramic coating, or 410 stainless steel. It comes with either a hex-head or Phillips head in 3/16- or 1/4-inch diameters.

Titen HD Anchor: A larger-diameter, higher-load version of the Titen screw. Simply drill a hole to the appropriate size using a standard-sized drill bit (not included), clean the hole, and drive the anchor in using an impact wrench. It cuts its own threads and does not impart an expansive force into the base material like other mechanical anchors do. It comes in either a zinc-plated or mechanically galvanized zinc finish. Loads are dependent The Titen HD on where in the masonry wall the anchor is anchor. installed.

Heli-Tie Helical Wall Tie: A stainless-steel connector used to anchor brick and masonry building facades to structural members or to stabilize multiple-wythe brick walls.

Once installed, it provides resistance to both tension and compression. It installs by predrilling a pilot hole through the facade and the backup material. Then the tie is driven until it is countersunk into the outer material, thus providing an inconspicuous connection. Most The Heli-Tie helical wall tie and its installation tool.

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commonly, it is provided in Type 304 stainless steel, but it can be special-ordered in Type 316 for the highest corrosion resistance.

Adhesives: These come in either two-part epoxies or acrylic formulations. True epoxies can provide a little ScreenTube In Hollow CMU stronger anchorage in some cases, while the acrylic formulations cure faster and are more appropriate for work in cold weather. For application in hollow masonry, screen tubes are required, which allow the adhesive to consolidate behind the face shell of the block without having to fill the entire void with adhesive. Manufacturers have recently had to reformulate their adhesives to meet new codes for concrete anchorage, but Simpson Strong-Tie still offers some of the previous versions for use with masonry.

• SET-XP epoxy is a high-strength, two-part epoxy.

Simpson Strong-Tie also offers an original formulation of SET epoxy for masonry applications. For both adhesives, the loads are dependent on where in the masonry wall the anchor is installed.

• AT-XP is the primary Simpson Strong-Tie acrylic adhesive for concrete, but the original formulation, AT, is still available for masonry applications. As with other anchors, the loads are dependent on where in the masonry wall the anchor is installed.

While anchors are typically embedded or installed into masonry or concrete, structural connectors are made from light-gauge steel and are used to connect two members together, such as wood and masonry. These products generally need some type of fastener, such as a small masonry screw, to connect them into masonry. However, some connectors embed in the masonry wall during construction. Simpson Strong-Tie offers the following connectors for masonry applications: CCQM Series Connectors: These connectors embed in the top of a masonry pier to connect a wood structure to the masonry pier. These products came about after Hurricane Katrina, when construction along the Gulf Coast had to be built much higher off the ground than previously due to stricter flood insurance requirements.

Contractors needed an easy way to connect the frame of the structure above to the top of the masonry pier. These connectors come in several configurations based on the layout of the framing above, either with the beams straight (CCQM), in a “T” configuration (CCTQM), i n a c ro s s con f i g u r a t i on CCQM series connectors.

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CONNECTORS, ANCHORS AND FASTENERS

(CCCQM), or a corner (ECCLQM). The mason would embed these into the top of the pier prior to filling with grout.

Placement is relatively easy, since usually the outside of the seat will be flush with the edge of the masonry pier. These would typically be hot-dipped galvanized along the Gulf Coast, but they are also available in grey powder-coat paint for installation in non-corrosive areas.

LGUM/HGUM Beam Hangers: These are hangers for connecting wood beams and trusses into the side of a masonry wall. They use the Titen HD heavy-duty masonry screws to fasten to the side of a grouted masonry wall to support various types of joists, beams or trusses. Years ago, typical HU-style hangers, installed with the smaller-diameter Titen masonry screws, were recommended for use to connect horizontal framing members to masonry walls. While this solution is still available, Simpson Strong-Tie realized there was a need for a product designed specifically for masonry. By using the larger-diameter Titen HD screws, far fewer fasteners are required (which equals less hole drilling) and higher loads can be achieved.

PA/HPA Purlin Anchors: Building codes require that, LGUM/HGUM beam hangers.

in high-wind and seismic areas, framing for floor and roof diaphragms must be connected into the side of masonry walls to prevent the walls from being pulled outward by wind or seismic forces.

These products have to be embedded into the side of the masonry wall by the masonry contractor, at the level where PA/HPA purlin the floor or roof will be. anchors.

They have embedment lines stamped in them to help the contractor know the correct embedment depth. The contractor also needs to ensure that there is some horizontal rebar placed in the wall at the strap location because the code requires the strap to hook around the rebar.

Embedded Truss Anchors: In high-wind areas, roof framing must be connected to the top of a masonry wall to resist uplift forces. In some areas, like Florida, builders have found that the easiest way to make this connection in residential structures is to use a strap that Restoration Team Experience Since 1978

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September 2016 • www.masoncontractors.org

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embeds into the top of the wall and fastens directly to the roof framing. Simpson Strong-Tie offers five distinct models of embedded truss anchors, with each model available in several lengths.

Now that you know some of the anchors and connectors available, you’ll need some help selecting from those products to determine what’s right for the job at hand.

Simpson Strong-Tie offers two separate software programs for selection of post-installed anchors. One, called Anchor Designer Software for ACI 318, ETAG and CSA, is used to select anchors for concrete. The other, Anchor Designer Software for Allowable Stress Design, is used to select anchors for grout-filled and hollow CMU. Both software programs give designers and contractors a lot of choices when a project calls for anchoring.

To use the Anchor Designer Software to choose an anchor, the user enters the following information: the general type of anchor desired, the diameter, the location of the anchor in the masonry wall, whether the masonry is grout-filled or hollow, the masonry thickness, the applied loads, and the anchor spacing, end, and edge distances. Then click continue, and the applicable solutions will be shown For connector applications, Simpson Strong-Tie also offers software to help users pick the right connection. Their Connector Selector (Allowable Stress Design) software tells

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you which products are appropriate for your connection, then sorts them by lowest installed cost. The built-in Job List can track your projects and print a shopping list, including required anchors and fasteners.

For those who prefer a printed aid, Simpson Strong-Tie has a new High Wind-Resistant Construction Application Guide. Rather than being arranged by product, as the Wood Construction Connectors Catalog is, it is arranged by application, such as connections for roof to masonry wall. Technical information and installation instructions for all Simpson Strong-Tie anchors is contained in the Anchoring and Fastening Systems for Concrete and Masonry catalog.

The Anchor Designer software, the Connector Selector software, catalogs, and the High Wind-Resistant Construction Application Guide can be downloaded for free at www.strongtie.com.

Users can be assured that the products they use will perform as expected. All Simpson Strong-Tie products for masonry have been lab-tested. To develop the most economical applications, products often go through two or three iterations before they are fully developed and released. yMAS Randy Shackelford, P.E., is manager of codes and compliance with Simpson Strong-Tie Co. He can be reached at rshackelford@strongtie.com.

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

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Brick Veneer Anchors

By Paul Curtis

CHAPTER 12 OF THE TMS 402/ACI 530/ASCE 5 2013 BUILDING CODE REQUIREMENTS defines the prescriptive design methods for Anchored and Adhered Masonry Veneer. This code was accepted in 2015 by the International Building Code. Here are some common questions and answers regarding this code chapter.

When is a wall considered a veneer?

If the exterior wall doesn’t add to the strength of the backup in resisting out-of-plane loads, then the exterior wall is considered a veneer wall.

If the exterior wall does add to the wall strength by resisting out-of-plane loads, then the wall is either a multi-wythe, non-composite or composite wall.

What about water penetration?

Water penetration through the exterior veneer is expected.

Make sure the backup wall is designed to resist water. Sheathing must be water resistant or covered with a water-resistant membrane, and the veneer must include flashing and weep holes.

The weeps must be a minimum of 3/16-in. diameter and be spaced a maximum of 33 in. on center.

Under what conditions can I use the Prescriptive Requirements for Anchored Veneer?

• Velocity pressure 40 psf or under.

• Buildings with a preservative-treated wood foundation height not exceeding 18 ft.

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• Wood backup framing 30 ft. or less, or 38 ft. or less at a gable.

• Cold-formed steel framing backup walls 30 ft. or less, or 38 ft. or less at a gable with veneer supported each story above the 30 ft. height.

• Interior veneers with wood backup weight of 40 psf or less.

• Exterior veneers with an installed weight of 40 psf or less and a 12-ft. maximum height supported by wood construction. (Horizontally spanning element deflection from dead and live loads cannot exceed 1/600 or 0.3 in.)

• Openings where anchored veneer is not self-supporting must have non-combustible lintels or supports attached to openings.

• Maximum distance of 4 1/2 in. between the inside face of the veneer and the outside face of the solid sheathing/framing.

Five types of anchors are listed in the Code.

What are they and where can I use them?

1. Corrugated sheet metal anchors. These are the smaller/thinner, field-bendable anchors typically found

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

2.

3.

4.

5.

in residential brick homes. Minimum requirements are 22 gauge (0.3 in.) x 7/8 in. wide. They can be used only with wood backup walls with a 1-in. airspace.

