Walls & Ceilings April 2011

Feast your ears on this… Turn to page 13 for more info

April 2011

Volume 74, Issue 4

The Voice of the Industry Since 1938™ WC03114CERTCEIL-CC.indd 1

C O N V E N T I O N

C O M P A N I O N

I S S U E

2/17/11

FOUR? SCORE. National Gypsum introduces e2XP Tile Backer, the final piece of the puzzle for extended exposure fiberglass-faced gypsum panels. Designed for use as a substrate for interior tile applications in high moisture areas, e2XP Tile Backer is the perfect fit for interior residential and commercial applications. To learn more about our complete family of e2XP products, including Sheathing, Shaftliner, Interior Extreme and Tile Backer, visit purplechoice.info.

Technical Info: 1-800-NATIONAL or visit nationalgypsum.com

R

FOR

RUST

MOISTURE LABOR

The Contractor ’s Choice. GRAY or TAN foundation sill screeds and casing beads, for stone veneer applications, look

Foundation Sill Screeds

great and eliminate painting. Get a rustproof job that saves Termination Beads

STONE VENEER

COLOR TRIMS

time and money – with moldedin, permanent, non-chipping color that looks good too!

The rustproof alternative to metal laths, Ultra-Lath® is easy on hands and easy to install.

ULTRA-LATH® Plastic Lath

RUSTPROOF PLASTIC LATH Improve moisture End cap fits window/door drip edge

management and job quality with our patented low profile end caps. For 1" • 1-1/2" • 2" foam systems.

LOW PROFILE END CAPS For more than 40 years, Plastic Components’ PVC trims have delivered proven remedies for rustproofing your installation, lowering installed costs and controlling moisture.

Our matching reveals and intersections control moisture in stucco-clad structures – and deliver a great-looking result.

We are also the only trim manufacturer whose products are Listed by Warnock-Hersey for superior quality and proven compliance with ASTM standards.

No field assembly and no worries.

PREFABRICATED INTERSECTIONS us in Visit 18

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8 0 0 . 3 2 7 . 7 0 7 7 • F a x 3 0 5 . 8 8 7 . 2 4 5 2 • w w w. p l a s t i c o m p o n e n t s . c o m © 2010 Plastic Components, Inc

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Up Front

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Finish Line by Robert Thomas

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Smart Business by Jim Olsztynski

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Straight Green by Chris Dixon

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Industry Voices by Robert Wilson

departments

April 2011

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Trade News

16

Product Focus

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Toolbox

71

Classified Marketplace

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Advertiser Directory

Volume 74, Issue 4

on the cover

The Voice of the Industry Since 1938™

Omaha, Neb.-based Fe Fi Faux Studios Inc. designs and installs faux finishes and a variety of interior plasters for homes and businesses.

C O N V E N T I O N

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| Walls & Ceilings | April 2011

features

by Mark Fowler

18 Training Day A Texas train station repaired and refurbished with an eye towards the past.

22 Ambitious Artisans Three women in the plastering field get real, talk faux.

28 Soundproofing’s Speedy Evolution The science of reducing sound is only 90 years-old and now there are a wealth of options for making the world quieter.

32 Energy Savings Makes Cents Insulation is an investment that pays off in more ways than one and more than just once.

36 Annual Convention Companion Directory

ON THE WEB www.wconline.com Breaking News W&C Blogs Web-only Features Special Sections W&C Architect

W&C Digital Edition Media Kit Facebook White Papers/ Case Studies

INSTALLATION

SY STEMS Between us, ideas become reality™

armstrong.com/drywall4wc 1 877 ARMSTRONG

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FRONT

All Wet Can cement stucco and EIFS work in wet climates? The answer is yes and we can prove it. A recent study from the NAHB Research Center reported that brick veneer was the most dry of all claddings they tested. They really need to know all the facts. First, EIFS was omitted from the test, which in my mind was a good thing. Not because EIFS is bad but the test they performed was bogus. Second, the test was sponsored (paid for) by the Brick Industry Association and the EIFS and brick industries have been fighting each other for years. The test was performed on eight wall assemblies with wood framing and various “selected” claddings over them. As reported, each wall was exposed to the weather for a year. Here is the kicker: Each wall was constructed so a portion of the water-resistant paper was “compromised” and water was poured behind the cladding. I could have predicted the results before they even started the test. The brick veneer, the only cladding with a 1-inch clear cavity, won. The water flowed down the back side of the brick, never touching the building paper on the sheathing. If you think this proves that brick is

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| Walls & Ceilings | April 2011

better, you can put the same airspace on any cladding (we call it rainscreen). Now, if they would have tested brick veneer with a 1-inch airspace against similar wall assemblies that would be fair. The test was, in my opinion and from what I’ve read, 100 percent rigged and pointless. I will not trash brick as a cladding. It is a good cladding and a historic material but let’s be fair and honest about testing. Good construction means dry walls and bad construction means trouble, regardless whether it is brick, EIFS, wood siding or stucco cladding. A clear airspace certainly affords for some poor construction practices, but it does add cost. How about building it right from the start? Using qualified contractors, good details and traditional systems will keep walls dry at a reasonable cost. If you are into reports and must have one to back up your design choice, how about the ASTM STP

