As a child, summer meant carefree days, flip flops, swimming, barbecues and baseball. As a grown-up gardener, summer is about watering and weeding to keep the garden from going to seed.

During these dog days of summer, we would like to

picture you suffering at the beach or in a mountain cabin with the latest edition of Construction Design News.

"A perfect summer day is when the sun is shining, the breeze is blowing, the birds are singing, and the lawn mower is broken." ~James Dent

So maybe your perfect summer day is as simple as a broken lawn mower and an excuse to take a much-needed break from the heat.

Our team has taken the proverbial gardener’s approach to summer by continuing to water, weed and fertilize, so we can continue to have new things to tell you about.

Our first and most notable news is the addition of Warren Barber to our team. An industry veteran, he brings expertise and a passion for design and construction. See his article on maintaining the integrity of the building envelope, while meeting more stringent energy efficiency requirements.

Tom Boissy highlights a new application in wet areas to keep water out of the wall cavity using cement backer boards such as PermaBase®.

Scott Hughes explains the critical differences in abuse and impact resistant products. Understanding these distinctions can mean the difference between a satisfied client and a client with a maintenance headache.

Speaking of heat, the Bulletin Board features several ways to beat it.

• We introduce a new 3-hour shaftwall to round out the existing 1-, 2- and 4-hour shaftwall assemblies.

• If that’s not enough hot air, read about a new gas turbine at our Burlington, N.J., plant that’s helping us dodge the high temperatures.

• Last and not least, since we are trying to stay cool indoors, don’t forget about the health and safety benefits of finishing with ProForm® brand Lite Joint Compound with Dust-Tech®.

It’s been a long, hot summer, but we did receive a cool breeze in late July when a federal court judge dismissed lawsuits claiming our gypsum board exhibited the same characteristics as defective Chinese drywall.

As summer 2012 comes to a close, we are preparing for Construct 2012 next month in Phoenix, Ariz. Until then, we will enjoy the image of you relaxing with this edition of Construction Design News while toasting your broken lawn mower.

construction design news A N A T I O N A L G Y P S U M P U B L I C A T I O N

V O L U M E 1 2 I S S U E 2 S U M M E R 2 0 1 2

Strengthening Your Building Envelope

By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited

By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference

By Scott Hughes

Bulletin Board

"Ah, summer, what power you have to make us suffer and like it." ~Russell Baker

Mundise Mortimer, LEED APManager, Technical Marketing704.365.7494 Officemmortimer@nationalgypsum.com

Please stay in touch!

Send any e-mail changes or additions to mmortimer@nationalgypsum.com so you can continue to receive Construction Design News.

Energy efficient buildings are airtight buildings. Energy efficiency is an important consideration when constructing or renovating commercial buildings. Energy efficient standards are increasingly code driven as evidenced by revisions to the 2012 Inter-national Code Council (ICC) International Energy Conservation Code (IECC) and the introduction of the International Green Construction Code (IgCC). Reducing energy consumption saves money and reduces greenhouse gas emissions. These standards define the performance of the building envelope, including the air barrier layer outside of the stud cavity. In addition to the structural layer, a building’s exterior walls have four control layers: rain control, vapor control, air control and thermal control. The vapor, air and rain control layers are often comprised of a single component. The new energy standards call for a portion of the thermal layer to be outbound of the stud cavity to prevent heat and cooling loss from thermal bridging. This insulation layer is typi-cally rigid foam-board or spray foam (SPF). Spray foam is gaining popularity because it conforms to the definition of continuous insulation without a need for joint treatment. Spray foam can also meet the definition of an air, vapor or rain control layer, serving as four control layers in one. Six of the eight climate zones outlined in ASHRAE 90.1 require additional insulation outbound of the stud cavity, ranging from R-3.8ci to R-7.5ci (Charts A&B).

Fiberglass-faced exterior sheathing, such as Gold Bond® BRAND e2XP® Sheathing, performs as a substrate for the control layers to ensure a flat, fire-resistant, dimensionally stable surface for air, water, vapor and thermal control products. When a building envelope experiences air leakage through a dam-aged or poorly performing window, door, vent or pipe,

moisture is allowed into the envelope. It’s not a matter of if, but when, the wall will leak. Storm intrusion, humidity or HVAC deficiencies can also contribute to moisture accumulation in the wall cavity. Highly engineered building products and modern construction practices cannot accommodate the effects of air leakage, humidity and even condensa-tion. When the rate of wetting exceeds the rate of drying, mold can grow as a result of persistent wet conditions. Mold is not the problem; it is a symptom of a moisture problem.

