Lightweight Concrete Masonry November 16, 2009

Outline Properties and Benefits of Lightweight Concrete Masonry Lightweight Concrete Masonry Markets Market share Lightweight Opportunities The Future

LW-CMU Properties Fire rated Energy efficient – higher R value, makes insulation more efficient Sound absorption – 2X NW CMU High strength Low shrinkage Low absorption Sharp edges and corners

Benefits of LW CMU Designer benefits Owner benefits Mason contractor benefits

Designer Benefits Fire resistance High strength to weight ratio Energy efficiency Sustainable design

Fire Resistance Lightweight concrete masonry has greater fire resistance than normal weight (heavy) c/m of the same equivalent thickness

Equivalent Thickness Calculation Method Extensive testing has established the relationship between fire resistance and equivalent solid thickness for concrete masonry walls. The relationship determines fire endurance based on types of aggregates used and the equivalent thickness of the unit. Equivalent thickness is defined as the solid thickness that would be obtained if the same amount of concrete were cast as a solid block. ET is obtained through ASTM C 140 testing. The ET has its basis in the conduction of E119 fire tests on concrete masonry wall assemblies and from this test the fire resistance rating of a particular wall assembly is determined. It has been shown that for concrete masonry wall assemblies, the fire resistance rating is dependent on the aggregate composition of the concrete masonry unit (CMU) and the CMU’s equivalent thickness. Through a testing program using different aggregate-type CMUs, a database exists of observed fire resistance ratings as a function of aggregate types. From this database, conservative equivalent thicknesses were chosen and are used as minimum requirements. These minimum requirements for equivalent thickness appear in the following building codes and documents:

Equivalent Thickness This is the table of equivalent thickness requirements. It shows the required thickness to get the hourly fire rating. If is dependent on aggregate type. For example, a limestone unit that has an equivalent thickness of 4 inches, is a 2-hour rated block. It has 2 footnotes: A - says that you can interpolate between the columns - that is if a test reports an ET of 4.5 inches for a limestone block, its fire rating can be calculated to be 2.5 hours. B - says that you can interpolate between the rows - that is if you have a block with different aggregates, you can still determine the fire rating by knowing the percent aggregate in the CMU. This is also call blended aggregate fire rating determination. An example is shown a following slide.

R 9.5 SmartWall = R 19 Metal Stud Wall w/ Batt Insulation Thermal Efficiency SmartWall Provides High R Values With Low Thermal Bridging Through Webs Good Thermal Mass R 9.5 SmartWall = R 19 Metal Stud Wall w/ Batt Insulation Another feature of the SmartWall System is Thermal Efficiency. Through the inherent high R values, Thermal mass and low thermal bridging through webs a significant reduction in heating and cooling costs can be realized.

R- Values for Unreinforced Concrete Masonry Walls The R values made possible by the SmartWall unit eliminate in some cases the need for core inserts. When used in conjunction with Foamed cores, the units gain a very respectable R value of 10.5 in the 12” unit. These values are for un-reinforced units – See later slide for values for “Typical” reinforced walls. R Values per NCMA TEK 6.2A & NCMA CMS 10911. SmartWall 90 lb/cu ft. Heavy Weight 130 lb/cu ft.

Sustainable Development Lightweight Concrete Masonry and Green Buildings LEED Certification with Lightweight CMU LEED Credits can be earned in 3 categories Materials and Resources Energy and Atmosphere Innovation and Design

Owner Benefits Higher quality Lower installed cost Lower life-cycle cost

Higher Quality Better fire resistance Greater energy-efficiency More design flexibility Fewer shear walls More and larger openings Greater comfort and safety for occupants Increased worker productivity

Initial Wall Costs Lightweight The weight of the CMU affects many of the initial costs associated with the installed wall cost. Even though the per cmu cost of the SmartWall unit will increase… the total wall cost is lowered due to the reduction in labor costs, delivery costs and overhead costs. Lightweight Medium Weight

Significant Reduction in Heating & Cooling Costs Thermal Efficiency Lightweight CMU Provides High R Values With Low Thermal Bridging Through Webs Good Thermal Mass Significant Reduction in Heating & Cooling Costs Because of their superior R factor, SmartWall Systems walls have Thermal Efficiency. Through the inherent high R values, Thermal mass and low thermal bridging through webs a significant reduction in heating and cooling costs can be realized over the life of the building.

Total Life Cycle Wall Costs Materials manufacturers and contractors are by definition “First Cost” oriented. But building owners and designers have to live with the building, and cannot just look at first cost. Total LCC cost is the real cost of ownership and SWS lowers Total LCC. ---------------------- Hope to add more LCC info, masonry vs other (steel panel, glass, etc) wall systems - - Reference CMR LCC study ~1995. “Typ.” Lightweight Lightweight

Mason Contractor Benefits Lighter weight Increased efficiency More production with less effort Improved competitiveness for masonry More jobs

Why is this man smiling? These 12 x8x16 SmartWall CMUs weighed 36 # compare that to a heavy weight 2 man block 48#

Lightweight Concrete Masonry Quality Value Energy Efficient Fire Safe Labor-friendly

Concrete Masonry Units ASTM C90 Classification Light-weight Medium Weight Normal Weight Density <105 pcf 105-125 >125 pcf 8X8X16 12X8X16 <30 lb <40 lb 32-35 lb 44-48 lb 36-38 lb 50-54 lb

Productivity vs. Weight

Lower Weight Benefit – less effort Example – 200 units/day MW (32 lb) - 6400 lb. LW (27 lb) - 5400 lb. (1000 lb. less / day) (16% reduction)

Lower Weight Benefit – increased efficiency Example – 200 units/day + 15% increase, or 230 units/day MW - 6400 lb. (@ 200 units/day) LW - 6210 lb. (190 lb. less / day) (3% reduction) More production with less effort!

