CONTINUOUS INSULATION SHEATHING USAGE ACIG Quality Summit 2016 Presented by: Ron Jackson and Sam Hatchell Danis Building Construction Company and Jaynes Corporation
DOW THERMAX XARMOR CONTINUOUS INSULATION EXTERIOR INSULATION Ron Jackson Director of Quality Assurance Danis Building Construction Company
KETTERING CANCER CENTER DOW Thermax XArmor ( ci ) Exterior Insulation
Lessons Learned and Best Practices
PROJECT DESCRIPTION • 5‐Story Steel Framed Construction including Connector Bridge to Main Campus • Primary Architect is Cannon Design with local Partner LWC Incorporated • 120,000 Sq.Ft. ( Levels 2 and 3 are Shelled Space for Future Fit‐Out ) • $ 40,500,000 • DOW Thermax XArmor ( ci ) Exterior Insulation • Brick and Cast Stone Veneers • Composite Metal Panels • Full Height Curtain Walls and Punched Openings
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
PROJECT RENDERING
PROJECT DESIGN HISTORY • Initial Exterior Envelope Design was 2 3/8” Spray Polyurethane Foam Insulation over 5/8” Exterior Sheathing • Third Party Consultant Wiss, Janney, Elstner conducted a Peer Review based on this design • Delay’s in receiving 100% Design Documents would have dictated trying to apply the SPF Insulation in January in Ohio which would have required fully tenting and heating the structure to meet the SPF Insulation temperature requirements
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
PROJECT DESIGN HISTORY • Architect(s) and Owner asked for alternatives to keep the project on schedule • Exterior Sheathing Sub‐Contractor had experience with installing the DOW Thermax Systems and offered it as an Alternative • Owner and Architect accepted the proposed Alternative to stay on schedule • Wiss, Janney, Elstner conducted a “ Commentary Only “ review of DOW Thermax System
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
PRODUCT DESCRIPTION AND COMPOSITION • 4’ x 8’ x 12’ panels with ship lap configuration at top and bottom of panel • Exterior face of panel: glass‐fiber reinforced polyisocyanurate foam core faced with a nominal 4 mil embossed thermoset‐coated aluminum. Exterior face serves as a drainage plane and a water‐resistive barrier • Interior face of panel: 1.25 mil embossed aluminum
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
FASTENING PATTERN
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
FASTENER ACCESSORIES – DOW PANEL TO STUD
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
FAST BUILDING DRY‐IN POTENTIAL
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
MASONRY ACCESSORIES – BRICK TIES
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
LIQUID FLASHING MATERIAL • Elastomeric Spray that forms a tight, seamless barrier**
• Surface and Ambient Temperatures should be 35F and rising and below 120F during application • Applied at 50 mils +/‐ 5 mils • Build up to 50 mils with two passes, one to fill the joint, the next to build the thickness and achieve proper joint coverage • Joint coverage is 3” +/‐ 1” • Coverage into rough openings is 3” onto the face and 3” into the opening • Penetration coverage is 2” onto the face and 2” onto the penetration
** When applied correctly per Manufacturers Instructions
LESSONS LEARNED DOW Thermax XArmor ( ci ) Exterior Insulation
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
PRODUCT DAMAGE IS TO BE EXPECTED
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
GAPS GREATER THAN ¼” WIDE MUST BE TREATED
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
GAPS AT STRAP BLOCKING FOR STONE
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
SEQUENCING OF GAP TREATMENT BEFORE SPRAYING • Encourage Installer to provide two crews such that Gap Treatment can stay ahead of Spraying Operations • Drying Times of Gap Treatment need to be factored into Scheduling of Spraying • Coordination of other Trades Work being held up waiting on Gap Treatment and Spraying
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
CLEAR COMMUNICATION TO NEW SITE WORKERS • Trade Worker who began initial start of spraying on West Elevation was not at the Pre‐Installation Meeting • 1st Work Inspection revealed that he did not understand extent of spraying detailing at vertical soffit to roof transition • Corrective Action was implemented • New Trade Worker to site repeated the same deficiency on South Elevation
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
STRUCTURAL LINTEL CONDITION SNAF‐OOO • Architectural Detail showed bolted Lintel Connection with bolt head on exterior side of metal stud • Transition from 2 ½” Thermax to narrower section without reducing drainage cavity
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
STRUCTURAL LINTEL CONDITION ADJUSTMENT
BEST PRACTICES DOW Thermax XArmor ( ci ) Exterior Insulation
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
PROPER FLASHING OF PENETRATIONS
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
THOROUGH INSPECTION OF SPRAYED AREAS PRIOR TO MOVING TO NEXT AREA
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
GOING THE EXTRA MILE AT METAL PANELS
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
VERIFY SEALANT COMPATIBILITY WITH DOW
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
ENGAGE DOW TECHNICAL STAFF EARLY WITH PROJECT SPECIFIC DETAILS AND QUESTIONS
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
REQUEST DOW TECHNICAL FIELD OBSERVATION AT 1ST WORK INSPECTION
COMPLIANCE to COMMITMENT
Ron Jackson Director of Quality Assurance Danis Building Construction Company Direct:
937‐228‐1225
Cell:
937‐673‐0978
[email protected] Copyright © 2016 American Contractors Insurance Group
Claims • Risk Management • Safety • Quality
JOHNSMANVILLE CONTINUOUS INSULATION FOAM SHEATHING Sam Hatchell Corporate Quality Manager Jaynes Corporation
MARIE HUGHES ELEMENTARY Jonhsmanville AP Foil Faced Polyisocyanurate Foam Sheathing
PROJECT DESCRIPTION • 2 story elementary school • Structural steel framed construction • 87,000 Sq/.ft • $15,000,000 contract price • Johnsmanville Foil Faced Polyiso Rigid Insulation 1.5 Inch (exterior sheathing) • Cladding Systems • 3 coat Portland Cement Plaster (Stucco) • Flat Metal Panels • Porcelain Tile • Storefront punch openings COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
PROJECT MODEL
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WALL SYSTEM DESIGN (STUCCO)
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WALL SYSTEM DESIGN (PORCELAIN TILE)
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WALL SYSTEM DESIGN (METAL PANEL)
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
CI PRODUCT • Foil Faced 1.5 Inch Polyiso insulation • Attached with large capped fasteners • All seams and corners taped
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
SEAM TAPE PRODUCT • DOW Weathermate used instead of JM recommended 3M Tape • Blue polypropylene film facer with butyl adhesive
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
FASTENER PRODUCT • UltraFast Fastener • #12 steel, polymer‐coated • 3” Round Locking Blue Plastic Plate • Fastening Pattern: 16 inch O.C. vertically and horizontally when over steel stud directly
MOCK‐UP
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
MOCK‐UP
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
MOCK‐UP
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
MOCK‐UP
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
DETAILS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
DESIGN DETAILS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
DETAILS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
PENETRATIONS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
PENETRATIONS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
ITEMS TO CONSIDER DURING INSTALL
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
ITEMS TO CONSIDER DURING INSTALL
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
ITEMS TO CONSIDER DURING INSTALL
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WORK IN PROGRESS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WORK IN PROGRESS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
WORK IN PROGRESS
COMPLIANCE to COMMITMENT Claims • Risk Management • Safety • Quality
Copyright © 2016 American Contractors Insurance Group
COMPLIANCE to COMMITMENT
Sam Hatchell Corporate Quality Manager Jaynes Corporation Direct: 505‐345‐8591 Cell: 505‐235‐3098
[email protected] Copyright © 2016 American Contractors Insurance Group
Claims • Risk Management • Safety • Quality
Building Better Builders