1269 on the life-cycling cost of EIFS and other claddings? EIFS, brick and stucco were all compared using good design and construction practices. The winner was stucco with EIFS coming in a very close second place for life-cycle costing of cladding for a commercial building. Of course, they all have to be assembled within industry and code standards. So, I guess if you plan to build it correctly, use EIFS or stucco. If you plan to construct the wall incorrectly, we encourage you to stay away from stucco and EIFS. But stucco in a wet climate? I was asked to visit a five-story condominium with cement stucco cladding installed over two layers of Grade D paper. The building sat on a hill in Seattle. The midrise stucco building with no overhangs was exposed to the Pacific Northwest’s famously nasty, wet weather for more than 10 years. An earthquake rattled the building and while the stucco developed a few hairline cracks, which were no issue, so did the window frames and they started leaking into the cavity of the wall. It was decided that the windows had to be replaced and that removal of all the stucco was basically the same cost as patching around all the windows. When I arrived back at the site, the stucco had been removed. T he 10 -year- old wood-based sheathing under the stucco looked like new. The lesson learned was good design, with good f lashings and a good contractor to install them, works. The architect who designed and detailed this cladding used basic flashings but required all penetrations to be walked and thoroughly inspected prior to plastering. He also set qualifications for the plastering contractors who bid the work in his specifications. He knew that a low price was just not worth it in the long run. W&C If you read this article, please circle number 388.

PLATINUM EXTERIOR SHEATHING

Platinum Protection for serious professionals

Jeanne McGrath, President Holmes Drywall Supply, Inc. One of the Midwest’s largest drywall distributors

“ We are very serious about meeting the needs of today’s construction professional, and for our customers nothing but the best will do.” – Jeanne McGrath Introducing Weather Defense Platinum™, Lafarge’s newest exterior gypsum sheathing offering superior mold and mildew resistance backed by a 12-month exposure warranty. Weather Defense Platinum is easier to handle and cut than traditional fiberglass-faced boards and has the industry’s highest percentage of recycled content (over 90%) for higher LEED® credit contributions.* Get covered with Platinum Performance. *For specific LEED credit information visit certguide.lafarge-na.com

www.lafargenorthamerica.com s 1-800-237-5505 Please Circle #106 On Reader Action Card

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EDITORIAL ADVISORY BOARD Bob Drury — Executive Director, NWCB Michael Kwart — Executive Director, ICAA Michael Gardner — Executive Director, Gypsum Association Steve Pedracine — Executive Director, Minnesota Lath & Plaster Bureau Jon Mooney — President, Acoustics by J.W. Mooney Elizabeth Steiner — Executive Director, ICFA

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LIST RENTAL Postal contact — Rob Liska: (800) 223-2194 x726, [email protected] Email contact — Shawn Kingston: (800) 409-4443-828, [email protected] WALLS & CEILINGS (ISSN 0043-0161) is published 12 times annually, monthly, by BNP Media II, L.L.C., 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $115.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $149.00 USD (includes GST & postage); all other countries: $165.00 (int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media II, L.L.C. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: WALLS & CEILINGS, P.O. Box 2147, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to WALLS & CEILINGS, P.O. Box 2147, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

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“Everyone should use MEGA LATH !” ™

The University Gateway Project, a 1,600-bed dormitory at USC, incorporates some 18,000 yards of Structa Wire’s Mega Lath product.

“We substituted Mega Lath for 3.4# metal lath and are glad we did. With Mega Lath, 3-coat stucco production is faster, stress cracking is greatly reduced, and end lap cracking is eliminated entirely. Everyone should use Mega Lath!” - Gary Paoli, President Premier Wall Constructors, Inc.

Structa Wire congratulates our customer, Premier Wall Constructors, on winning the prestigious Walter F. Pruter award for its multi-family residential project at the University of Southern California. These annual awards recognize quality craftsmanship, materials, and design in the construction industry.

Please Circle #296 On Reader Action Card

When our customers win, we win! 1.800.887.4708 | www.structawire.com

TRADENEWS CALENDAR APRIL 14-16 NWCB ANNUAL CONVENTION AND TRADE SHOW Fairmont Empress Hotel Victoria, British Columbia www.nwcb.org

MAY 12-14 AIA New Orleans www.aia.org

BORAL TO DISTRIBUTE BASF’S FINESTONE Boral USA has announced a distribution agreement with BASF Wall Systems for the distribution of its Finestone Architectural Wall Systems. The agreement provides Boral exclusive distribution rights for the Finestone brand in 11 southeastern states and a portion of Florida. Boral’s expansion into the stucco segment and alignment with this leading brand is a key development in expanding the company’s cladding strategy and balancing the product portfolio across both residential and commercial segments.

JUNE 22-24 PCBC Moscone Center San Francisco www.pcbc.com 22-25 TLPCA/SCWCPA Hyatt Regency Hill Country Resort & Spa San Antonio www.tlpca.org

JULY 15-16 FWCCA SOUTHEASTERN CONVENTION & TRADE SHOW OMNI Hotel at Chamption’s Gate Orlando, Fla. www.fwcca.org

SEPTEMBER 13-16 CONSTRUCT/TFM 2011 McCormick Place Chicago www.constructshow.com 22-24 ICAA ANNUAL CONVENTION & TRADE SHOW Contemporary Resort Orlando, Fla. www.insulate.org For additions or corrections to our Calendar, please call (248) 244-6404.

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| Walls & Ceilings | April 2011

CLARKWESTERN AND DIETRICH FORM JOINT VENTURE Marubeni-Itochu Steel America Inc. and Worthington Industries Inc. announced that they have reached an agreement in principle to combine ClarkWestern Building Systems and Dietrich Metal Framing in a newly-formed joint venture. In the transaction, MISA will acquire a 75 percent interest of the joint venture and Worthington will acquire a 25 percent interest. As part of the exchange, Worthington will also acquire the assets of the non-automotive service center business of MISA Metals Inc. consisting of three steel processing facilities located in Ohio and Tennessee. Both parties anticipate the deal will be signed by the end of the month. “We are making two businesses stronger by combining them in a joint venture,” said John McCon n el l , c h a i r m a n a nd C E O of Worthington Industries. “The economic downturn has been particularly difficult for the construction industry and by creating the joint venture, we best position them to be profi table now, and for success when the market begins to recover. We are also pleased that a large number of our current employees will have an opportunity to work for the joint venture.”

