Innovative Column Options for the 21st Century
Transcription
Innovative Column Options for the 21st Century
An American Institute of Architects (AIA) Continuing Education Program HB&G Building Products Tim Bobo PO BOX 589 1015 Brundidge Blvd. Troy, AL 36081 Innovative Column Options for the 21st Century 800-264-4424 334-670-6512 Credit for this course is 1 AIA HSW CE Hour www.hbgcolumns.com tbobo@hbgcolumns.net Course Number: hbg06c Please note: you will need to complete the conclusion Innovative Column Options for the 21st Century quiz online at RonBlank.com to receive credit © Ron Blank and Associates, Inc.® 2006 An American Institute of Architects (AIA) Continuing Education Program Approved Promotional Statement: Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product. An American Institute of Architects (AIA) Continuing Education Program Course Format: This is a structured, web-based, self study course with a final exam. Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to certificate@ronblank.com Design professionals, please remember to print your certificate of completion after successfully completing a course conclusion quiz. All AIA and non-AIA members will be sent a copy of their certificate to the email address they have provided in their RonBlank.com account. Please note: you will need to complete the conclusion quiz online at RonBlank.com to receive credit Course Description Discover the innovative column options that are available today and the variety of materials that are used to create this classic product. Learn about the current trends that have affected columns in the construction industry. Course Objectives Upon completion of this course the Design Professional will be able to: Become aware of the column design options and the materials they are made from. Describe the manufacturing process for column materials. Explain the construction process of the different column material options. Identify the characteristics of the materials used in column construction. Explain the current trends and construction standards that have affected column design in the construction industry today Columns and the Materials They are Made From Things to Consider When Selecting a Column: Weatherability Application Ease of Installation Warranty Quality Price Columns and the Materials They are Made From The five classical orders are: • Tuscan • Doric • Ionic • Corinthian • Composite History Since ancient Greek and Roman times, columns have signified importance and power. During these times, decorative columns were strictly made of stone and are still impressive today Columns and the Materials They are Made From Temple of Athena Roman Coliseum Prestige Facade Entry Modern Day Ancient Greece & Rome Pantheon History Today, columns are made from a variety of different materials, and are one of the most important millwork elements in the residential building industry. Drive through any residential development and it seems like columns are on every other house. Example: Current day residential USA. Notice the resemblance of Greek and Roman ideology in modern day architecture. Columns and the Materials They are Made From The majority of current day columns are made from five basic materials: • Wood • Aluminum • Fiberglass • FRP (Fiber Reinforced Polymer) • Stone History Let’s review these materials independently, to understand the history, manufacturing, and installation procedures required for each. Wood Columns Throughout history wood has been the material of choice for millwork use. Alternative options did not become available until the 1960’s. Wood columns were first introduced to America with a style of architecture known as Neoclassicism (circa 1780’s). History Today wood columns, as well as most other wood millwork elements are being surpassed with the new synthetic products. Most column manufacturers would agree that wood is a small percentage of sales to what it was only 20 years ago. Wood columns can be found in any shape, even their knotted, twisted natural form. Wood Columns The manufacturing process of round wood columns is a fairly straight forward process. Manufacturing Process 1 2 3 4 Strips of wood called staves are cut to the desired length of the column. The strips are notched on each side to allow them to be placed together. Glue is applied between the staves, and a band is place around the attached staves. The glue is then allowed to dry. Wood Columns Manufacturing Process 5 6 Once dry, the bands are removed and the column is placed on a lathe. During this process the column is turned on the lathe, and the column becomes smooth, close to the look of the finished product. Once the column is turned, some light patch work is performed, and the column is ready to be packaged. Square wood columns are simply four boards, some with surface etchings, that are glued and nailed together on the job sight. Wood Columns Installation Let’s take some time and look into the installation of round wood columns. Step 1 - Measure full opening less the height of the cap and base. Columns must be installed on level surface or shimmed to level. To get the height of the cap and base simply place cap on top of base and measure. Step 2 - Locate saw kerft at top of column and trim using hand saw or circular saw. Sand or rasp smooth to guarantee even contact with capital. Step 3 - Measure from newly trimmed top of shaft to desired length placing