Architects and contractors need to ensure that their carefully designed, highly engineered and constructed commercial buildings have a layer of fiberglass-faced gypsum sheathing such as e2XP Sheathing that meets or exceeds the air permeance requirements of the weather-resistive barrier. It also should mitigate damage that can occur when the envelope is compromised. Many materials can be used as a substrate for a continuous air barrier and a continuous insulation layer on the exterior layer of the envelope. Experience has shown that fiberglass-faced gypsum sheathing provides superior performance. Whether installed behind an Exterior Insulation Finishing System (EIFS), stucco, brick or a variety of rain screens, fiberglass-faced gypsum sheathing signifi-cantly helps to mitigate moisture-related concerns. These sheathings also increase the durability of the structure, providing dimensional stability and superior fire resistance. Fiberglass-faced gypsum sheathing also enhances the construction schedule and offers design and construction flexibility. Exposure resis-tance cannot be compromised by rain, ice or snow. These scenarios illustrate the need for a building envelope that addresses the desired levels of energy efficiency and meets the interior environmental quality needs of the building’s occupants. e2XP Sheathing is a key component that will strengthen the design and performance of the structure. The result is a building envelope that is energy efficient, durable and sustainable.

Strengthening Your Building Envelope By Warren Barber

Warren Barber, LEED APConstruction Design Manager678.296.6179 Officewarrenb@nationalgypsum.comTechnical Info: 1-800-National

Climate Zone CI Requirement Code  Zone 1  Zone 2  Zone 3  Zone 4  Zone 5  Zone 6  Zone 7  Zone 8 

2012 IECC R‐13 +  

5 ci 

R‐13 +  

5 ci 

R‐13 +  

7.5 ci 

R‐13 +  

7.5 ci 

R‐13 +  

7.5 ci 

R‐13 +  

7.5 ci 

R‐13 +  

7.5 ci 

R‐13 +  

7.5 ci 

ASHRAE 

90.1 2010 R‐13  R‐13 

R‐13 + 

3.8 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

2009 IECC  R‐13  R‐13 R‐13 + 

3.8 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

ASHRAE 

90.1 2007 R‐13  R‐13 

R‐13 + 

3.8 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

R‐13 + 

7.5 ci 

CONTENTS

Home

Strengthening Your Building Envelope By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference By Scott Hughes

Bulletin Board

Chart A

Chart B

Have you ever started a project at home or work and thought, “There must be a better way”? Why do we settle for the devil we know versus the devil we don’t know? Yet there’s a reason we do things the same accepted way with less than optimum results. My guess is we’re reluctant to change. You can almost always find a better way when you take the time to do the research. This must have been what the inventors of cement board were thinking. Today, if you wanted to tile your shower or a wall in your bathroom, would you install metal lath and then float a bed of mortar? Not likely. You would drive to the local home center and purchase sheets of cement board to do the project. I doubt that before cement board was invented, anyone would have thought it strange to float a mortar bed wall. In 1964, tired of floating mortar beds for tile walls, a tile setter and a lather/plasterer in Cincinnati, Ohio, developed the first cement board. It was made in molds. Since that time, cement board has become a widely accepted building material with several variations available.

Cement board is basically portland cement, sand, ag-gregate and fiberglass reinforcing mesh molded into a sheet or panel. Cement board thick-nesses range from 1/4 inch for floor underlayment and countertops to 1/2 inch and 5/8 inch for walls and ceil-ings. Some common ce-ment board sizes are 3'x5', 4'x4' and 4'x8', but there are more depending on the application. Cement board wet-area design has been improved by the recent introduction and popularity of liquid-applied, waterproofing membranes. Since cement boards are porous, moisture will pass through without damage or degradation of the board.

Although it’s not always required, some de-signers call for 15-pound building paper between the wood studs and the cement board to prevent moisture from entering the wall cavity. In steel stud construction, a polyethylene plastic is some-times specified. Attaching plastic to steel studs poses a problem for some and is less than desirable but adequate. Roll-on or spray-applied waterproofing membranes have solved any long-term potential moisture migration concern and eliminated the need for a barrier behind the cement board. There are several manufacturers of waterproofing membrane products. Typically, thin-set manufac-turers have liquid-applied waterproofing membranes to complement their thin-set mortars and offer a total system. The membranes are made of flexible rubber polymers. Like paint, they are typically rolled on and dry to .020 –.030-inch thick when cured. The membranes dry quickly to form a seamless barrier so the tile is set directly over the membrane. When adding a liquid-applied waterproofing membrane to your cement board shower design, contact the manufacturer of the membrane and thin-set for the correct specification language for product selection and execution. If you were a fan of cement board in wet-area construction before, you now have one more reason to celebrate. In this case, change is good.