Labor Savings Productivity Means Faster Completion >> Quicker Occupancy Lower Direct Labor Costs Lower Contractor Overhead Costs Better Ergonomics w/ Lighter Units Less Fatigue & Fewer Injuries Lower Workman’s Compensation Lighter units not only save in direct productivity (Labor rate divided by units laid per hour) but also in Overhead costs. If a SmartWall job is done on Thursday instead of Friday, All of Friday’s overhead costs – insurance, utilities, job supervision, etc – get charged to some OTHER job. ERGONOMICS – congress has killed the ergonomics law, but eventually it will be enacted and it will affect construction. In the meantime, the ergonomic benefits of lighter units are available today. Optimize Ergonomics with SmartWall!

Increased Productivity Does NOT mean working FASTER DOES mean less fatigue permits the mason to maintain his/her NORMAL pace longer Result: More production with less effort Benefits are even more significant with 10-inch and 12-inch units

Improved Competitiveness Installed wall cost is driven by labor cost 3:1 Labor:block cost As block weight is reduced, installed cost is reduced Some of the cost saving goes to lower bid prices Lower bids make masonry more competitive vs. other wall systems

More Jobs Lower bid prices mean more projects for masonry More projects mean more jobs!

Opportunities Mason Contractors Examples Will recognize productivity benefits Will recognize safety benefits Examples Minneapolis, MN Atlanta, GA Lansing, MI Should reflect reality in bids and Wall Cost Guides

Opportunities Architects Examples Will specify lightweight to get the benefits Will allow lightweight substitution Will look for promised cost savings Examples Minneapolis, MN Atlanta, GA Lansing, MI

Rotary Kiln Expanded Shale Clay and Slate Lightweight Structural Grade Ceramic / Refractory Inert Non-Staining The structural grade lightweight aggregate used is a rotary kiln expanded shale clay or slate with the general characteristics of being between 40 -55 pcf or nearly half that of normal weight aggregates. It is produced by calcining or burning the raw shale clay or slate at a temperature of approximately 2000 deg. F in a large rotary kiln This process causes a bloating action in the raw materials where thousands of non connected air voids are created The resulting product is structurally strong, stable, durable and inert yet lightweight and insulative

Lightweight Concrete Masonry Lighter, Stronger Concrete Masonry. Outperforms Other Wall Systems: Installation Efficiency Structural Performance Fire Resistance & Durability Life Cycle Energy Savings SmartWall is a national program developed by the ESCSI SmartWall positions high performance concrete masonry units as a solution for the design community. SmartWall units are lighter and stronger than regular lightweight units in ASTM C90. It is a program that offers the specifier a wall system that has functionality and consistency across regions and from a variety of producers, and is a system which is supported by an industry certification program SmartWall promotes the upgraded characteristics of masonry that are possible when a high performance spec is utilized such as Lower Installation Cost, Improved Strength to Weight Ratio “Structural Efficiency,” Fire Resistance & Durability, and Energy Savings. Cost of the wall is important. Initial wall costs are made up of construction costs such as labor, product, and overhead. Longer term life cycle costs include energy efficiency, and maintenance. SmartWall masonry wall system takes into consideration these items and provides a cost effective solution to designers that are looking for optimum performance, safety and flexibility from the wall systems that they design

Lightweight Concrete Masonry Built With… High quality structural grade expanded shale clay or slate aggregate Aggregate is manufactured to optimum gradation for compaction, strength, shrinkage, uniformity of texture The primary component of the SmartWall system is the High Performance Concrete Masonry Unit manufactured using high quality expanded shale clay or slate aggregates that have been manufactured to optimal gradations for compaction, strength, shrinkage, and uniformity of texture.

This sums it up…

ESCS Aggregate: Thermally Stable, Insulating, Refractory Aggregate type: ESCS has already been “fired” during production. While it is insulating because of its low density, it is also a structural aggregate even at elevated temperatures and is thermally stable. ESCS used in refractory linings for kilns and ovens in industrial applications worldwide. Thus it should come as no surprise that SWS walls perform so well both in the testing laboratory and in real world fires.

SOLUTIONS Lightweight Concrete Masonry walls provide solutions: Jobs Completed Sooner at Lower Cost Because of Increased Productivity Structural / Seismic Economy Improved Fire Safety & Durability Life Cycle Energy Conservation The use of SmartWall Systems provides many benefits for the owner, the architect and the contractor…

The Future

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