marks every inch around column. Next, place a mark around shaft using a straight edge (something that will bend). Step 4 - Trim column with a hand saw or circular saw. Slowly rotating column will insure a level cut. Installation Wood Columns Step 5 - For exterior applications, paint inside of column shaft with nonfibrous, asphaltum- type roof coating. Application must reach a minimum of 4’ up column shaft. Next, paint the bottom end of shaft with an oil base wood primer. Also paint top end of column with oil base primer. Step 6 - Using a jack post lift beam, remove existing column or post. Beam should not be lifted more than ½’’ inch. Step 7 - Determine top centerline and mark on beam using a straight edge. Next, hang a plumb line from top center line to determine bottom center line. Mark center point of column. Using a large square, draw a center line perpendicular to the outside edge of substrate. Draw another line parallel to outside edge. Step 8 - Place marks at center line of all four sides of each capital and base. When installing shaft, capital and base, all four sides will line up evenly insuring a perfectly aligned column. Installation Wood Columns Step 9 - Center base on bottom of column shaft and apply using nails or screws. Place column shaft with applied base into place and align base with marks. Step 10 - Center capital on column shaft and align with marks. Toe nail or screw through shaft into capital. Nail or screw through capital into beam in 4 corners of capital. Nail or screw through base into substrate in 4 corners of base. Caulk seam at top of column shaft and at bottom. Use a high quality paintable exterior caulk for best results. The proper painting of wood columns must be met to comply with manufactures warranty. When using wood columns for exterior use, the column must be painted with a high quality oil base primer and top coat. Aluminum Columns Aluminum is the most abundant element in the Earth’s crust and constitutes 7.3% by mass. Aluminum was discovered in 1808 by Sir Humphry Davy and today is produced more than all other nonferrous metals combined. History Aluminum was introduced to the construction market in the mid- 1960’s and is featured in a variety of different millwork applications including siding, rail systems and columns. The following picture showcases aluminum columns in every day applications. Manufacturing Process Aluminum Columns Aluminum columns are produced by a process known as sheet and plate. Sheet and plate manufacturing occurs when aluminum is passed between rolls under pressure. When the raw aluminum is rolled, it becomes thinner in the direction in which it is moving. Sheet is the most widely used form of aluminum. Construction applications also include siding and gutters. The following pictures show the sheet and plate process; Picture one is the raw aluminum billets. Picture two showcases the rolling machine rolling the billets into a sheet form. The last pictures shows aluminum once it is rolled. Aluminum Columns Installation Although available in pre-manufactured shafts, aluminum columns are traditionally sold in sheet form with locking or mechanical joints. These columns are generally acceptable to load bearing or wrap around installations. To assemble an aluminum column in a load bearing application: Step 1- measure the required height and cut aluminum staves with a hacksaw prior to assembly. ( add ¼ inch to measurement for new construction and subtract ¼ inch for wrap around construction. Step 2- assemble staves by rotating together Step 3- assemble final interlock by rapping with the hands, starting at one end of the column. For a wrap around assembly steps 2 and 3 are preformed around support. Aluminum Columns Installation Step 4a- cut base with a hacksaw along diagonal, splitting lugs on underside of base. Place ½ of split base around column, so edge is parallel to edge of structure. Fasten column top and bottom with two angle brackets. Step 4b- Place second ½ of split base and cap around column and drill three 1/8’’ holes through base and cap and into column, in line with ribs. Fasten with screws as in figure 5b supplied in base of master carton. Step 5a- For Primary Support slide cap and base on column ends. To avoid scratching of column, slide base on until bottom is flush with end of column. Raise structure ½’’ to permit plumb installation of assembled column. Lower structure to secure column. Step 5b - Drill three 1/8’’ holes through base and into column, in line with ribs. Fasten with screws supplied. The normal weight of the porch roof is enough to hold the columns in place. In a coastal area special fasteners such as rods or cables may want to be used. Fiberglass Columns History In 1880, Herman Hammesfahr was awarded a patent for a type of fiberglass cloth. As early as 1942, Owens-Corning was producing fiberglass airplane parts for the war effort. Fiberglass is fairly new to the architectural world and was first introduced to millwork in the 1970s and is used in ornament, molding and columns today. Fiber-wound fiberglass is the first generation of synthetic columns, not to be confused with fiber reinforced polymer (FRP) columns that we will discuss later. Fiberglass columns are generally thin wall shafts, light in nature, and are characterized by a slick exterior finish, similar to modern day boat hulls. Fiberglass Columns Manufacturing Process Fiberglass columns are