1. Lightweight Concrete Masonry
November 16, 2009

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

3. 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

4. Benefits of LW CMU Designer benefits Owner benefits
Mason contractor benefits

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

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

7. 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:

8. 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.

9. 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.

10. 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 SmartWall 90 lb/cu ft. Heavy Weight 130 lb/cu ft.

11. 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

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

13. 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

14. 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

15. 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.

16. 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

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

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

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

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

21. Productivity vs. Weight

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

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

24. 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!

25. 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

26. 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

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

28. 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

29. 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

30. 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 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

31. 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

32. 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.

33. This sums it up…

34. 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.

35. 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…

36. The Future

37. For more information...
Thank you.