Larger airspaces require the sheet metal anchors below.

The corrugated sheet metal anchors are not allowed in CMU backup walls! The nail or fastener into backup must be within 1/2 in. of the 90° bend.

Sheet metal anchors. These anchors are factory bent and must be a minimum of 7/8 in. wide and 16 gauge (0.06 in.). Sheet metal anchors can be used with wood backup. Note that sheet metal anchors can be corrugated, but they are not the same as the corrugated sheet metal anchors above. The difference is the thickness of 16 gauge instead of 22 gauge, as well as being factory-bent.

Wire anchors. These must be a minimum of 9-gauge wire (0.148 in.) and must have the horizontal bends in the veneer bent a minimum of 2 in. Wire anchors can be used with masonry backups and wood backups Joint reinforcement. Can be either ladder-type or pintle/eye-type and be a minimum of 9-gauge wire (0.148 in.). Wire ties will be spaced 16 in. on center.

Used with CMU backup only.

Adjustable anchors. Sheet metal components must be a minimum of 16 gauge (0.06 in.), and the wire

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portion a minimum of 9 gauge (0.148 in.).

Maximum clearance between connecting parts is 1/16 in., and the maximum offset (above or below the plain of the backup anchor) is 1 1/4 in.

Adjustable anchors are used with wood, steel framing, masonry and concrete backups.

How often are the anchors spaced and how thick are the joints? • Spacing. Adjustable anchors, 9-gauge wire anchors and 22-gauge corrugated sheet metal anchors require one anchor

Figure 1.

Figure 2.

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Figure 3.

Figure 4.

Figure 5.

for each 2.67 ft² of wall space. All other anchors are spaced one anchor each 3.5 ft². Maximum spacing is 32 in. horizontally and 25 in. vertically, not exceeding the maximum square foot area. Additional anchors are required around openings over 16 in. in either dimension. Anchors should be placed within 12 in. of the opening.

• Joint thickness. The mortar bed needs to be at least twice the thickness of the anchor (3/16-in. diameter anchor requires a 3/8-in. joint) What about seismic zones?

Category C: Isolate the sides and top of the veneer so the vertical and lateral seismic forces resisted by the structure are not transferred to the veneer.

Cate gor y D: In a d d i t i o n to t h e c a t e g o r y C requirements, reduce the maximum wall area supported by each anchor by 75%. Wood backups require a corrosion-resistant 8d ring-shank nail or a screw 0.19 in. minimum in diameter or a fastener with equal or greater pullout.

Categories E and F: In addition to the Category C and D requirements, support each story of the building independent of the other stories.

What do I do in high-wind areas?

For areas with velocity pressure over 40 psf not exceeding 55 psf and the roof height is 60 ft. or less, reduce the maximum wall area 70% and space anchors a maximum of 18 in. on center.

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What do I do if my building doesn’t fit into the Prescriptive Requirements or if there is a new product that doesn’t fit in any of the code requirements?

Section 1.3 of the code states that you have the right to present data on the new design to a board of examiners composed of licensed design professionals appointed by the building official. This board will investigate the data of the new system and formulate rules governing the design and construction to meet the intent of the Code.

What about adhered veneer?

Adhered veneer walls must be designed and detailed to meet the water-resistant, flashing and weep hole conditions listed above for anchored veneers. There are no rational design provisions for adhered veneer in any code or standard. TMS 402 section 12.3 allows the designer to use alternative unit thicknesses and areas for adhered veneer. yMAS For more information on these and other anchorrelated questions, contact Paul Curtis at paul@ heckmannanchors.com.

Paul Curtis is president and CEO of Heckmann Building Products Inc., manufacturers of masonry anchors and ties since 1923.

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Resupporting Old Structural Masonry

By Paul Potts In 2011, the Homer, Mich., school district began a building project. The plans included the construction of a new high school/ middle school adjoining the existing K–8 building, demolition of the old high school and replacement of the existing brick veneer with masonry matching the new high school.

Stripping the brick veneer from the north elevation of the old middle school gym was ongoing when I arrived at the site on a sunny spring morning in March 2013. At first sight, the exposed masonry was attention getting. There were voids in the CMU, missing head Figure 1. joint mortar, and poorly constructed structural piers built from pieces of block and leftover brick mixed with copious amounts of mortar supporting the roof beam.

There were no weep holes and no drainage cavity.

There were no control joints in either the interior or exterior width. And, while there were flat metal ties sticking out from the CMU joints for connecting the brick to the block, the missing joint mortar and broken block made the CMU width seem lacking in horizontal strength.

It appeared that the exterior bearing walls were intended as composite construction that would have required parged CMU faces or a full grout collar joint between courses, but there was no evidence of parging, and the gap was filled with mortar only sporadically. Any moisture that had gotten through the brick veneer would have been absorbed by the CMU, causing freeze-thaw cycling.

Indeed, the deterioration of the CMU was attention getting, but the condition of the masonry piers that supported the I-beam holding up the roof structure was more serious. Expert evaluation and advice were needed.

When I reached Scott Wilmot, the field construction manager for Wolgast Corp., we discussed suspending the veneer removal altogether, but the decision was reached to proceed with added caution.

After consulting with both Scott and Jeff Bates, project manager for Wolgast Corp., I took some photos and prepared a report for the structural engineer, Bert Sherman at Teton Design.

The school district’s construction budget was mostly committed, except for a contingency of $225,000.

That was not enough to build a new gym. The fact that a new roof had been put on the gym two years earlier

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would also weigh on the decision.

The gym was supposed to reopen the following school year. That was only seven months away. So, we were working with a limited budget and a tight schedule.

I sent the report and photos to Bert and gave him a call. We discussed the condition of the structure and concluded we needed a masonry expert to help with the evaluation and recommendations.

We a g re e d t h a t S c o t t Walkowicz, of Michigan Structural Masonry Coalition, was right for the job.

Figure 2.

I had confidence that Scott Walkowicz was the expert we wanted. I had worked with him previously on the evaluation of settlement at St. Paul’s Episcopal Church, a historic building across from the Capitol in Lansing, Mich.

Bert and Scott arrived the next day and, joined by Scott Wilmot, they examined the exposed CMU wall.

I discussed the schedule and the owner’s budget with them. After surveying the entire building, they reported there were solutions within our budget, but it would use up

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

Figure 3. Bert Sherman, Scott Walkowicz and Scott Wilmot examining the masonry structure. The poor condition of the masonry was not noticeable before the demolition started, but once the brick veneer was removed, the defects were readily apparent.

most of the remaining contingency.

When Bert called a few days later, he said we could choose from two recommendations to resupport the existing masonry: • Build a structural steel frame and metal stud infill to anchor and support the existing masonry.

OR • Build a new masonry cavity wall of CMU and brick veneer on a new foundation and connect it to the existing CMU masonry.

Bert said he had no preference for either solution — it was more a matter of schedule and cost — but he needed a few days to put together documentation on the two designs.

Including circulation and time and getting prices, the whole process would take up to a week.

The ready availability of the masonry contractor became a factor in selecting between solutions. There was already a reliable contractor, Zimmerman Masonry, actively working on the site that could mobilize right away, but there was no steel contractor similarly available on short notice. The steel solution would probably have advanced the schedule a bit more quickly once the work got under way, but that single positive factor was not enough to sway everyone. Also, the likelihood that the masonry solution would be cheaper, according to the construction manager’s estimates, would probably close the deal.

A meeting with the superintendent of schools was arranged for the next week to put the plans before him. The meeting ended pretty quickly; both the owner and the construction manager opted for the masonry solution. It involved a known cost, because Zimmerman had already submitted their price, and soliciting the steel bids would have set the project back several weeks.

The comfort in making this decision was aided by our acquaintance with Zimmerman Masonry.

The steel solution would still have to be used on the west elevation, where the gym connected with classrooms and the existing veneer sat on a steel angle brick ledge above the adjacent roof.

Bert’s design required construction of a new cavity wall of CMU and brick veneer on an extended foundation connected with dowels to the old foundation. The new masonry would have a drainage cavity, insulation, mortar www.masonrymagazine.com

Figure 4.

net, weep holes, control joints, and horizontal and vertical reinforcement.

The new wall would be reinforced with vertical #5 rebar at 32 inches on center, except the window piers would have a rebar at 8 inches on center. The new CMU was reinforced with multi-width, truss-type, horizontal reinforcement at every other course, with hook-and-eye connectors for attaching the brick veneer.

The design provided for connection of the new wall to the existing wall with triangular adjustable wall ties similar to a Wire-Bond Type 3 at 16 inches on center in both directions, the plate anchored to the existing CMU with two 1/4-inch, hex-head stainless steel Tapcon anchors.

The wall tie would provide a secure connection between the old and new masonry, adjust to the variable distance in the cavity and allow for differential movement.

There were other complications that became apparent as the work progressed.