manufactured using a filament winding process. During this process, continuous glass fibers, epoxy and/or resin, are spun up and down a column shaped lathe in two directions at 90 and 45 degrees (notice this process in the first two pictures). This allows for strength, durability and the light weight nature of fiberglass columns. The epoxy or resin is the glue that holds the glass strands in place and provides a workable finish (bottom right picture shows the fiberglass column once the spinning process is complete). FRP Columns History In 1936, Carlton Ellis of DuPont was awarded a patent for polyester resin. Resin was introduced to the construction market in the early 1990’s and is used mainly for columns and some large décor. Resin is the main component in FRP columns. As mentioned earlier, FRP columns differ from fiberglass. FRP (Fiber Reinforced Polymer) columns can also be specified as GFRC (Glass Fiber Reinforced Composite), using ¼ to ½’’ chopped fiberglass as a tensile reinforcement, not as a structural component. The following pictures show resin columns in the field. FRP Columns Manufacturing Process FRP columns are manufactured by a process know as spun cast. During the spun cast process, the resin material is spun inside a mold housed by a cage. Centrifugal force takes the resin to the outside of the mold. The process starts with a positive mold made from wood or a polymer product. (left.) The negative mold is made from the positive mold. (middle.) The bottom right picture shows the cage that houses the negative mold. Manufacturing Process FRP Columns The FRP composite (containing resin, filler, chopped glass, and a catalyst) is poured into the mold and allowed to spin. It typically takes around 15 minutes to spin an 8x8 FRP column. Larger columns take a greater amount of time. After the spinning process is complete, the mold is then opened, and the shaft is allowed to cool. (note center picture.) Keep in mind, resin columns are a chemical reaction between the plastic and catalyst producing heat. After cooling, the column is taken to the finishing stage where it is patched, sanded, and packaged for shipping. Bottom right picture shows a typical finishing procedure. Installation FRP Columns When installing FRP, as well as fiberglass columns, Step 1- measure the opening in four places; front, back, left and right. Mark column accordingly. If column is too long, shorten length from bottom. Step 2- Use an abrasive saw (masonry or carbide tip blade). Fine trim top and bottom with rasp to assure flat surface contact. Step 3- Slip base over top of column shaft and allow to slide to base of shaft. Slip cap over shaft and allow to rest on neck mold. Some sanding may be required. Step 4- Apply construction adhesive to top and bottom surfaces of column. Installation FRP Columns Step 5- Put assembly in place and plumb. Make sure load is centered over column shaft and evenly distributed around the bearing surface. (Ensure concentric loading of the column 100% of bottom must contact substrate and 75% of the top) Step 6- Mark and drill holes in floor and column shaft for corner brackets. Install brackets at bottom and top of column. Step7- Apply construction adhesive to top of cap, press against structure, and screw or nail into place. Step 8- Also apply construction adhesive to bottom of base and nail or screw to floor. Cap and base will cover up angle brackets on column shaft. Installation FRP Columns On square FRP columns, the neck mold is mitered and glued with construction adhesive and screwed to the column shaft. Cover screw holes with latex caulk. Resin and fiberglass columns can also be split to wrap around existing load bearing structures, and once split, are not load bearing. FRP columns require priming and finish painting. Most column manufacturers recommend a high quality latex primer and finish coats per paint manufacturer’s recommendations. Stone Columns History Cast stone is basically a manmade limestone and dates back to around 500 BC. Structures from the Roman Empire were built using cast stone parts and are still in existence today. Cast stone columns are primarily used in upper scale homes, commercial buildings, and churches. This is because of the higher price associated with cast stone columns. I will discuss this further when we cover column comparisons. Stone Columns Manufacturing Process Cast stone columns are produced by mixing crushed stone that has been compressed under extreme pressure into a pre-designed shape or form to create a man made limestone. The process is called hand-forged stone. This process is very similar to that used when a child builds a sand castle, by pressing moist sand into a bucket, only on a much more permanent scale. The final result of the process is a hand forged limestone that is very difficult to distinguish from natural limestone. Top left picture shows the making of the mold. Once the mold is made, the aggregates used are washed, screened, graded, tested, and placed in a bin. (top middle picture) During the mixing process, the aggregate is ground until every particle is surrounded by Portland cement. Mineral oxides are added to achieve the desired color (top right). Stone Columns Manufacturing Process In the casting stage, the mix is placed into a mold and vibro-tamped by machine to include every detail of the mold (bottom left). The curing stage is the last step in the order. During this