“The joint venture will provide our customers access to a broad product line, high-performing equipment and excellent customer service,” said Bill Courtney, president of ClarkWestern Building Systems. “Our combined technical expertise has the potential to benefit our customers through improved efficiency, innovative products and strong leadership. We are excited about the opportunities we can offer by having a broad distribution capability supported by our combined well-respected workforce.” The exchange of assets is being structured as a cashless transaction with the exception of working capital adjustments and other transition payments.

ABP REPORTS STRONG 2010 PROFITS National distributor Allied Building Products recorded a 147 percent gain in operating profit last year to $51.1 million even though sales increased only 6 percent, its parent company CRH reported. The distibutor’s earnings before interest, taxes, depreciation and amortization increased 54 percent to $82.8 million during 2010 from the previous year. Exterior products accounted for 85 percent, while interior products, including wallboard, accounted for 15 percent. EBITDA as percent of sales grew to 4.8 percent for the year from 3.3 percent, while operating profit as percent of sales more than doubled to 3 percent from 1.3 percent. “Since 2008, Allied has closed or merged 27 locations, many in smaller markets, and added three locations,” CRH said. “This process has provided an opportunity to evaluate Allied’s market footprint and to position the business for future opportunities. In addition, the business has concentrated on purchasing and transportation initiatives, rationalization of administrative and geographic oversight functions, thereby increasing efficiency, con-

WHAT AMERICA’S MADE OF™ .

We helped a timeless classic stay timeless. When the historic Miami Woman’s Club needed renovation, QUIKRETE® products helped restore the building to its original textured stucco facade. Over 50 bags of QUIKRETE® Fast Set Repair Mortar were used for structural repair. And over 1,700 bags of QUIKRETE Base Coat Stucco were used to match the original Mediterranean exterior. It’s further proof that no matter what you’re building, QUIKRETE® has everything you need to keep pouring. And with over 90 manufacturing plants, we can speed hundreds of high-performance products right to your jobsite. QUIKRETE even offers technical support. For a free construction product guide, visit QUIKRETE.COM or call 1-800-282-5828. Please Circle #349 On Reader Action Card

TRADENEWS trol and profitability. This aggressive operating approach has substantially benefited 2010 operating results.” The distributor also launched a new product initiative called TriBuilt Materials during 2010. The program is designed to differentiate Allied in the market at the same time building a brand identity.

GWBM ACQUIRES GRABBER DISTRIBUTION BUSINESS Great Western Building Materials announced that it has acquired

Grabber Construction Products’ distribution business in San Francisco. The transaction became effective Jan. 1, 2011. GW BM will continue to carry Grabber’s available products including drywall, steel framing, insulation, Grabber screws and tools. New products will include full lines of acoustical ceilings, FRP, lath and stucco and Sto acrylic fi nish products. Tinting will be provided at the San Francisco branch for all Sto products. GWBM will now provide

in-house stocking crews to accommodate contractors’ needs for all commercial and residential projects. Grabber will continue to offer its full line of fasteners and other products through GWBM.

MURCO CELEBRATES 40 YEARS Murco Wall Products, a supplier based in Irving, Texas, announces its 40th anniversary. The company was founded by Bud Murphy in 1971. The company began in Murphy’s garage and continues to be a family-run business. In honor of four decades of service, the company will be celebrating this achievement throughout the year with special events. Check the company’s Web site at www.murcowall.com for more information.

DRYVIT’S COLORANT TECHNOLOGY NOW AVAILABLE Dryvit Systems Inc. announced that its proprietary StratoTone high performance colorant technology is now available as an option for any project. The technology has been utilized on a limited basis for several years by numerous national accounts, helping meet their needs for bright, vivid colors with high fade resistance that matches their branded color standards. The colorants can be used in all company manufactured pigmented, textured fi nishes, as well as in Dryvit’s Demandit, Weathercoat, Weatherlastic Smooth and Revyvit coatings. In addition to its resistance to UV degradation, the pigments are VOC and APEO free, meeting the most stringent environmental and regulatory requirements. “StratoTone colorants offer the highest level of performance, which is what our customers have come to expect from Dryvit for more than 40 years,” said Tony Stall, vice president of marketing and sustainability at Dryvit Systems. “… architects can now specify virtually any color, on any project and get a warranty against fading.”

DRYWALL NOT RESPONSIBLE FOR FT. BRAGG DEATHS Conclusions from a broad investigation by the U.S. Consumer Product

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Please Circle #319 On Reader Action Card | Walls & Ceilings | April 2011

Product: Ecophon® Master™ Solo S Free Hanging Units Project: Sly Fox Brewhouse & Eatery, Phoenixville, PA Contractor: Benner & White Construction, Inc., Harleysville, PA

Feast your ears on this… M E E T EC O PH O N ® M A S T E R ™ S O LO S - A free-hanging, high density fiberglass panel with superior sound absorption on all sides for enhanced acoustical control. - Ideal for schools, offices, restaurants, or any other space where the look of an open ceiling is desired but acoustics are a concern. - Great for use in pre-existing or new spaces where traditional grid and tile systems are not feasible or desired. - Simple components make for an easy installation in any environment. - Simple integration of lighting components.

“The Ecophon® Master™ Solo S system was easy to assemble and install, which simplified this process. It’s a good system and it worked out really well for us.” –Tyrone Deschler, ceilings superintendent for Benner & White Construction, Inc.