The old masonry was 3–4-inches out of plumb from top to bottom, which would result in a gap of varying dimensions between the two courses of CMU, and require additional work at the window and door openings.

One thing was certain: the added wall, at 24 inches thick, would lower the district’s heating bills.

The top of the gym parapet was 7 inches out of level from the northwest to the northeast corner. A new metal frame parapet would correct for that, but it would require an extension of the roofing to cover the increased parapet — another added cost. Also, the windows in the north elevation were 8 inches higher than the openings in the east elevation. The fact that the windows were not level was hardly noticeable before the parapet was corrected, but once that was done, it was obvious there was a lot of work to do on the window openings. I was glad we had Zimmerman Masonry working with us.

The roof beam that had been so precariously supported on a faulty masonry pier was now supported on an 8-inch square steel tube. It was reassuring to see when it was finally in place.

As already stated, the window openings in the north elevation were 8 inches higher than the windows in the east elevation. The architect insisted — and rightly so — that September 2016

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>>> CASE STUDY

CONNECTORS, ANCHORS AND FASTENERS the window openings match. It was easy with masonry to remove one block from the sills in the north openings to lower them 8 inches, but the head was a little more complicated. On the outside, the new metal fascia panel covered the new metal framing, but the inside required masonry soaps set on a lintel attached to the metal framing to provide masonry for painting.

Fortunately, the gym was scheduled to be painted under the original contract.

None of repairs that were ultimately deemed necessary could have been ascertained by looking at the building before the veneer was removed. The physical appearance was entirely deceptive. It looked substantial from both the inside and the Figure 5 — The remodeled gymnasium was completed and turned over to Homer outside. In the future, I will pay more attention Community Schools on Oct. 1. to older buildings that don’t have weep holes or control joints. This can be a hint there are other providing the community with an improved image of their shortcomings that are not visible. school buildings…and a safer one, too. yMAS The Homer School Construction Program provided a Paul Potts writes for the design and construction new high school/middle school addition and significant industry. He has worked as a construction administrator improvements to all of the campus buildings. The for architects and engineers and owner’s representative construction team members — Homer Community during construction. Potts can be contacted at Schools, Kingscott Associates, Wolgast Corp. and Zimmerman Masonry — were proud to play a part in paulpotts1@comcast.net.

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Jobsite Safety Inspections

Photography courtesy of 123rf.com | © Ian Allenden

THERE ARE MANY REASONS WHY WORKPLACE SAFETY INSPECTIONS ARE ESSENTIAL. Safety inspections prevent injuries, illnesses, and deaths on the job. Let’s discuss how inspections prevent injuries and also several other things accomplished by jobsite safety inspections.

By Zach Everett

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Why Are Safety Inspections Necessary?

Inspecting a project for safety deficiencies, but more importantly hazards, helps establish what is called a hazard analysis. With that information, you’re able to make decisions on what is needed on the job, such as personal protective equipment, tools, equipment and training, to name a few.

Some of the questions you should ask are: • Is the environment wet or muddy? Is it hot or cold?

• What equipment is needed, or what equipment might be creating hazards on the job?

• Are there noise hazards or vibration?

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

Safety Tips

Safety in the Saw Area • Will work be done at night or during the day? Is there proper lighting?

• Is there proper ventilation?

• Are there guards on all the equipment and tools?

• Are there biological hazards or chemicals being worked with? What are those chemicals, and how do we prevent injury from them?

• Are there ergonomic hazards, such as lifting bags of mortar or heavy block or stone? Is there repetitive motion?

• Are the tools being used the right tools for the job? Are they hand tools or power tools?

• Are there any electrical hazards in the area?

By having an intimate understanding of the job and its processes, we are able to better identify the hazards associated with our individual tasks and then how to protect ourselves from those hazards so that we may go home healthy.

The area around a masonry saw can become very dangerous if not kept up properly. The first item to have is a small dumpster placed next to the saw for material waste. Tripping hazards are the last thing you want around a fastspinning blade. Masons like to have their material close to the saw, with an extra pallet to place the newly cut items. These need to be placed close, but not so close as to interfere with the process of cutting or to catch on clothing.

Another item of great value in the saw area is a rubber mat with holes in it — the ones used around garage workbenches. Usually they are at least 1 inch thick. These work well both inside and outside to keep the saw person out of mucky slurry, and to keep one’s feet dry. The mess of the slurry can become a slip hazard very quickly, especially indoors. Also, the mat prevents the fatigue on your feet that would otherwise be felt from standing on a concrete surface all day.

A pail of water with a wash-down brush is usually placed next to the saw to help keep warning labels visible and to keep the tape measure readable on the table.

Last is a plastic tote to keep all the PPE for the saw, so it does not become lost or damaged. The PPE includes aprons, rubber boots, safety glasses, a hard hat with a face shield (my company has been using the logger-style mesh mask instead of plastic), rubber gloves and ear protection.

Depending on the water pump design of the saw, you may have an extra pump for backup. The saw should also be properly maintained to make sure all guards are on and functional.

With these safety precautions in place, you’ll lower the risks of using a masonry saw.

Happy cutting! yMAS Paul M. Cantarella, Cantarella & Son, Inc. Pittsfield, Mass.

(Original text from the MCAA Safety Advantage e-Newsletter, July 12, 2016)

Other Benefits From Jobsite Safety Inspections Besides the most important reason By performing jobsite safety inspections, of keeping our people safe from injuries, we may be able to find underlying reasons why illnesses and death, there are other reasons to perform jobsite safety inspections. hazards present themselves or we may One is so that we can listen to the concerns of our workforce. When we’re out see lagging indicators and violations that tell us in the field, we can see them in action and can talk to them and understand what to step up our safety program in general. they’re dealing with, which will better equip us to give them what they need to accomplish the job safely. We may be able to find undershe is not the only one who can do it. A corporate safety lying reasons why hazards present themselves or why emdirector, any safety manager who works under him, genployees are having behavioral problems with safety. For eral superintendents, project managers, and basically example, someone may be having a hard time at home; anyone who is knowledgeable of safety and goes on the a marital conflict or problems with kids may be affecting job should be responsible for performing a safety inspechis state of mind on the job. Inspecting the jobsite also tion while there. Whether that inspection translates into gives us an opportunity to re-evaluate our safety proa written report or not is up to the owner of the comgram. Perhaps by the inspection, we will see lagging inpany and the safety director. dicators and violations, which tell us that we need to step Should it be a written report, or should a checklist be up our written program or safety program in general. used? I am a fan of any written safety report. Even if a project manager or a general superintendent is performA Few Concluding Points ing the inspection, I believe it is well worth the time to Let’s address a few more issues concerning a safety ingenerate at least a brief written report of the observaspection. tions. Having a paper trail recording the observations Who should do the report? A safety person would be and any corrections made is worth a great deal in a court at the top of the list to carry out this inspection, but he/ room, for example. www.masonrymagazine.com

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SAFETY ON THE JOBSITE

With a hazard analysis, you’re able to make decisions on what is needed on the job, such as personal protective equipment, tools, equipment and training.

How often should inspections be conducted?

The frequency of inspections is contingent on what is being inspected. Scaffolding, for example, must be inspected before each shift and before employees can be released to work from the scaffold. Concerning a more general safety inspection of the job, the site superintendent should do a daily inspection, and an inspection whenever a new hazard is introduced into the employees’ tasks. Project managers, safety personnel and similar individuals are not given specific regulations by OSHA, but I believe they Safety continued on page 42

Safety On The Jobsite

Skilled, Knowledgeable and Safe How LIUNA Training Turns Out Safe Laborers For LIUNA Training and Education Fund (LIUNA Training) and its affiliated network of training centers, safety is a top priority.

Safety is not only a cornerstone of journey-worker and apprenticeship training, but it is also integrated into LIUNA Training’s instructor certification and Train-the-Trainer programs.

LIUNA Training infuses safety concepts into all its courses, which cover everything from general construction safety and OSHA safety training requirements to specialized safety information and skills that address a wide variety of job hazards.

An experienced mason tender knows the potential hazards on a jobsite are many, whether it’s cutting brick or block, driving a forklift, or erecting and working on scaffolding. That is why LIUNA Training’s apprenticeship program offers a concentration in masonry. Journey-workers can take a variety of masonryspecific courses that cover safety skills. The first two hours of LIUNA Training’s 40-hour Mason Tender class are dedicated solely to safety and health. Trainees learn such essentials as how to use personal protective equipment and the damaging effects of silicosis and cement contact dermatitis.

The Mason Tender course also weaves safety into each classroom lesson and hands-on activity. Trainees learn about the importance of pacing and developing a work schedule, material strength and stability, the use of temporary bracing, and the impact of weather.

LIUNA Training also features information on reducing back injuries and utilizing respiratory protection. OSHA 10 and OSHA 30 courses help trainees learn how to recognize potential jobsite hazards and prevent injuries to themselves, their co-workers and the public.