time, hot steam, carbon monoxide, and carbon dioxide are applied to speed up the curing process (bottom right). Stone Columns Installation Cast column installation is quite simple, yet very time consuming and requires a good mason. From a clean, level and structurally sound substrate, assemble cast pieces from the bottom up. Each component is anchored to the adjacent piece with a combination of pins and epoxy and/or mechanical fasteners. A ¼” mortar joint is required when fitting all pieces together. As you move vertically, pins should be drilled and epoxied into each piece and stacked on top of one another. ¼” spacers will assist in maintaining the required mortar joint. Each layer is also fastened to the structural post. Fasteners are available for almost any application. Stone Columns Wood, two steel spacers, and concrete are indicated in the bottom middle photo. The process described should be repeated for all remaining pieces. A few finishing notes need to be pointed out. Most manufactures require a variation of 3 finishing requirements: Installation (1.) Extreme care should be taken to cover and seal the top of the column if it is exposed to weather and elements. (2.) When joints abut other materials, a sandable caulk should be used instead of grout to eliminate excessive cracking during expansion and contraction of the adjacent materials; (3.) A sealer should be applied to all exposed surfaces according to manufacturer’s recommendations Comparison of Materials Wood Aluminum FRP Fiberglass Stone Comparison of Materials So far we have explored the manufacturing and installation processes of the different column materials. The next couple of slides will showcase the comparison between column materials with a series of graphs and field pictures, both good and bad. All of today’s column materials have their advantages and disadvantages. One material might be strong in a certain area but weak in another. The following characteristics all need to be considered when specifying a column. Comparison of Materials Wood columns have the look, feel and versatility, but lack the durability. With wood, rotting and warping are quite common unless proper installation and upkeep are met. Aluminum columns are lightweight, easy to install, and prefinished. With aluminum however, appearance and proportion are not always correct. Aluminum columns also scratch and dent fairly easy. Fiberglass columns are rot and insect resistant, lightweight and have an appealing price. On the downside, fiberglass columns have a thin wall that bring structural integrity and durability into play. Because of the slick finish associated with fiberglass, the columns can be difficult to paint. Comparison of Materials FRP columns are also rot and insect resistant, carry a lifetime warranty, and have a wood like feel. FRP materials were also one of the first fire retardant elements to come out of the plastics industry. On a negative note, resin columns have limited finishes, and must be painted with a light color paint. Mold cost and painting are also issues when working with resin columns. It can cost upward of 10 thousand dollars to produce a new mold. All dust must be removed prior to painting a resin column. Stone columns have the authenticity and durability, as well as fire retardant capabilities. With stone, cost, weight and installation time are all negative factors to be considered. Comparison of Materials Advantages Wood Characteristic Comparison Aluminum Fiberglass FRP Stone Disadvantages Rot and Warping, Upkeep Look and Feel, Versatility Availability, Painting Methods, Warranty Lightweight, Prefinished Ease of Installation Appearance/Proportion, Durability,Structural Integrity Rot and Insect Resistant, Lightweight Structural Integrity, Durability, Wall thickness, Painting Rot and Insect Resistant, Lifetime Warranty Wood like Appearance, Fire Retardant Authenticity, Durability Fire Retardant Limited Finish, Mold Cost, Painting Cost, Weight, Non Load Bearing Comparison of Materials Wood Columns The pictures on this slide showcase the importance of installing wood columns properly. The bottom right picture shows how the base on a wood column is vented to allow for proper ventilation. Top right shows a base that was not vented and how the column has deteriorated as a result. The staves will separate if the column is not properly vented and/ or maintained. Improper installation will allow moisture to wick its way into the shaft, and the column will rot from the inside out. Wood and Stone Columns Comparison of Materials With wood, rotting and warping is inevitable unless proper maintenance is met, as the top left picture shows. Wood square columns built in the field are also common and tend to separate very quickly. An 8x8 stone column tips the scales at around 400 pounds and can split as a result if not installed properly as the bottom image demonstrates. Compare this to a 8x8 FRP column that weighs around 65 pounds, wood 35 pounds, and an aluminum column at a feather weight of around 15 pounds. Comparison of Materials Aluminum Columns I want to point out some extreme characteristics associated with the different column materials in the form of application pictures. The top left picture shows an aluminum column and the lack of proportion. Notice how the shaft diameter does not match the size of the cap and base. Top middle also shows an aluminum column with the noticeable