“With Ecophon® Master™ Solo S, we were able to solve our acoustical problem while not interfering with the big, open look that we wanted in our ceilings. The new ceiling looks dynamite.” –Pete Giannopoulos, owner of Sly Fox Brewhouse & Eatery

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TRADENEWS SPACKLE BY DAVE COVERLY

Safety Commission presented to Ft. Bragg military officials and families found no evidence either of hazardous drywall or environmental factors linked to the deaths of three infants. This investigation confirms the results of previous analysis of Ft. Bragg homes by others which also found no link to drywall. Studies conducted by the nationally recognized fi rm Environmental Health and Engineering Inc. under contract with CPSC looked at the drywall to see if it met the criteria established by CPSC and other federal agencies for identifying “problem” drywall. EH&E also studied the indoor environment and the heating, ventilating and air-conditioning system to determine if possible environmental factors may have contributed to the infant deaths. The EH&E report presents data from samples taken from two homes at Ft. Bragg where three infants died. All chemical and physical testing and evaluation established that the drywall in the two homes studied did not contain the factors that identify problem drywall other than the time period of construction. EH&E’s environmental testing included nearly 400 different tests conducted for fungi, metals, pesticides, organic compounds, aldehydes and volatile organic compounds in the water, air and dust. From all this testing, only the levels of two pesticides, permetherin and cypermetherin, were found to be in the high-normal range. All other pesticides were either not detectable or in the low range. For additional fi ndings from the Interagency Drywall Task Force’s investigation, visit www.drywallresponse.gov.

DOW SUPPORTS HABITAT FOR HUMANITY’S REVITALIZATION INITIATIVE Dow Building Solutions is donating insulation and air sealing products in support of Habitat for Humanity’s Neigh-

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Please Circle #320 On Reader Action Card | Walls & Ceilings | April 2011

borhood Revitalization Initiative. The manufacturer will provide select products from its building envelope product portfolio, including Styrofoam Brand Extruded Polystyrene (XPS) Foam Insulation, Great Stuff Window & Door Insulating Foam Sealant and Work Wipes, and other products, as needed, for a Jonesboro, Ga., home construction project of Southern Crescent Habitat for Humanity. Launched by Habitat for Humanity International in 2009, the Neighborhood Revitalization program is designed to help Habitat U.S. affi liates support homeowners in distressed neighborhoods suffering from high foreclosure rates, abandonment and home maintenance issues. Southern Crescent Habitat is partnering with 70 low-income homeowners to complete exterior improvements and maintenance work, weatherization and energy efficiency upgrades on their homes. “This marks the 30th year that Dow has supported Habitat for Humanity initiatives, and we are especially glad

PEOPLE Tara Murray has been appointed marketing manager of Benjamin Obdyke Inc. Terex Aerial Work Platforms has announced that Tom Saxelby has been appointed to vice president of sales, North America.

Rainville

Jeff Rainville has been named director of sales and marketing for Polygon. The American Concrete Institute announced Kevin Mlutkowski, LEED AP as its director of sustainability.

to participate in this initiative for revitalizing and retrofitting some of America’s most distressed neighborhoods,” said Scott Young, global director of energy efficiency and sustainability for Dow Building Solutions. “The Jonesboro Neighborhood Revitalization program aligns with many of Dow’s 2015 Sustainability Goals, including energy efficiency, community success and local protection of human health and the environment.”

Mlutkowski

“Dow Building Solutions has been a longtime partner and supporter of Habitat for Humanity, and we are very pleased to be working together again on a project which will provide much needed help for this community,” said Larry Gluth, senior vice president of U.S. and Canada for Habitat for Humanity International. “Weatherization helps create affordable housing that’s energy efficient and can help low-income homeowners save.” W&C

ProÅts Right at Your Feet Hacker Industries, Inc., the leading supplier of gypsum concrete floor underlayments and acoustical control mats, is looking to expand its Licensed Applicator network. Broaden your product offering to both existing and potential customers with FIRM-FILL® Brand products. We offer the following and more. Technical Assistance Architect Support Onsite Training

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(800) (800) 642-3455 642-3455 • • (949) (949) 729-3101 729-3101 www.hackerindustries.com www.hackerindustries.com

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Gypsum Concretes

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Please Circle #321 On Reader Action Card April 2011 | Walls & Ceilings |

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product

FOCUS

on

Fasteners and Nailers Fuel and nail pack PASLODE The Fuel + Nail Combo Pack with a twist-on adapter, allows users of older-generation Paslode cordless framing nailers to take advantage of the convenient combo pack concept. Now the company’s cordless framing nailers can achieve optimized performance with the PowerBoost Black Tip Coated Nails (3 inch and 3¼ inch), which are only available in the combo packs. The coating is proprietary and allows cordless framing nailers to drive the nail flush into the hardest engineered lumber, such as LVL. The coating also translates into better performance at higher altitudes in parts of the U.S. where, typically, combustion-type framing nailers have had drivability issues due to the lack of oxygen. These nails allow remodelers and builders in high altitude markets to benefit from the freedom of cordless framing nailers without the hassle of hoses and compressors. The new nails feature paper tape collation which reduces scrap and eliminates flying debris. Plus, they are full head nails that offer maximum holding power, helping professional contractors comply with building codes where a round head nail is specified. If you read this article, please circle number 270.