The quality of LIUNA Training’s safety and health program is also evident in the instructors themselves. LIUNA Training builds on each instructor’s experience by providing them with professional development and career-long education and training opportunities. The cornerstone of this process is the Instructor Certification Program, accredited by the American National Standards Institute (ANSI).

Once certified, LIUNA instructors can enroll in the Masters of Instruction program, which is available in three tracks: Trainerof-Trainers, Curriculum Design, and Vocational English for Speakers of Other Languages.

Lastly, LIUNA Training offers instructor programs that focus on safety, supervision, and trade skills in construction and environmental remediation.

LIUNA Training’s integrated, comprehensive approach to apprentice, journey-worker and instructor training is a frontline force for a safe, skilled and productive workforce. yMAS Mark Mancini is the communications/staff writer for the LIUNA Training and Education Fund. He can be reached at mmancini@ liunatraining.org.

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

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SAFETY ON THE JOBSITE

Photography courtesy of 123rf.com | © Igor Stevanovic

Safety continued from page 40

should do an inspection each time they go to a project site. This helps to comply with OSHA standards, such as re-evaluating the safety program; but most importantly, it can stop unsafe acts and conditions that could result in injuries or worse.

If there are violations or deficiencies, how should those things be corrected and followed up on? Any time a violation is observed, it needs to be stopped and corrected. Some employees may require disciplinary action, some may not.

Each situation should be evaluated on its own merits. It may be a training issue or supervision issue.

All safety-related observations should be recorded, as well as the corrections made. There are many existing safety inspection checklists that can be utilized, or you could create your own or choose from several smartphone apps.

The bottom line is that safety inspections are an essential part of a safety program. Most importantly, they save lives! yMAS Zach Everett is corporate safety director for Brazos Masonry. He can be reached at zeverett@brazosmasonry.com.

Project managers should do an inspection each time they go to a project site.

This can stop unsafe acts and conditions that could result in injuries or worse.

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The Voice of the Masonry Industry

Common Myths About Active Fall Protection

By John Kemp

THROUGHOUT MY 22 YEARS IN THE FALL PROTECTION INDUSTRY, WHAT HAS AMAZED ME THE MOST IS THE NUMBER OF COMMON FALSEHOODS, myths and misconceptions related to an active fall event — one where a worker experiences an unintended loss of balance and then must rely on his active fall arrest system to bring him to a controlled, predictable stop and also rely on his company’s rescue plan to get him down quickly.

Let’s go through some of these myths and misconceptions.

Wearing Fall Protection Is Sufficient Unfortunately, there are countless post-fall-related news articles that reference a serious or fatal injury, even though the worker was wearing his full-body harness. Often they state, “The worker was not hooked up at the time the catastrophic loss of balance occurred.” This usually means the worker had to unhook his personal fall arrest system in order to move vertically or horizontally.

Anytime you disconnect your lifeline, you are at risk of a serious, if not fatal, injury. If it is not 100 percent, it’s not fall protection.

Workers Are Always Conscious Before a Fall Event In just about every training I conduct on fall protection, one attendee will say, “Well, when I fall, I’ll do this or I’ll grab that.” I immediately remind them that they can never assume they are conscious just before they lose balance. Perhaps a medical issue rendered them unconscious and triggered their fall. Everyone must think of and plan for the worst-case scenario.

A Conscious Worker Can React Quickly Enough to Eliminate or Minimize Injury During a fall event, a worker will fall about 20 feet before his brain can get his body to react. Even a conscious and uninjured worker will find it physically impossible to grab anything that may be in reach to (hopefully) stop the fall. Manufacturers and employers must partner together to provide fall protection equipment that is as automatic as possible. A worker should never have to rely on physical reflexes to stop a fall.

Serious or Fatal Injuries Occur Only at 20 Feet or Higher The U.S. Bureau of Labor and Statistics has shown that approximately 57 percent of fall fatalities, where the fall height was known, were from a height of 20 feet or less. Astonishingly, approximately 10 percent were from a height of only 6 feet or less. This is an important statistic to share during training.

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Why? Because, even though workers have the right fall arrest equipment and they were trained on it, they often feel the height at which they are working does not warrant it. The next time you train, ask, “If you were 15 feet up on a flat roof that is 20 feet wide, would you use fall protection?” The resounding answer will be no. Change just one factor: the height is now 1,000 feet in the air. This time, all answers will be yes. It’s amazing how perception influences the use of fall protection, when fall protection should be used at all times.

Workers Can Last an Hour or More Suspended in a Full-Body Harness Waiting for Rescue The average person suspended in a full-body harness after a fall arrest event would say that they could last at least an hour or two waiting for rescue. Numerous tests have proven that the average person can last only about 15 minutes suspended in a full-body harness before possibly experiencing medical issues related to suspension trauma.

Rescue must be without delay.

For companies that adopt ANSI Fall Protection Standards, a written rescue plan must be in place for every known location where active fall protection is being used. I have yet to see a fall protection plan that includes every area where active fall protection is being used. There is a great deal of work ahead.

Online Training Is Sufficient for Workers Exposed to Fall Hazards Most online fall protection courses provide only instruction, not training. They lack the hands-on, show-and-tell component that is paramount for workers to fully grasp the dos, don’ts and limitations of the equipment, systems and rescue plans that they might one day need to rely on to save their life.

Stay fall-free! yMAS John Kemp is director of technical services for Malta Dynamics. He can be reached at jkemp@ maltadynamics.com.

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

EZG Manufacturing, the nation’s premier masonry equipment manufacturer founded by Damian Lang, presents America’s Fastest Growing Fall Protection Company - Malta Dynamics.

The purpose of Malta Dynamics is to manufacture safety products that meet the stringent standards of the men and women who use them in the field, starting with the employees of the Watertown Enterprises family: Wolf Creek Contracting and Lang Masonry.

Contractor, businessman, and innovator Damian Lang will settle for nothing short of the best.

He began the company by assembling a team of industry leaders in the fall protection market. These veterans manage the development of fall arrest products, including personal protective equipment, engineered systems and mobile fall arrest systems.

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WOMEN IN MASONRY

Building on a Strong Foundation THROUGHOUT ITS NEARLY 90-YEAR HISTORY, GENERAL SHALE HAS BEEN A LEADING PROVIDER OF BUILDING MATERIALS SOLUTIONS FOR NORTH AMERICA. While the company has long been a key player in the production of brick, stone and concrete block, over the past few years it has navigated a rebranding, greatly expanded its portfolio of masonry products, and established a robust digital community.

Dawn Henning, General Shale’s director of marketing and retail sales.

Henning’s Expertise Helps Integrate General Shale’s Marketing Strategies

By Ron Treister

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These transformations took place under the watchful eye of Dawn Henning, General Shale’s director of marketing and retail sales. A native of east Tennessee, Henning is a marketing and communications professional with more than 20 years of experience.

While obtaining her undergraduate degree at the University of Utah in Salt Lake City, Henning discovered that she wanted to pursue a marketing career.

“During church, I listened to a talk given by a fellow church member, and I thought, ‘Wow, this guy has an innate ability to speak publicly and has a gift to really grab the audience’s attention,’” Henning says. “I went up to him afterward and said, ‘I don’t know who you are or what you do, but I want to do what you do!’”

With guidance from her new mentor — who turned out to be the vice president of public relations for the local NBA team — Henning embarked on a career that has enabled her to work for a number of nationally recognized entities, including two Fortune 500 companies.

In 2011, she returned to her roots in Tennessee to work for General Shale, helping to carve out a leading market share for the company while forging a career path in a male-dominated industry.

While the number of women in the business is gradually increasing, Henning is often met with surprise when she shares her title.

“Across the board, the number of female executives in marketing is growing — slowly, but it’s growing,” Henning says. “In construction, however, the gender demographic is still fairly one-sided. I look at that and see an opportunity to share a distinctive new voice.”

Henning’s vision also brings a fresh look at building materials originally developed in antiquity.

“When you think about the construction business, typically you think bricks and mortar,” she says. “But this is also a business that’s heavily focused on colors, textures and patterns. The most successful builders realize that a career in this industry is as much about design as technical know-how. They know it’s about creating beauty and

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

resonating with clients as they expand city centers and collaborations to come and much work to be done on the college campuses, or build offices, retail complexes, high-rise marketing front. apartments, first homes or dream homes.”

“This is a field that’s always changing and expanding,” For many years, General Shale has understood the value she says. “To be competitive, you not only have to be aware of marketing and invested in active promotional strategies. of what’s going on, but also remain informed about what’s Henning’s focus on clear communication has led to a new coming next and what it all means for the industry. That’s an approach in the way General Shale speaks about and meaexciting challenge.” yMAS sures quantities of materials required for building projects, a Ron Treister is president and owner of Communicators method she says has helped better equip the brick industry International Inc. He can be reached at rlt@ communicatorsintl.com. to demonstrate masonry’s superior capabilities over other forms of cladding.

“When you take on a new build project, the mental acrobatics required to price and order materials can be a real challenge,” Henning says.