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy, "The Gypsum Guy"

CONTENTS

Home

Strengthening Your Building Envelope By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference By Scott Hughes

Bulletin Board

Tom Boissy, CSI, CCPR, LEED AP"The Gypsum Guy"Construction Design Manager630.390.5686 Mobiletpboissy@nationalgypsum.comTechnical Info: 1-800-National

CONTENTS

Home

Strengthening Your Building Envelope By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference By Scott Hughes

Bulletin Board

Remember when it was easy to write a gypsum specification? All you needed to worry about was what thickness and core type to specify. In a rela-tively short time, that has changed. There are so many products to choose from, it’s difficult to know when to specify what product. Just as important, you need to understand what performance features are compromised if a lower cost product is substituted for the higher performing product. One of the biggest concerns is determining when to specify an abuse resistant “AR” or impact resistant “IR” product. There are real performance differences between these two product categories that need to be defined. Let’s see if we can get a better under-standing of when you need to specify abuse resistant or impact resistant gypsum board. Abuse resistant gypsum boards are designed for use in wall assembly areas where surface abrasion is a concern. Abuse resistant products are excellent at preventing surface damage due to abrasion or scuffing in high traffic areas during standard use, and indentation of the wall surface from low impact accidental or occasional impact. Impact resistant gypsum boards do all of this with the added feature of reducing penetration damage due to intentional or continual force that would break through standard gypsum board into the stud cavity. Manufacturers add fiberglass mesh reinforcement to the gypsum core to help reduce penetration damage. Abuse resistant products do not have additional reinforcement.

When the impact resistant gypsum board specification is not clear or a contractor tries to substitute abuse resistant gypsum board for impact resistant gypsum board, it is important to understand that you are giving up significant performance. The dollars saved may be spent making repairs for years to come. ASTM C 1629 is the standard used to qualify abuse and impact resistant gypsum boards. ASTM C 1629 has four specialized tests. Each Classifica-tion Level is based on specific minimum or maximum results depending on the test. A product may meet Level 1 on one test and Level 3 on another test,

which means that each performance characteristic should be specified based upon the desired Classifi-cation Level. National Gypsum reports these values on its website and in its product literature. Here are the tests and Classification Levels for ASTM C 1629:

Looking over the chart, you can see that in some tests, like the Hard Body Impact test, the differences between Classification Levels are significant. Did you know that the result of Annex A1 testing for standard gypsum board is 35 ft.-lbs.? That means that a Classification Level of 1 for this test only improves performance by 15 ft.-lbs. Abuse resistant gypsum boards do not test in this category because they are not designated as impact resistant. When tested, abuse resistant products usually score a Level 1. If you are concerned about penetration into the stud cavity, impact resistant gypsum products must be specified and installed. National Gypsum offers choices when it comes to abuse resistant and impact resistant products. The XP® abuse and impact resistant products have a heavy duty, mold resistant paper facing. We also offer an e2XP® family of fiberglass-faced abuse and impact resistant products with a 12-month exposure warranty in addition to mold and moisture resistance. That means the e2XP Interior Extreme products can be installed prior to the building being dried in. All of National Gypsum’s abuse resistant and impact resistant products are GREENGUARD Children & SchoolsSM Certified for indoor air quality. Call your Construction Design Manager or 1-800- NATIONAL for the information you need to choose the right product and write an accurate specification.

Specifying Abuse or Impact Resistant?How to Know the Difference By Scott Hughes

Scott HughesConstruction Design Manager484.678.6132 Mobileswhughes@nationalgypsum.comTechnical Info: 1-800-National

ASTM C 1629 Classifications and Performance Requirements

ASTM D 4977 Surface Abrasion

ASTM D 5420 Surface

Indentation Resistance

ASTM E 695 Soft Body Impact

Annex A1 Hard Body Impact

Classification Level

Abraded Depth Maximum

Indentation Maximum

Impact Minimum

Impact Minimum

1 0.126" 0.150" 90 ft.-lbs. 50 ft.-lbs.

2 0.059" 0.100" 195 ft.-lbs. 100 ft.-lbs.

3 0.010" 0.050" 300 ft.-lbs. 150 ft.-lbs.