Lithium ion system DEWALT The company’s 12-volt MAX* Lithium Ion system includes a 1/4-inch Screwdriver (DCF610S2), 3/8-inch Drill/Driver (DCD710S2), 1/4-inch Impact Driver (DCF815S2), 3/8-inch Impact Wrench (DCF813S2), LED Work Light (DCL510), Inspection Camera (DCT410S1), Infrared Thermometer (DCT414S1) and two combo kits (DCK210S2 and DCK211S2). The platform combines compact, lightweight design with industry leading features contractors need. The system can handle a variety of drilling, fastening and measurement applications and complements the company’s 18-volt platform. (*Maximum initial battery pack voltage, measured without a workload, is 12 volts. Measured under a workload, nominal voltage is 10.8 volts)

Manual staple and nail gun ARROW FASTENER COMPANY LLC The T50 R.E.D. professional manual staple gun and 1-inch brad nail gun is the first in the company’s new R.E.D. product line, which is an acronym for “Reliable. Ergonomic. Durable.” The tool is the only manual tacker capable of firing a 1-inch brad nail. It features U.S. patented drive technology that enables the user to set a staple or nail on virtually any surface. The staple gun features a high and low power setting that allows you to adjust when working with hard surfaces like melamine or softer surfaces like an upholstery project in pine. It also offers up to 40 percent more power than select competitive products on the market, which makes it more versatile on the job site. If you read this article, please circle number 273.

If you read this article, please circle number 271.

Screws for light gauge steel

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High pressure compressor, nailers

GRABBER CONSTRUCTION PRODUCTS

MAKITA The company has released its new high pressure pneumatics technology through new products. The technology increases air pressure created in the compressor and delivered to pneumatic nailers. The launch of the high pressure pneumatics consists of the 2.5-horsepower High Pressure Air Compressor (AC310H), the 2½-inch High Pressure Siding Coil Nailer (AN610H), and the 3½-inch High Pressure Framing Coil Nailer (AN911H). With a high pressure 1.6-gallon tank, the AC310H provides the same capacity as a conventional 5-gallon tank at 120 PSI, but with less noise and a more compact size for easier transport. The AN610H nailer can operate at 140-320 PSI, and with its high pressure capacity and superior power to weight ratio is up to 30 percent more compact than a conventional nailer. The AN911H has the power to consistently drive larger nails into dense materials like OSB, LVL and glue lam, giving framing contractors one nailer to handle all of their framing needs.

The company’s Spectrum screw was specifically designed to produce exceptionally high pull-out values in light gauge steel without sacrificing fastener drilling speed in these new materials. Spectrum’s 7 gauge shank diameter, buttress threads and reduced drill point all combine to offer superior drilling performance. Additionally, the fastener is ideal for attaching high density sheathing products to the new materials being used in the market today. For all 16 through 20 gauge applications, the screw is specially designed to work with the next generation of steel framing.

If you read this article, please circle number 272.

If you read this article, please circle number 274.

| Walls & Ceilings | April 2011

Sustainability – it’s serious business. CertainTeed Gypsum is committed to preservation of natural resources, recycling, waste management, and reclamation in our operations. We are part of Saint-Gobain, the world’s largest gypsum wallboard manufacturer. Our innovative, sustainable building materials can contribute to the built environment’s indoor environmental quality, acoustics management, fire resistance, and materials recycled content. To see how sustainability suits you, visit: www.CertainTeed.com/Sustainable

800-233-8990 • www.certainteed.com ROOFING • SIDING • TRIM • WINDOWS • DECKING • RAILING • FENCE INSULATION • GYPSUM • CEILINGS • FOUNDATIONS • PIPE

Please Circle #153 On Reader Action Card

TRAIN(ING) DAY P

rofessio f i by b Matt M Henson H (which ( hi h specializes in ornamental, flat plaster and decorative finish restoration on historic buildings) worked with Woodpartners of Houston to repair water damage to the Texas and Pacific Train Station in Fort Worth, Texas. The companies put their expertise into erasing the damage done by a leaky water pipe and recreating the “damage” of eighty years of exposure to the Texas wind and weather. The train station was built in 1930 by a Dallas construction firm and is a good example of the Art Deco st yle of architecture. T he main lobby was built on a grand scale (it’s got a 36-foot tall ceiling) to be a welcome and inspiring sight for travelers heading across the country.

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Th days The d when h A Americans i traveled l d exclusively l i l b by railil might be gone but some expert repair work by a first-rate plaster company has brought an historical jewel of the southwest back to life. By Alex Lundberg Travel by rail has waned over the years but the building is still in use—and still in use as a working train station. It was during a period when some rooms above the train station proper were being renovated that a leak developed in some water pipes. Eventually there was damage to the grand space below. That was when the building’s owners called upon Matt Henson. He and his company, Professio by Matt Henson, had worked in the train station a decade earlier when the building was renovated in the

late-1990s. Henson and his people knew the building’s owners and, more specifically, knew the building well enough to undertake the restoration of the old jewel. T he company k new the place well enough to be awarded a CSI Award for excellence in Craf tsmanship in 2002 for the renovation of t he plaster i n t he T& P lobby back then. Professio also re c eived awa rd s f rom H istor ic Fort Worth Inc. in 1999 and Texas Architects magazine in 2001 for the same project.

PIPE DOWN Now that a bad pipe called them back into the Fort Worth train station, Henson’s company had their work cut out for them. There were three different venues comprising 6,380 square feet total in two rooms for the plaster repairs needed to correct the water damage; on the walls, ceilings and tiles. Portions of the ceilings, with their “zigzagmoderne” relief, were cracked and effloresced. All of the loose paint and plaster was removed to reveal sound original substrate that could be worked with. The chalking plaster was removed, cleaned and reconsolidated with a mixture of alkaloid resins. The project was completed using USG molding plaster and USG finishing plaster.