“In particular, there’s a broad misconception that brick is more expensive than other building options, such as fiber cement siding. That’s because, for many years, brick was priced and sold by the thousand, rather than by the square foot. We’ve challenged the industry to think differently in this regard, and have helped builders and homeowners research their options by creating custom apps and calculators. When you’re able to compare apples to apples, you realize that the more attractive building materials can also be the most affordable.”

Since joining General Shale, Henning has also worked to create an online community.

“At the start of our social outreach,” she says, “we had 20 followers on our Facebook page.

Five years later, we have more than 17,000 followers, and we’ve established a strong presence on Twitter, Instagram and more. Social media has allowed us to connect with people we never would have met before, and that’s very Lighter units mean…more profit with less pain rewarding.”

Henning continues to develop ways to demonSafer job site conditions (fewer injuries) strate the beauty and durability of masonry materials, for builders and beyond. Working in such a large Less workers compensation claims and diverse industry, she says, fuels her creativity Improved workforce satisfaction and keeps her engaged.

Increased productivity “I love the challenge of working for large companies, and General Shale is represented worldwide,” she says. “Learning how different countries and cultures interact with the market, how we access and employ our resources, is all really enjoyable. It pushes you to think about how to best implement initiatives, and when you experience success, it’s great to share that and catch up with colleagues from all over the world.”

Henning’s international list of colleagues is comprised of friendships gained over the past For more advantages of using lightweight masonry, visit: two decades, and her mentor from Utah is still at the top of that list. www.escsi.org/mason.htm “To this day, he’s one of my most admired friends,” she says, noting there are many more

HEAVY

MASONRY DOESN’T HAVE TO BE

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▶ ▶ ▶ ▶

www.masonrymagazine.com

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FULL CONTACT

PROJECT MANAGER

By “Coach” Gary Micheloni

Charging Into 2016 – Part 5

What Is Safe?

What do we mean by “safe”? MCAA is always concerned about safety, as are its members. Masonry Magazine has done a great job of outlining specifics when it comes to making the workplace much safer. What can Coach Gary possibly add that will make a difference to you?

Then it hit me: this issue is being released in September 2016, just as everyone in the country is talking about the 15th anniversary of 9/11. “Safety in the workplace” takes on a special meaning when you begin talking about 9/11 and the former Twin Towers of New York City.

Let’s look at the Towers’ specs. Each tower had 110 floors, 97 passenger elevators plus 6 more just for freight.

Each tower was over 1,360 feet tall, contained 198 miles of heating ducts, with a total building weight of some 500,000 tons per tower.

Between the two, there were 12,000 miles of electric cables, 200,000 tons of steel, 425,000 cubic yards of concrete, 43,000 windows, 1.2 million cubic yards of excavation, a peak workforce of 3,500, and a project total of 10,000 construction workers, from whom 60 lives were claimed.

Once completed, some 50,000 people worked in the buildings on any given day, while another 200,000 visited or passed through daily!

Safety concerns? Yikes!

Sixty seems like a horrific number of deaths, and it is, particularly for the families of those 60. And yet, that’s not 48 |

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the number of deaths we normally associate with the Twin Towers, is it? As Americans, we know that number to be around 3,000. Put another way, safety ended up being a much bigger concern post-construction: 50 times as deadly. Looking at it another way, 60 deaths out of 10,000 is 0.6 percent, while 3,000 out of 50,000 is 6 percent. No matter how you look at it, the numbers are way too big for all the people involved.

Whether contractors or citizens, we are practical and pragmatic. Both groups grieve the deaths. Yet there is an inescapable reality when you look at the math: the construction industry, charged with oversight of those 10,000 workers — and sometimes seen as the industry “bad boy” who needs to clean up its safety efforts — did a far better job of safety than did those with responsibility for the 50,000!

I say all of that just to remind us of this: these days, safety goes far beyond the jobsite, doesn’t it?

This column has to serve double-duty for me, as it will be my only opportunity prior to the general election to remind everyone how important it is that we all vote, and all take very seriously proper governance of our country.

Older than most of you, I was raised in a different time, when virtually nobody dropped out of high school. It

September 2016 • www.masoncontractors.org

Photography courtesy of Wikipedia.

~ Towering Concerns ~

was rare. We had no fenced-in schools, metal detectors or grief counselors on campus, and if the teacher sent us to the principal’s office, we’d be in trouble because our parents or families would side with the school before they’d believe our flimsy excuses!

U.S. history was a required class, and nobody yet had dared try rewriting it.

So, we studied it, instead. We raised the (American) flag every day and pledged our allegiance to the USA. As a bonus, nearly everybody could read, write and do math — granted, some did so better than others — but everyone could function, and a diploma did mean something. A tradesman with those skills was really a prized employee.

Precisely because I have those high school skills, I understand that the U.S. Constitution pretty much begins by saying how a primary function of the federal government is to “provide for the common defence” of its people.

British spelling aside, it means that the The Voice of the Masonry Industry

people of the United States have a right to expect governmental protection of the country. And that’s where the builders and developers of the Twin Towers messed up.

You see, there was an assumption that, if we could somehow get the thing built, and in a safe manner, that the people using it and working there would be reasonably safe, because the building had been properly constructed, with all of the latest and greatest engineering, architecture, craftsmanship and componentry — that we were home free. As they say in the fairy tales, “happily ever after.”

Again, that pre-supposes that the people in charge are paying attention. I am not talking about the military, police or firemen here.

All our first responders performed exactly as planned, and actually even better. The building performed as designed, given the criteria with which it was engineered. Unfortunately, very few building specifications give any concern to withstanding a bombing attempt by a terrorist group. This was not a fault of the building’s architects and engineers, because it wasn’t their job at the time to consider those things.

As we move into this fall and into the election season, as good contractors and business people, we will do all that we can to ensure safety on our jobsites and in all of our workplaces — just as almost every one of us has always done. We put our stamp of approval on the noble idea that our people, to the greatest extent possible, should have a decent workplace, one that is as safe as reasonably possible.

I’m pretty conservative, but am also simple and rational. I am still concerned that we keep vigilant on the jobsite as well as at home.

When working in particularly dangerous locations and times, we are extra cautious. Maybe we need K-rails out in the street, flaggers watching traffic, portable light plants for night work, maybe even a police cruiser present.

“The only thing necessary for the triumph of evil is for good men to do nothing.”

— Edmund Burke

As a project manager or a business owner, I want my guys and gals safe. Whether at home or office, Little League field, Disneyland or Sea World, whether they are working there or enjoying the fruits of working, I have expectations of safety.

So that brings me back to the idea of this election season. Here’s what I’m thinking: I agree to do all I can to help and protect those who look to me. I, in turn, will look to those who are constitutionally mandated to secure my safety. This means I’ve got to make some tough decisions, because right now, particularly this fall, it’s nighttime out there.

These days, I could be in extreme danger just sitting at a sidewalk café, a night club, watching fireworks on a holiday…you name it. This is not the time for us to throw up our hands, figure that we can do nothing at all, and think our vote doesn’t matter. Please don’t take an attitude that says something like, “At this point, what difference does it make?” It makes a difference, just as it always has and always will.

As the year closes, be vigilant. Watch your workplace. Watch out for your family. Watch how you vote, particularly this year, because the stakes are greater than ever. yMAS COACH GARY’S CORNER: Gary Micheloni is a construction company marketer, speaker, author, consultant…and a coach. Get Coach Gary to speak for your group.

FullContactTeam@gmail.com Write him and ask!

Copyright 2016 Gary Micheloni www.masonrymagazine.com

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BUSINESS

BUILDING

By George Hedley

Develop a Simple Shop Drawing and Submittal System That Works How many times have you been delayed on construction projects when you don’t have all the necessary approvals in time to order materials and keep the job moving? For example, forgetting to get the concrete foundation design mix approved by the structural engineer can stop a scheduled concrete pour for days. Or when constructing concrete tilt-up or masonry building walls, you need to order the hollow metal door frames weeks in advance to have them manufactured per the exact opening sizes, door schedule, and finish hardware specifications. Another challenge is when the owner and architect can’t agree on which ceramic tile to choose until the week before tile is needed on the job. And when the tile is finally chosen, they will likely pick one that comes from Italy and takes 16 weeks to be delivered.

Don’t Let Owners and Architects Slow You Down These and many other approval problems happen on construction projects every day. To make matters worse, the delays and increased costs associated with not obtaining timely approvals are then blamed on your company, your suppliers, or other culprits who should have known better.

As a construction consultant, I have observed many disputes that ended up in court and cost hundreds of thousands of dollars in delays, wrong products, and non-authorized substitutions of 50 |

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materials that weren’t specified but were installed without proper approvals.

Assume Everything Needs Approval Before You Install It After you are hired to build a project, go through the contract and specifications (if there are any) to determine what approvals are required. If no specific instructions are outlined, still assume you’ll be required to obtain prior approval before you install any and every material, product, fixture, finish, color, structural component like trusses or steel beams, or custom shop-fabricated item. Don’t forget anything that will be visible to the eye when the job is completed, including concrete textures, glass, storefront, landscape plants, sprinkler heads, ceilings, walls, flooring, lights, or air conditioning grilles.

