Masonry Magazine July 1980 Page. 24
Surface Bonding System Aids in Construction of New England Facility
With the rising costs of fuel, double-digit energy savings is welcome news and savings of more than 50% is truly astounding. This case history has been documented over a full heating season by the Bay State Gas Co., Lawrence, Mass., and the owner, A.P. Sheehy of Dundee Park Properties in Andover, Mass.
The basic structure was originally conceived as a 6,000 sq. ft. unit with 20 ft. exterior walls and a usable volume of 120,000 sq. ft. Design considerations called for 12 in. heavyweight concrete block for exterior walls and a steel roof deck insulated with 1-½ in. of rigid insulation. Preliminary estimates produced a heating load factor of 433,000 BTUs per hour.
It was subsequently discovered that the new building would not conform to the Massachusetts Building Code for Energy Conservation, which requires a U factor of 0.30 for walls and 0.07 for roofs, and that a redesign would consequently be required. In addition to the requirements for increased energy conservation, savings on yearly maintenance and decoration were also important considerations.
Evaluation of various construction techniques at this time convinced the owners of the efficiency of the surface bonding system to help them meet all of their design criteria. Surface bonding incorporates dry-stacked concrete block bonded on two sides with a fiberglass reinforced cement mixture.
According to the building owners, the surface bonding system provides several unique features that are either not possible with other building systems or only are obtainable at additional cost. The owners report that the following benefits were realized utilizing Conproco Structural Skin surface bonding cement:
►Structural Skin applied to both interior and exterior surfaces formed an effective shield against air transmission, reducing the building's heating and cooling load.
Change to lightweight concrete block provided savings in material and building costs.
Since surface bonding requires no mortar above the first course, the concrete block could be dry-stacked very quickly.
►The application of surface bonding cement to both surfaces of the wall not only provided the necessary structural strength but in one coat resulted in a decorative and permanent finish that is resistant to water penetration.
The absence of mortar between the block allowed the use of perlite poured insulatin to lower U values for the wall to 0.15.
Also specified was an insulated lightweight concrete roof deck with a U factor of 0.07, thermopane glass and insulated doors. All of these changes added only 15% to the cost of the original building, while the heat load was reduced to 220,900 BTUs for a 50% reduction in fuel consumption, the owners said.
The estimated energy consumption was verified by an independent consultant, William Wong, a licensed Massachusetts professional engineer. Since the structure was occupied and completed in September, 1978, a nine-month heating season study could be immediately implemented.
In cooperation with Bay State Gas Company, degree days and actual fuel consumption for the nine month period were compilated and verified. Under the original construction plan, 9,950 cu. ft. of gas would have been required. As constructed, consumption was estimated at 5.104 cu. ft. Actual fuel consumption as reported by Bay State Gas Company was 4,640 cu. ft., a savings of over 50% for the heating season.
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Brick Firm Fined for EPA Violations
American Brick Co., the nation's last producer of common brick, was fined $50,000 for pollution violations in a decision handed down in U.S. District Court in Chicago on June 16.
The company has been at odds with U.S. Environmental Protection Agency officials since 1974. Details of plans to correct alleged pollution violations were spelled out in a consent decree filed with the District Court.
According to Robert Carey, president of the firm, American Brick agreed to shut down its Munster, Ind., division until pollution controls are installed. Its Dolton, Ill., plant is still operational.
The pollution problem arises about 30 times a year at both of the two plants when the yellow clay brick are fired in kilns. Carey said about 1.5 million brick are fired at once in a process that lasts about 60 hours.
American Brick, established in 1891, produces about 80 million brick a year.