Care was taken to preserve as much of the original finish as possible but parts of it had to be removed to reveal usable substrate in the areas near the damage to the ceiling. The areas that were cut away were consolidated, but in some places the crews had to recreate elements that were lost entirely. “The challenge was to do minimal damage and not remove materials where we could help it. Our quest was to fix things in place where possible and pull out and replace where we couldn’t,” Henson says. “If something was damaged we would add consolidated glue to the broken or dissolved surfaces.” He says they also had to keep a scrupulous record of what they had done and where. For historical purposes, he says special markings were

put on the building’s plans to show where they had done work and what was done. Eventually, someone is going to do some kind of work at the train station again and when they do, they’ll have a record.

CAST MOLDS Part of the building’s sugar cane tiles had been lost and construction crews used remaining good tiles to cast molds to make new ones as replacements. Some of the work they did on the site was done to prevent future work at the site. “We had to order a lot of masonite to protect the marble floor,” he says. Paint was its own problem in the restoration. Once all of the substrates were consolidated and the right moisture and pH levels were

April 2011 | Walls & Ceilings |

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reached, the project moved on to the paint process. Sherwin Williams prov ided c ustom-m i xed , ha ndmatched paints for the train station. One might think that colors haven’t changed much in 80 years, red is still red, but paint is a much different product today than it was then and time and weather took their own toll on the existing color scheme. Por-

tions of the ceilings and walls had aged at different rates and there were subtle differences in the colors that had to be dealt with on the spot. The walls had a delicate color shift in the paint and that was most evident in the sheen. Eggshell, flat and satin sheens used today are more tightly controlled than they used to be and the paint crews were forced to

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| Walls & Ceilings | April 2011

experiment with different sheens to get the uniformity they needed. Henson says the most challenging matches were the glazed portions of the ceiling. Aluminum areas for the ceiling were bright and shiny, leading Henson and company to use an oil-based aluminum powder paint to match existing colors and textures. A dark blue latex glaze was then brushed on and wiped from all of the high-relief areas. The paint crews matched the gold colors by mixing acrylic and mica paints with a latex glaze that was lightly wiped from the higher elements. Even the newly-cast sugar cane tiles were painted with a soft brown glaze and wiped to match. The last step in the process was applying accent colors on the ceiling. People may not flock to the T&P Train Station to travel by rail today but residents and those passing through will certainly appreciate a solid and restored historic building. W&C If you read this article, please circle number 390.

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Ambitious

Artisa G

one are the days of a strictly m a le - dom i nated work force in construction. According to the National Association of Women in Construction, women account for 9.6 percent of the construction sector. Walls & Ceilings was recently made aware of three special talents in the U.S. from information shared by Specialized Building Products. The decorative finish line supplier suggested we profile some women involved in the plastering trade. Since this isn’t a subject the magazine has covered—at least in a while—we figure it’s time to feature a few in the field.

GEORGIA REACH Georgia Morrow Long is owner of Plasters by Georgia Inc., a subcontractor that does both commercial and high-end residential surface design and applications. The Laguna Beach, Calif.-based company works on any surface or materiall

Walls & Ceilings profiles three key female artisans in their pursuit of all things faux finishing in the plastering trade. By John Wyatt

within a building, such as walls, ceilings, floors, domes, fireplaces, cabinets, wood, glass and more. “My background as an artist allows me to see the interaction of colors and textures and my knowledge of plasters and application techniques allow me to turn the vision into a reality,” says Long. She got into the trades back in the early 1990s when she moved into a large house in Atlanta that needed a great deal of work. Long took a few workshops on plaster and as she put it, “fell in love” with working with the material. When she finished her home rehab projects, friends and neighbors began asking her to work on their places and soon word-of-mouth put

Georgia Morrow Long Sandra K. Lassley

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her in high demand. It was through this work that Long developed a business plan, formed a corporation, got licensed and joined the trades. “I discovered that plaster and decorative finishes combined my two favorite art disciplines—sculpture and fine art painting,” says Long. “The art is in the overall feel, the ‘gestalt’ that is created in the space. The art is also in the fine details when you look closely.” When asked what “gestalt” means, Long says, “When you first look around a room your eye should move continuously and not be drawn to any one spot. The room should give you a warm, subtle feeling and one of harmony. If it doesn’t, something is out of place with the colors, the textures, the placements or the perspectives. It’s like hitting an off-key note.” After 20 years, Long still continues to develop her skills by taking workshops to keep up on current trends and new products. She studied plaster techniques in France and Italy and taught Marmorino plaster application in Verona, Italy. She has participated in historical restorations—most recently in a 16th century church in France. All this hard work hasn’t been met without reservation, though. Long has had her share of skepticism from the old-timers. She does admit that the majority of those she works with are professional and respectful. “I give everyone respect and expect to be treated in a respectful manner,” she says. “I play fairly and I expect

ans everyone else to do the same. I am not afraid to stand up for myself if someone tries to blame me for something that is not my fault. The best insurance to avoid this nonsense is to have a close and credible relationship with your customer.” Not only does Long do her best to build good relationships, she also delivers a high level of quality to overcome any critics. In the case of Venetian plaster, she says any ‘ol plasterer can attempt to do it. Long says she treats this application like art. “Anyone can slap plaster on a wall but the trick is in making it look good,” she says. “The color and texture have to be just right in order to pull in all the other colors and textures in the room into a harmonious union. The plaster should be the backdrop, the palette, not the focal point in a room.” Many of the referrals Plasters by Georgia gets come from contractors who have worked with the company because they know what they can expect, Long says, adding that it also helps to have a loyal and protective crew that has a low tolerance for shenanigans.