Approvals can also be required on more than products, materials and finishes. Approvals can be required by the owner, architect, engineers or lender on your subcontractors and suppliers, payment cost breakdown or schedule of values, work plans or proposed schedule, milestones, proposed supervisors and project managers, testing company, jobsite logistics plan, or insurance policy and coverage limits. When you don’t ask in advance whether approvals are needed for these items, the owner or architect can stop your project or payment application until you get an item approved.

September 2016 • www.masoncontractors.org

Create a simple, standardized project

approval system by making a master

list of

every detail that might need the owner’s

or

architect’s approval.

Create an Approval Plan To create a simple, standardized project approval system that works, take a few moments to sit down with your project managers and superintendents. Brainstorm to make a master list of every detail on every type of project that might need the owner’s or architect’s approval.

Use this as a company-wide project approval checklist to fill out before you start every job. When awarded a contract, the project manager and contract administrator can review the project documents to determine which approvals they anticipate will be needed. Don’t forget to include long-leadtime items and project-specific equipment and finishes affecting your schedule as well. To get started, email GH@ HardhatPresentations.com for your copy of “Project Management Forms for Contractors.”

The Voice of the Masonry Industry

By implementing a proactive

approval process you’ll avoid potential and not

delays,

allow the owner or

architect to slow

you

down.

As a professional construction BIZCOACH and popular industry speaker, George Hedley helps contractors increase profits, grow and get their companies to work!

He is the best-selling author of “Get Your Construction Business To Always Make A Profit!” available at his online bookstore at www.

HardhatPresentations.com. E-mail GH@HardhatPresentations.com to

sign-up for his free e-newsletter, join a peer mastermind BIZGROUP, attend a BIZ-BUILDER Boot Camp, implement the BIZ-BUILDER BLUEPRINT, or get a discount for online courses at www.

HardhatBizSchool.com.

George Hedley, HARDHAT Presentations, (800) 851-8553 www.hardhatbizschool.com

Get Your List Approved Next, meet with the project customer, owner or architect to submit your proposal, shop drawing and approval list for their review. Include each item needing approval along with its deadline to keep your schedule moving forward on time. Also include on your list all the items you’ll be requesting to substitute as alternatives to the specified materials. Then explain to your customer that if the approval deadlines aren’t met, the project will be delayed and you’ll expect to be compensated for all costs associated with their slow processing of approvals.

It is imperative you insist your subcontractors and suppliers make their approvals a priority as well. When awarding contracts to them, tell them up front what you require and the deadlines for submitting their shop drawings and other proposals for approval. Put these dates in writing in their contracts or purchase orders, and then manage the process tightly. Put your contract administrator or field superintendent in charge of managing the shop drawing and submittal approval process. Meet with them weekly to review the progress and address any slow or missing approvals.

Be Proactive By implementing a proactive approval process and not waiting for your subcontractors and suppliers to submit their required shop drawings and proposals whenever they get around to it, you’ll stay ahead of the game, avoid potential delays, and not allow the owner or architect to slow you down. yMAS www.masonrymagazine.com

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

INDUSTRY

NEWS New Study Debunks Actual Cost of Brick Homes An independent study debunks common misperceptions of the actual cost to build a brick home versus competing exteriors.

RSMeans, a leading supplier of construction cost information in North America, developed “The Installed Cost of Residential Siding” study for the Brick Industry Association (BIA).

The October 2015 study compares RSMean’s estimated construction cost of homes with brick veneer over wood framing with stone veneer, fiber cement, wood siding, wood shingles, vinyl siding and cement stucco in major metro areas throughout the U.S. Nationally, RSMeans estimates that the average total construction costs of brick wall cladding is just 8 percent more than vinyl siding, 1–3 percent more than stucco and wood siding and 4–6 percent more than wood shingle and fiber cement siding. Moreover, brick is estimated at 13–15 percent less than comparable homes with stone veneer. In 11 of 17 major, selected U.S. markets, brick’s cost is not only less expensive than stone in every single market, it is also less expensive than wood siding.

“The initial cost of a brick home is quite competitive, especially since most homes require less exterior cladding than people think,” said Ray Leonhard, BIA’s president and CEO. “An average 2,700-square-foot, two-story house only needs 2,265 square feet of cladding material when accounting for windows, doors, etc.”

Leonhard said the unparalleled benefits of brick more than offset the relatively small increase in the initial cost of a new a brick home, including little to no maintenance with no painting required; extreme dur abilit y w ith some 100-year www.masonrymagazine.com

Please submit your news and events to: karen@lionhrtpub.com

manufacturer warranties; better fire and wind safety; non-fading color and reduced exterior noise with improved energy savings.

For more details, visit www.gobrick. com.

NY Engineers and Architects Get Lesson on Restoring Masonry Structures More than 110 New York metro area architects and construction engineers, including some of the top restoration experts in the city, attended two seminars on masonry restoration conducted by Cathedral Stone Products, Inc. at Superstructures Engineers + Architects in New York on July 13.

The AIA-credited seminar provided an overview of options for masonry

restoration systems and stabilization systems, including injection mortars and pinning systems, casting systems, as well as surface preparation and cleaning products, and coating systems that allow masonry to breathe so it will not peel or crack. Members of the American Institute of Architects (AIA) who completed the seminar are eligible for one education credit.

Cathedral Stone Products conducts AIA-credited seminars and hands-on workshops for architects, engineers and construction specifiers throughout the year, as well as certification programs for masonry contractors.

For more information about scientific masonry restoration systems or upcoming workshops, visit the Cathedral Stone Products website, www.cathedralstone.com, or call (800) 684-0901.

News continued on page 54

Atlas Copco Construction Names New President to Lead North American Growth Atlas Copco Construction recently appointed Scott Carnell as president of its U.S. division.

Carnell replaces Erik Sparby, who has accepted the role of general manager, Customer Center CR Greater China. Carnell will lead the company in growing each of its product lines, including construction tools, portable energy and road construction equipment, within the contractor, dealer and rental industries across North America.

Carnell brings more than 32 years of industry experience to his role, the last 10 of which have been with Atlas Copco. Carnell served as the business line manager for the Atlas Copco portable energy business area, where he led the market expansion of the air compressor and generator lines. Just prior to his new role, Carnell was the president of Atlas Copco Rental in North America, based in LaPorte, Texas.

Carnell will be based in Rock Hill, S.C., where Atlas Copco’s new 180,000-square-foot manufacturing facility will open the spring of 2017. The new LEED-certified space will help the company grow with customers’ demands and offer a wide reach of customer support. yMAS

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INDUSTRY NEWS News continued from page 53

New Members The Mason Contractors Association of America (MCAA) is proud to welcome the following new members to the Association. The MCAA would like to thank them for joining their fellow mason contractors nationwide in helping to build a strong and successful masonry industry.

SEPTEMBER 2016 Blackson Brick Co. Dallas, Texas (214) 855-5051 www.blacksonbrick.com Regional Associate Member

Assistant Professor Jennifer Akerman (left, AIA, LEED AP, UT College of Architecture and Design) and Mayor Rogero (center) pose in front of the new Beardsley Farm facility with some of the UT architecture students who contributed to the building.

Design/Build Partnership Leads to New Urban Agriculture Education Center On May 9, 2016, Knoxville (Tenn.) mayor Madeline Rogero, the city council and other officials opened a new urban agriculture community education center as part of CAC Beardsley Community Farm. The center includes 1,200 square feet of indoor education space and 1,800 square feet of covered outdoor education space. The LEED-certified building also includes offices for three CAC Urban Agriculture staff and two CAC AmeriCorps members, much needed accessible restrooms, fully accessible parking and a water catchment system for irrigation.

Beardsley Community Farm is operated by CAC Urban Agriculture and CAC AmeriCorps, and was one of the earliest urban farms in the region, servicing community members, especially children in low- to moderate-income neighborhoods and schools. The facility is open to the public for visitors to develop their urban agriculture skills at no cost.

The new urban agriculture facility was a collaboration between the City of Knoxville, CAC Beardsley Community Farm, UT’s College of Architecture and Design, Elizabeth Eason

Architecture LLC, Merit Construction and the Public Building Authority. Additional funding and materials support were provided by the Siddiqi Charitable Foundation, General Shale Brick Inc., the Thompson Charitable Foundation, former mayor and ambassador to Poland Victor Ashe, StonePeak Ceramics Inc., American Institute of Architects – East Tennessee, Paulk & Co., Keene Building Products, Columbia Forest Products Inc., Baird & Wilson Sheet Metal, and many other local sponsors.

City Public Service crews contributed a major construction effort, along with student volunteers from UT’s College of Architecture and Design on the concept of a design/build partnership. The students collaborated for one full semester with Elizabeth Eason Architecture to create the structure’s design. Professors Bob French and Jennifer Akerman and more than 50 University of Tennessee (UT) student volunteers worked over the past two years with project partners to see the facility through, even assisting with construction.

