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Lightweight Concrete Masonry November 16, 2009. Outline Properties and Benefits of Lightweight Concrete Masonry Lightweight Concrete Masonry Markets Market.

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Presentation on theme: "Lightweight Concrete Masonry November 16, 2009. Outline Properties and Benefits of Lightweight Concrete Masonry Lightweight Concrete Masonry Markets Market."— Presentation transcript:

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 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. Calculation Method Equivalent Thickness

8

9 Thermal Efficiency R 9.5 SmartWall = R 19 Metal Stud Wall w/ Batt Insulation High R Values With Low Thermal Bridging Through Webs Good Thermal Mass SmartWall Provides

10 R- Values for Unreinforced Concrete Masonry 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 Medium Weight Lightweight

15 Thermal Efficiency High R Values With Low Thermal Bridging Through Webs Good Thermal Mass Significant Reduction in Heating & Cooling Costs Lightweight CMU Provides

16 Total Life Cycle Wall Costs “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?

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 lb lb lb 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

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 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 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

31 Lightweight Concrete Masonry  Installation Efficiency  Structural Performance  Fire Resistance & Durability  Life Cycle Energy Savings Lighter, Stronger Concrete Masonry. Outperforms Other Wall Systems:

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

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34 ESCS Aggregate: Thermally Stable, Insulating, Refractory

35 SOLUTIONS Jobs Completed Sooner at Lower Cost Because of Increased Productivity Structural / Seismic Economy Improved Fire Safety & Durability Life Cycle Energy Conservation Lightweight Concrete Masonry walls provide solutions:

36 The Future

37 For more information...


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