HAVE FUN, WILL TRAVEL President and head designer of Fe Fi Faux Studios Inc. Sandra K. Lassley has been involved in the business of plastering for 21 years. Based in Omaha, Neb., the company designs and installs faux finishes and a variety of interior plasters for homes and businesses. Like Morrow, Lassley has had extensive training both in the U.S. and Italy. Her work has been featured in several trade and design magazines. The company has completed proj-

Plasters by Georgia Inc. is a subcontractor that does both commercial and high-end residential surface design and applications.

tight time frame,” she says. “The outside of the bar was plaster with a copper leaf wave through the center. The entire thing was studded with thousands of upholstery nails.” In regards to being a female contractor, Lassley also reports similar to Morrow that it hasn’t been much of an issue but still there are skeptics. “Years ago, the guys told me they used to place bets on whether I would be carrying in my own stuff, such as ladders, etc. for the job. By the time the week was over and watching us work, they had very positive comments before we left the job.”

CHICAGO CARROLL

Fe Fi Faux Studios designs and installs faux finishes and a variety of interior plasters for homes and businesses.

ects in the west, southwest, south, plains and midwest. In addition, this artisan continues her education by attending several teaching studios including Miller Wagenaar Studios in Chicago, The Faux Institute in Denver and Kelly S. Kings Institute of Decorative Finishes in Nebraska. Lassley has at tended trade classes through an industry group called International Decorative Artisans League in San Francisco; Charleston, S.C.; Memphis, Tenn., as well as others in Pennsylvania and Atlantic Cit y. She has enjoyed working on a home that was featured in the TV show “Extreme Home Makeover.” Last fall she worked on the walls of the 50 0 -yea r- old C ast le C ag l ia noa where she attended a class near Umbria in the Italian countryside. She does work extensively with Vella Venetian plaster products. Lassley was more or less born into the trades and was introduced to finishing at an early age. “My father moved to Omaha from South Dakota to open his paint and decorating business when I was a baby,” says Lassley. “I was raised around the painting trade. When

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I got interested in faux marble in the mid-80s, I told my father about it and showed him some photos of techniques I’d seen. He predicted this as the wave of the future.” She got into plastering and decorative finishes after reading an article about a southwest-style living room that had a decorative wall finish. She tried it on her own walls and home and says the results were inspiring. From that point she says she was “hooked” and began to educate herself on faux finishing. Lassley says that turning a space someone has dreamed of into exactly what they were looking for is the most rewarding aspect to her job. But there are challenges she says. Taste is subjective, so it’s important to communicate well and use samples whenever discussing a project with a customer. When asked about any special projects that the company found especially challenging but yet found the ultimate outcome rewarding, Lassley recalls a specific one. “A giant bar that we copper leafed, but accidentally sealed with the wrong sealer, which had to be redone before a party with a very

Kathy Carroll of The Chicago Institute of Fine Finishes and Faux By Kathy has been a part of the faux finishing industry for more than 20 years. During this time, she has been a working artisan, mentor to students and an instructor. When asked how she has become so successful in her field, Kathy says that she credits her success largely to her “genuine concern for the individual artisan’s success.” Her roots in decorative plaster date back to March 1988 when she opened her first business Gotcha Covered Inc. with her husband. The business started out as hanging wallpaper and straight painting. As the business grew, Carroll began making job estimates, which opened up new opportunities for her and the business. While meeting with customers, she was often asked interior decoration questions which she really didn’t know the answers to. Rather than send her clients to someone else for their interior decorating needs, Carroll enrolled in an interior design program at her local community college. Taking the interior decorating classes changed Gotcha Covered in that Carroll could now begin applying the education she learned. Soon, the company became a full-service design studio complete with five interior designers. During her time at the community college, Carroll honed her skills in faux finishing and expanded her knowledge base, but she was about to make another leap in her career. She was introduced to a muralist that was interviewing for a position at Gotcha Covered and was intrigued by the

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Fe Fi Faux Studios has worked on projects throughout the country and has been featured on the TV show “Extreme Home Makeover.”

portfolio. This interest led to the use of water-based colors as opposed to the oil-based paints Carroll was familiar with. She im mediately sought out training with water-based products and has not looked back. In 1998, Carroll decided to close the interior design portion of her business. Upon completing her training in the water-based products, she opened a manufacturer-sponsored faux finishing school in addition to her contracting business. After three years of running the school, she sold her contracting business to focus more on the teaching aspect of her career. Carroll sold her contracting business to an employee who is still successfully running the business today.

In 2002, Carroll opened her own school under the name the Chicago Institute of Fine Finishes. After opening her new studio, Kathy’s business continued to grow, adding to it her Vella line of products, her e-commerce site fauxbykathy.com, gofaux.com, an informational site for the industry, and learnfauxnow.com, Carroll’s e-Learning system that allows students to learn faux finishing techniques. Fauxbykathy.com serves as a hub where visitors to the site can purchase materials through her e-store, find information about classes and keep up to date on new products, techniques and industry news. To this end, her Web site is updated with new information every month.

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Carroll is always looking for ways to expand services for those that want to learn about the trade. One way that she has done this is through her “Learn Faux Now” online courses. Her new offering, “Quick Inspirations,” will follow the same concept of allowing online instructional services. It offers artists the opportunity to order completed samples and recipes of the featured finish, allowing them to update their portfolio without having to attend a class or make the samples themselves. Through her “Artisan of the Month feature” on her Web site, Carroll spotlights an artist in the industry by showing the finisher’s work and including their biography. W&C If you read this article, please circle number 391.

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PA1000 © 2009 SPEC MIX INC.

SOUNDPROOFING’S SPEEDY EVOLUTION

M

any argue that sound, reverberation and echo control began in ancient Greece. It was there, they say, that construction projects such as the Theater of Epidaurus achieved acoustics that allowed 14,000 spectators to hear sounds as minute as coins dropping on the performance space. These claims suggest humans have been enhancing sound for thousands of years but in 1922 an American physicist named Floyd Rowe Watson claimed that blocking sound is a far newer endeavor. “Before 1915 little was known definitely about [soundproofing] and cut-and-try methods were used when

A vinyl sound barrier behind a resilient isolation clip connected to the proper bushing.