The new building will serve as a home base for the farm, creating a new front door to their educational program.

The primary structure is triple-wythe load-bearing brick, detailed

Commercial Concrete Solutions, LLC Kenmare, N.D. (701) 578-4819 www.concretesolutionsus.com Contractor Member

McCarthy Masonry & Concrete Inc. Quakertown, Pa. (215) 538-1874 www.mccarthymasonry.com Contractor Member

Nibbelink Masonry Lancaster, Calif.

(661) 948-7859 www.nibbelinkmasonryconst.com Contractor Member

Painter Masonry, Inc. Gainesville, Fla. (352) 378-7511 Contractor Member

Stronghold Steel Phoenix, Ariz.

(480) 788-4446 www.strongholdsteel.com Contractor Member Discover the many benefits your company is missing by not becoming a member of the MCAA. Call 800-536-2225 or visit www.masoncontractors.org/join to join the MCAA today. Together, we are stronger.

to take advantage of historic structural methods while also addressing thermal performance and water mitigation.

General Shale donated all brick and mortar for the project and provided News continued on page 56

54 | MASONRY

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

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INDUSTRY NEWS News continued from page 54

support for students to learn the craft of masonry from master mason J.C. Newman.

Staff at the farm worked with the designers and students so that the facility would enhance all aspects of operations. For example, the outdoor wash area was designed with a bench and counter spaces so that gardeners could wash up while also having convenient space to wash produce from the garden. A pass-through window at the wash area will allow cleaned produce and tools to be easily moved to interior storage.

For more information, visit www. beardsleyfarm.org.

Education Calendar The following is the MCAA’s education calendar: September 7

October 12

A Crystal Ball — Early Warning Signs of Construction Claims and Disputes

Assuring the Successful Continuation of Your Family Business

Location: Online Discipline: Ethics and Business Practices Credits: 1.5 Cost: Free

Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free

September 14

How to Prepare a Professional Masonry Submittal Package Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free

October 19

How to Become an Equal Partner With the General Contractor Location: Online Discipline: Ethics and Business Practices Credits: 1.5 Cost: Free

September 15

Mortar With Added Bacterial Film Resists Water Uptake A team of scientists at the Technical University of Munich (TUM) has found an unusual way to protect mortar from moisture: when the material is being mixed, they add a biofilm — a soft, moist substance produced by bacteria.

As a professor of biomechanics at the Institute of Medical Engineering (IMETUM) and the Department of Mechanical Engineering, Oliver Lieleg deals mainly with biopolymer-based hydrogels — in other words, slime formed by living organisms. These include bacterial biofilms, such as dental plaque and the slimy black coating that forms in sewage pipes.

During a conversation with a TUM colleague, Professor Christian Grosse, Lieleg came up with the idea of using biofilms to alter the properties of construction materials. Grosse holds the Chair of Non-destructive Testing. Among other things, he investigates self-healing concrete, whose cracks close autonomously.

One variant of this concrete contains added bacteria. Activated by the ingress of moisture, the bacteria close the cracks with metabolic products containing calcium.

For his own project, Lieleg used mortar instead of concrete. Instead of mending cracks after damage has occurred, he wants to prevent News continued on page 59

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Overview of Masonry Special Inspection, Codes and Standards (NCMCA Module 7) Location: Greensboro, N.C. Discipline: Codes and Standards Credits: 6 Cost: $150

October 26

DOL Regulations Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free

November 2 September 21

Multi-Employer Pension Withdrawal Liability and the Financial Risks to the Company and Your Assets Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free

September 28

How to Develop and Implement an Effective Quality Control Program Location: Online Discipline: Codes and Standards Credits: 1.5 Cost: Free

October 4

Networking Round Table Discussions Location: Scottsdale, Ariz.

Discipline: Ethics and Business Practices

Seismic Requirements of the Building Code Location: Online Discipline: Codes and Standards Credits: 1 Cost: Free

November 30

Harassment and Discrimination Basics Location: Online Discipline: Ethics and Business Practices Credits: 1 Cost: Free

December 7

Masonry Past, Present and Future Location: Online Discipline: General Credits: 1 Cost: Free

Credits: 2 Cost: Free

October 5

Scaffold Plank Identification and Inspection Processes Location: Online Discipline: Safety Credits: 1 Cost: Free

Online classes available at: www.masoncontractors.org/live For more information and to view a complete list of all upcoming education, please visit www.masoncontractors.org/education

September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

2

0

1

6

2016 REGIONAL SCHEDULE

1. Missouri - Wednesday, June 15, St. Louis, MO Call: Craig Kasten (314) 565-4892.

2. Florida - Friday, Aug. 5, Panama City Beach, FL Call: Sam Prater (404) 513-6609 3. Ohio - Saturday, Aug. 13, Cincinnati, OH Call: Brian Tillett (513) 615-4986 4. Utah - Friday, Aug. 19, Salt Lake City, UT Call: Patrick McCarthy (801) 809-9506 5. Oregon - Wednesday, Sept. 7, Aurora, OR Call: Don Dodroe (206) 718-2632 6. Colorado - Thursday, Sept. 15, Littleton, CO Call: Riley Allen (303) 819-7459 7. Wisconsin - Thursday, Sept. 22, New Berlin, WI Call: Dan Neuens (414) 313-3210 8. Texas (Houston) - Thursday, Sept. 22, Houston, TX Call: Trey Harris (214) 728-4592 9. Quebec - Wednesday, Sept. 28, Montreal, QC Call: Alain Jette (514) 942-1270 10. Pennsylvania - Thursday, Sept. 29, Crum Lynne, PA Call: John Paci (610) 656-1608 11. Louisiana - Friday, Sept. 30, Metairie, LA Call: Larry Theobold (985) 519-7161 12. Ontario - Wednesday, Oct. 5, Waterloo, ON Call: Dean Garbutt (519) 240-7265 13. Oklahoma - Thursday, Oct. 6, Tulsa, OK Call: Carson Wann (918) 230-6124 14. Illinois - Thursday, Oct. 6, Chicago, IL Call: Matt Pfotenhauer (630) 707-8200 or Luke Kisielewski (630) 414-7618 15. Arizona - Thursday, Oct. 13, Phoenix, AZ Call: Dennis Berger (623) 764-8369 16. New Jersey - Thursday, Oct. 13, Clinton, NJ Call: John Mulvaney (973) 229-0201 17. Texas (Dallas) - Thursday, Oct. 20, Dallas, TX Call: Trey Harris (214) 728-4592 18. North Carolina - Thursday, Oct. 20, Charlotte, NC Call: Marty Schiraldi (305) 812-0687 19. Alberta - Friday, Oct. 21, Edmonton, AB Call: Denis Charbonneau (403) 966-4041

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20. Virginia - Thursday, Oct. 27, Manassas, VA Call: Matt Tiches (301) 653-1128 21. British Columbia - Thursday, Oct. 27, Surry, BC Call: Carlos Zamora (604) 368-6402 22. Tennessee - Friday, Oct. 28, Nashville, TN Call: Will Scott (615) 319-0793

A D V E R T O R I A L

Contractor Tip of the

Month | By Damian Lang

The 27 Times Rule As a team leader, you deliver the same direction over and over again. You explain, you demonstrate, you feel like you’re grinding it in. Then, just when you think your team finally gets it, they take two steps back!

Do you ever wonder when your direction and demonstration will become second nature to the person you are training? What I am about to tell you may stress you out, as you probably have a long road ahead to get what you expect from the people in your operation.

Here’s my rule: Around the 27th time you tell them what you expect, they will get it.

For 28 years, I attended Jamboree in the Hills, an outdoor music festival held in an open field. It is attended by around 100,000 people, all eager to rush in and find the best spot in the field to watch the show. It’s chaotic when the gates open first thing in the morning, and hard to keep track of your group with so many people running around. So each year we would tell our friends, “When they open the gates, run to the right side of the right aisle and stay back about 100 feet from the stage.”

Without fail, every year our group would scatter. Some ran to the left; some ran to the right. Some ran to a spot 50 feet back from the stage, while others ran 200 feet back. We ended up with small groups here, there and everywhere…often not having enough room for our large group to enjoy the show together from one location.

One year, we had a heck of a time finding our friend David. Eventually he came walking up to the group. When we asked where he had been, he said, “Well, I thought we were all running to the hot dog stand.” Apparently, we hadn’t explained our game plan enough times to ensure that everyone knew what to do and where to go in the midst of the chaos. It was several years and at least 27 times explaining the drill before everyone got it straight. When they did, we

always had plenty of room for a large group to enjoy the show.

For years, I have explained the 27 times rule to my staff. At a foremen meeting the other day, James Hoskinson, the president of our masonry division, stated, “Guys, I know I haven’t told you 27 times yet, so I am telling you again. When someone is late or doesn’t show up for work, we need you to write down the circumstances surrounding the absence on the master timecard so we will have this information to use during the next evaluation, and when considering future pay raises for the employees.”