Abuse Resistant Impact Resistant

Gold Bond BRAND Hi-Abuse XP Gold Bond BRAND Hi-Impact XP

Gold Bond BRAND e2XP Interior Extreme AR Gold Bond BRAND e2XP Interior Extreme IR

Gold Bond BRAND SoundBreak XP  

Drywall Lawsuits Against National Gypsum Dismissed in Federal Court

Federal District Court Judge John E. Steele issued an order on July 24 dismiss-ing all claims against National Gypsum in the Brincku and Brucker lawsuits. The two cases claimed National Gypsum’s American-made

drywall caused the same corrosive effects in the plaintiffs’ homes as defective Chinese drywall. This claim started a media campaign and eventually led to class action lawsuits against our company, all of which have now been dismissed. The lawsuits alleged the company manufactured defective drywall, which contained high levels of sulfur, released hydrogen sulfide gas from bacteria, and corroded copper and other metals inside the homes. Unrebutted scientific evidence provided by the company proved this was not the case. The court’s action allows us to continue our 87-year tradition of producing high-quality gypsum board and finishing products. July 24 will go down as a victory for National Gypsum, and we are pleased to share this news with you and your clients.

Chicagoland Rivers Casino First to Hit Gold Rivers Casino in Des Plaines, Ill., is the first ca-sino in the world to achieve the Leadership in Energy

and Environmental Design (LEED) Gold Certification. National Gypsum products that helped give this gaming destination its winning edge include Gold

Bond® brand e2XP® Extended Exposure Sheathing, Gold Bond® brand XP® Gypsum Board, Gold Bond® brand Fire-Shield® Gypsum Board, Gold Bond® brand Fire-Shield® Shaftliner XP®, ProForm® brand All Purpose and ProForm® Lite Ready Mix Joint Compound, and ProForm® brand XP® with Dust-Tech®. Products were locally sourced from plants in Waukegan, Ill., and Jasper, Ind. The casino was designed with a sustainability plan to reduce energy and water use. The building is located on a brownfield redevelopment site. The general contractor for the project was Pepper Con-struction and the architect was Klai Juba Architects. See the NGC Project Gallery for more sustainable projects.

Specify Healthy with Dust-Tech®

Specify ProForm® XP® mold resistant joint com-pound with Dust-Tech® for a low dust, cleaner, safer and healthier building.

• XP® offers mold resistance for added protection against the growth of mold.

• Dust-Tech® reduces airborne dust by 60 percent, saving time with quick and easy cleanup and providing better indoor air quality.

• Contribute to LEED Indoor Environmental Quality credits, including Construction IAQ Management Plan, During Construction (IEQ 3.1) and Low Emitting Materials (IEQ 4.1).

National Gypsum offers XP with Dust-Tech in both all purpose and light formulations. Professional finishers can select the product that best meets their requirements and still enjoy the benefits of less air-borne dust, for faster cleanup and extra mold protection. dust-tech.info

B U L L E T I N B O A R D

CONTENTS

Home

Strengthening Your Building Envelope By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference By Scott Hughes

Bulletin Board

New 3-Hour Shaftwall

National Gypsum rounds out its offering of fire-rated shaftwall assemblies with the introduction of UL W414, a 3-hour rated shaftwall. Our current assemblies include UL designs U499 (1 hour), U497 and U498 (2 hour) and V451 (4 hour).

If you need help finding the right fire-rated assembly for your project, please call our technical team at 1-800-National. Lisa Roberts, Mark Chapman and Tony Fuller are available to answer all of your technical questions Monday-Friday from 8:00 a.m.- 4:45 p.m. EST.

Burlington Gas Turbine Increases Energy Efficiency Pipefitters and electricians have completed the installation of a land-based gas turbine, which will provide electricity and half of the thermal requirments for the Burlington, N.J., plant kiln. The turbine was commissioned this August. Recycled Energy Development (RED) owns and operates the turbine. The $7 million project received $1.3 million in funding from a grant with the New Jersey Economic Development Authority. An addi-tional $400,000 in funding came from the American Recovery and Reinvestment Act. With low natural gas prices, small gas turbines can cost effectively produce electricity. The Burlington turbine will generate approximately 3.4 megawatts of clean electricity. The excess will go to the power grid. The exhaust gases from the turbine will deliver more than 210,000 million Btus to the kiln, or about half its annual heating requirements. This will result in a 90-percent improvement in overall energy efficiency.

By using the turbine, the plant will reduce its greenhouse gas emissions. The project will serve as a model for energy efficiency and emission reductions at energy intensive industrial facilities throughout the United States.

B U L L E T I N B O A R D

CONTENTS

Home

Strengthening Your Building Envelope By Warren Barber

Rethinking Wet Areas: Cement Board Showers Revisited By Tom Boissy

Specifying Abuse or Impact Resistant? How to Know the Difference By Scott Hughes

Bulletin Board

Please stay in touch!

Send any e-mail changes or additions to mmortimer@nationalgypsum.com

so you can continue to receive Construction Design News.