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Blocking sound is an achievement that is in continuous development. By Eric Peters soundproofing was desired,” Watson wrote in “Sound Proof Partitions,” a book published in 1922. “These cases were usually isolated and few published accounts are available, so that little progress was made.”

THE CURRENT EVOLUTION Watson began to study and record the effects of various plasters, metals and outing flannel on sound, and by the ’50s and ’60s, materials and techniques as diverse as wooden studs, lead, furring strips, plaster,

A resilient isolation clip.

rag-filled cinderblocks and concrete were being used. “Another old approach to blocking noise was the ‘room within a room,’” says David Ingersoll, national sales manager at Acoustical Solutions Inc. “Entire walls were being built with space between them and the original walls.” While this method worked relatively well, it was far from ideal. “You would lose so much space and paying for labor, new studs and other materials, it just wasn’t

A mass-loaded vinyl sound barrier

 Resilient channels, isolations clips and mass-loaded vinyl sound barriers in the floors and walls as well as a mass-loaded vinyl sound barrier in the ceiling.

cost-effective in many situations,” Ingersoll says. One of the next steps in blocking sound transfer arrived when, Ingersoll says, soundproofing condensed into a single wall and was achieved either through a “mass game” or resilient channels. He explains the mass game was when people added as much massloaded vinyl as possible to the studs or joists, as well as layer upon layer of drywall to the outside of walls. Mass stops sound transfer, so the mass game did work but there comes a time when adding additional vinyl or layers of drywall is no longer an option. The answer to running out of places to add mass came in the form of resilient channels. Resilient channels decouple wall and ceiling surfaces from studs via metal bushings that create space. The small metal strips decrease the amount of surface area at the points of connection through which sound waves are able to travel, and because sound travels faster through solids, this was a very effective soundproofing tool. “The first resilient channels still weren’t perfect though,” Ingersoll says. “There was still metal directly attached to wood or metal studs, so some sound would still travel right through.”

Wall and floor/ceiling  acoustical treatment (resilient channels, mass-loaded vinyl and floor underlayment).

SMALL BUT STRONG As the rapid evolution in soundproofing continued, a small clip made the next big splash. Designed to attach to the metal bushings that create resilient channels, these clips employ small neoprene pads at the point of contact/transfer between the studs and bushings. The neoprene pads absorb the vibrations that once traveled through the walls. “Now that we had isolated the drywall from the studs and added mass inside the wall our attention turned to sealing joints and penetrations,” Ingersoll explains. “Corners, outlets, cable chases, we began to make sure every single crack was properly sealed with acoustical caulk or putty.” These small openings and joints are important because of what is known as the one percent rule. This rule states that a 1-percent opening will allow up to 50 percent of sound to pass through.

Fire-stop putty that is used to create acoustical seals around wires, electrical box outlets, etc.

Quiet Glue Pro is applied between two pieces of drywall to block noise.

The most recent step in the soundproofing evolution was the introduction of products like Green Glue and QuietGlue. These products were the first sound-damping compounds to be applied between sheets of drywall. Ideal for the retrofitting and enhancing sound mitigation capabilities of existing walls, these products are spread on the back of a piece of drywall that is then placed on the existing drywall. They work by distributing into various directions the sound that hits the first layer of drywall until that sound energy becomes heat energy and dissipates.

ish Columbia Institute of Technology believes “the acoustic industry needs to move from its traditional place inside a building to dealing with the exterior environment, and its impact through the building envelope with the user-occupied zones, be that either interior spaces, or exterior social zones such as balconies, terraces and patios.” Additionally, he says, “I am very interested in seeing psychological/sociological testing on whether there is a certain spectrum of sounds that are pleasant, and should be maintained for masking purposes, while frequencies of sound such as truck rumbling, or mechanical hissing could be isolated to create a more pleasant soundscape.” “I’ve noticed two trends emerging in soundproofing,” Ingersoll says.

MOVING FORWARD Wesley Wollin, an architect and building acoustics instructor at Brit-

April 2011 | Walls & Ceilings |

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SOUNDPROOFING “The first is that people are becoming far more interested in reducing foot fall and noise between floors, especially in multifamily dwellings.” He adds that using floor underlayment and adding mass to floors/ ceilings has been around for years, but only now does he see an influx in the amount of people and businesses interested in making it a part of their construction projects. “My guess is that it has to do with the fact that fewer rooms have wallto-wall carpeting now. Many people are moving back to hard wood and tile floors,” says Ingersoll. A far more obvious and prevalent trend, he says, is the movement toward environmentally friendly ways of blocking sound. “We’ve added as much mass and decoupling as we can, so the next step is about making it as environmentally friendly as possible. People either want to obtain LEED certification or just feel good about what they have in their homes and buildings.” Cellulose, which can be made from many different recycled products including paper and textiles, is an example of one of these new green products. It is similar to massloaded vinyl acoustically, but far more environmentally friendly. Where has this evolution taken us? As new soundproofing products and techniques appear, they don’t discredit those that have been used previously. For example, the “roomwithin-a-room” technique is still used in many recording studios. Instead of discrediting, these new products and techniques add to the potential effectiveness and ability to create more complete acoustical treatments. “It’s amazing how things have changed in just 10 years,” Ingersoll says. “Before, people just hoped to have a better sound blocking wall or ceiling, but now there are so many options, and people can choose different levels of treatment—good, better or best.” W&C Eric Peters is the communication specialist for Acoustical Solutions Inc., a soundproofing and noise control company based in Richmond, Va. He can be reached at [email protected].

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