It was satisfying to see the patience James displayed as he had learned and used the 27 times rule.

James has started reinforcing the rule with his team. When a foreman complains that the laborers are not setting the scaffold ahead of time so the bricklayers have a place to go when they finish their current wall, the foreman knows the first thing James will ask is, “Have you told them 27 times how to set scaffold ahead of time to ensure they got it?”

Your team can’t do the job well if they haven’t yet learned how to do it.

The Four Laws of Learning help explain this concept. The four laws are: • Explanation.

• Demonstration.

• Imitation.

• Repetition.

It takes all four steps for the human brain to master a concept, and No. 4 shows that doing the task just a few times simply isn’t enough.

Coach John Wooden used this concept to propel his team into greatness.

He is one of the most revered coaches in all of sports, leading UCLA to 10 national basketball championships in just 12 years. Since then, his management style has been adopted by both sports and business leaders alike. Coach Wooden insists that there are in fact eight laws of learning instead of four. His version in-

cludes: explanation, demonstration, imitation, repetition, repetition, repetition, repetition and repetition.

Based on my experience, I agree that repetition is more critical than the rest.

You might be asking yourself, “Why do I need to repeat it to my team? They’re adults. They should just get it.”

I understand that. I really do. We’re all busy. But we need our employees to repeat an action enough times that it stops being a task and instead becomes habit.

We want it to be automatic.

Repetition is the mother of skill. It creates muscle memory, allowing automaticity to finally happen. You can’t learn to type, play golf, shoot a foul shot or move scaffolding without practice. Repetition is essential.

So, the next time your crew is having a problem, remind yourself of the power of repetition. And even if you’ve told them 20 times, assume that 20 is not enough.

Take a deep breath and regroup. Then walk your crew through the process until you get to 27 times.

Remember that investing in this training isn’t a waste of time. It will pay off in spades as your team develops the right habits. It may also ensure they don’t end up at the hot dog stand!

Damian Lang owns and operates several companies in Ohio. He is the inventor of the Grout HogGrout Delivery System, Mud Hog mortar mixers, Hog Leg wallbracing system, and several other labor-saving devices used in the construction industry. He is the author of the book called “RACE— Rewarding And Challenging Employees for Profits in Masonry.”

He writes for Masonry Magazine each month and consults with many of the leading contractors in the country.

All rights reserved, © 2016 Damian Lang, President of Lang Masonry Contractors, Inc., and EZ Grout Corp.

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September 2016 • www.masoncontractors.org

The Voice of the Masonry Industry

INDEX TO

INDUSTRY NEWS

ADVERTISERS

News continued from page 56

moisture from penetrating mortar in the first place. Such invading water can cause serious problems — for example, by inducing the growth of mold or widening existing microcracks through freeze-thawcycles. To prevent such water ingress, he takes advantage of the fact that some bacterial films are highly water-repellent. In the journal Advanced Materials, Lieleg and his colleagues describe how to make a moisture-resistant hybrid mortar.

The key ingredient in the new material is biofilm produced by the bacterium Bacillus subtilis. “Bacillus subtilis normally lives in soil and is very common microorganism,” Lieleg explains.

“For our experiments, we used a simple laboratory strain that grows rapidly, forms plenty of biomass and is completely harmless.” Lieleg’s team bred the bacterial film in the lab. They then added the moist biofilm to the mortar powder.

In the generated hybrid mortar, water was significantly less able to wet the surface compared to untreated mortar. The scientists have evaluated and explained the surface properties of the water-repellent mortar via electron microscope images.

To find out if the hybrid mortar is resistant enough to actually be used in construction applications, it is currently undergoing mechanical tests in Grosse’s department. “If the mortar is in fact suitable, there should be no problem for companies to produce it on a large scale,” Lieleg says. Both the bacterial strain used and the culture media are standard and relatively inexpensive. “We’ve also discovered in our experiments that freeze-dried biofilm can be used equally well. Then, in a powder form, the biological material can be stored, transported and added much more easily.”

In the future, the scientists want to examine whether the biofilm can also be used to protect concrete against water. yMAS For more information, contact Prof. Dr. Oliver Lieleg at oliver.lieleg@tum.de. www.masonrymagazine.com

21

Advanced Building Products

33

McCausey Specialty Products

800.252.2306 www.advancedbuildingproducts.com

800.365.9663 www.mccausey.com

18

41

Advanced Production Mfg.

Mississippi Valley Stihl

520.743.4268 www.blockgrinder.com

800.447.2429 www.mvstihl.com

C3 Amerimix

13

888.313.0755 www.amerimix.com

800.664.6638 www.mortarnet.com

52

7, 9

ChemGrout, Inc.

Mortar Net Solutions

Non-Stop Scaffolding

708.354.7112 www.chemgrout.com

800.845.0845 www.nonstopscaffolding.com

26

37

Construction Tie Products

219.878.1427

www.ctpanchors.com

47 ESCSI www.escsi.org/mason.htm

11, EZ Grout / Grout Hog 58 800.417.9272 www.ezgrout.com

28

Flower City Masonry

585.633.GRIP www.PlateGrip.com

17

Grout Grunt

877.266.6432 www.groutgrunt.com

31

Heckmann Building Products, Inc.

800.621.4140 www.heckmannbuildingprods.com

2, Hohmann and Barnard, Inc. 29 800.645.0616 www.H-B.com

C2 Hydro-Mobile 888.484.9376 www.hydro-mobile.com

20

Hyload, Inc.

800.457.4056 www.hyload.com

42

IQ Power Tools

888.274.7744 www.iqpowertools.com

23

Keene Building Products

877.514.5336 www.KeeneBuilding.com

17

Kennison Forest Products

Northeast CAT (regional circulation)

800.RENT.CAT www.necatdealer.com

19

Owens Corning

www.cavitycomplete.com 844.Cav.Comp

52 PavMor 413.743.2064 www.paverplacer.com

5 Pavestone www.pavestone.com/

52

PR Diamond Products

800.445.1967 www.prdiamond.com

36

Push Button Masonry

563.552.2733 www.pushbuttonmasonry.com

40

Quikpoint, Inc.

800.368.2292 www.quikpoint.com

C4

The Quikrete Companies

800.282.5828 www.quikrete.com

3

Scaffold Mart

252.756.3862 www.scaffoldmart.com

51

Southwest Scaffolding

972.331.1094 www.scaffoldingrentalandsales.com

1, SPEC MIX, Inc. 57 888.773.2649

www.specmix.com

888.697.5585 www.kennisonforest.com www.sandslevel.com

49

32-33

27 Wirebond

Krando Metal Products, Inc.

Tradesmen’s Software

800.494.6922 www.tradesmens.com

610.543.4311 www.krando.com

800.849.6722 www.wirebond.com

45

55

Malta Dynamics

World of Concrete

800.494.1840 www.maltadynamics.com

https://worldofconcrete.com/

14-15 MCAA

800.497.1704 WWW.XMFG.COM

800.536.2225 www.masoncontractors.org

43

Xtreme Manufacturing

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September 2016

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C O V E R

PROFILE New Georgian Revival Home, Greenwich, Conn.

Acknowldegements 2016 Brick Industry Association Brick in Architecture Award, Residential — Single Family, Best in Class

Architect Charles Hilton Architects

Builder Hobbs, Inc.

Manufacturer Glen-Gery Corporation

Mason Contractor Nick and Gino Vona, LLC

Photography Robert Benson Photography, Nicholas Rotondi Photography

Details Located in the Khakum Wood neighborhood of Greenwich, Conn., this new 7,000-square-foot residence was designed in a classic style that would transcend passing design fads and minimize long-term maintenance costs. The 18th-century preference for simple elegance is ideally accomplished in brick, and it was the clear choice for this new Georgian Revival home.

The exterior of the house needed to fit seamlessly into the Khakum Wood neighborhood, a historic community of fine English and Georgian homes. Red clay brick’s historical precedence, warm color and abundant available shapes and

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sizes made it a natural choice for this home’s classic façades, which include a central pedimented entry, protruding one- and two-story bays and four soaring chimneys.

The brick façade was done in a “Georgian” Glen-Gery brick set with a Flemish bond pattern to add subtle visual complexity. The bricks were all handmade and oversized to accurately represent the brick of the Georgian period, while also scaling the house down visually. Grapevine joints add further complexity to the masonry surface and additional ties to Georgian tradition.

Although the majority of the house is made of the oversized,

September 2016 • www.masoncontractors.org

rectangular brick, other decorative units were used to articulate details throughout. A variety of shaped bricks articulate the home’s exterior details — from the water table base, to decorative bay panels all around the house, to straight and round lintels, to accent panels on the chimneys. Corbelling, another decorative and functional element, was used at the chimney cap. To hide the joints at each masonry opening, brick-red caulk was applied. Real masonry chimneys vent the indoor fireplaces, while the fourth brick-veneered chimney was designed to aesthetically conceal HVAC venting. yMAS The Voice of the Masonry Industry

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