seam in the middle and unsightly hardware holding on the base. Top right picture shows a fiberglass column. Notice how thin the wall thickness is when compared to the FRP column in the bottom left picture. The last picture shows paint peeling on a FRP column. The only time paint will not adhere to a FRP column is if the resin dust is not completely removed from the column. Comparison of Materials FRP Columns This slide showcases examples of FRP columns installed in the field. Top left shows a column that is not concentrically loaded. Notice how the left side of the column is not contacting the substrate. Top middle shows the same column, and the cracks that have occurred as a result. Top right picture shows how a resin column will also bow if not concentrically loaded. Comparison of Materials FRP Columns Bottom left shows a square column that has not been properly cut to match the substrate. Notice the shim at the bottom that has been installed to make it work. This column will more than likely crack over time. Middle picture shows a stone base that has been installed around a square FRP column. This is not a recommended installation procedure. Over time, the stone acted like an oven and caused the column to bow inward from corner to corner. Last picture shows how to install a threaded rod in the middle of a column if it is installed in a hurricane zone. This allows for hurricane code, 120 mile per hour wind uplift. The rod runs through the entire length of the column, and pulls the roof into the substrate. The increased number of hurricanes over the last several years have raised the standards of national building code, and columns are no exception. Comparison of Materials 3.5 3 2.5 2 1.5 1 0.5 0 Installation Time Aluminum Fiberglass Wood FRP Stone Wood Site Built In the construction business, time is money. Builders are seeking products that install quickly and easily to reduce labor cost. This chart shows installation time of the different columns and does not include finishing. Wood site built columns are the most time consuming of the bunch, with a time around 3.5 hours. Site built columns are wood square that are built and installed on the job site. Aluminum columns are put together in staves and take around an hour and a half to install. Resin and fiberglass columns both come in one piece with separate cap and base. Both take about 45 minutes to install. Both round wood and stone columns take around an hour and forty five minutes to install. We consider stone installation time to be a very conservative number taken from a stone manufacturer. Comparison of Materials 100 80 60 40 20 0 Warranty Comparison Aluminum Fiberglass Wood FRP Stone The warranty of a product is very important in today’s construction market, and columns are no exception. Callbacks are the worst enemy to the contractor that, in turn, can point back to the design professional. A one year warranty is the norm throughout the industry on wood columns. Aluminum and fiberglass both carry a standard 10 year warranty. Stone and FRP columns are the leaders in the group with a standard lifetime warranty. Comparison of Materials $500.00 $450.00 $400.00 $350.00 $300.00 $250.00 $200.00 $150.00 $100.00 $50.00 $0.00 Product Cost Aluminum Fiberglass Wood FRP Stone The retail price of an 8x8 aluminum column is around $ 85, the least expensive of the bunch. Fiberglass comes in next with a retail price around $120. Wood 8x8 columns retail around $135 followed by FRP at around $150. Stone columns are very expensive and retail around $450. FRP columns offer the look and feel of wood without the maintenance. New Urbanism Neighborhoods Market Trends In the early 1980’s traditional architectural forms reappeared in mass with the idea of Urbanism. The idea of Urbanism portrays the community as a whole. This translates into equality between all demographics. Where the 1950-70 Suburban neighborhoods sought space, particularly private rear lawns, as a feature of necessity, Urbanism’s direction is toward the public street. Unity, in lieu of individualism, is a primary focus. A front porch and columns are a major factor associated with these developments. Someone has done something right since Traditional Neighborhood Developments, or TND’s, are appearing throughout the U.S. in staggering numbers. The poster child for the TND movement was Seaside built outside of Panama City Florida in the early 1980’s. According to The New Urban News, today there are over 400 developments in 48 states, including Canada. Other examples: Argon in Pensacola, in Florida, and The Waters outside of Montgomery, Alabama. The following slide displays images of these developments. New Urbanism Neighborhoods Market Trends Seaside Argon The Waters Market Trends “It Takes a Village to Lure Buyers Back to Town” New Urbanism Neighborhoods By JIM CARLTON, Wall Street Journal, March 8, 2006; Page B1 “Built to look like charming villages, with old architecture and homes clustered within walking distance of a town center, only a handful of TND communities were built from the 1980s to mid-1990s. But now, roughly 500 of the communities comprising tens of thousands of homes have now sprouted up across the U.S., according to estimates by New Urban News, an industry trade publication in Ithaca, N.Y. Jim Constantine, director of community planning for Looney Ricks Kiss Architects in Princeton, N.J. projects as many as "20% to 30%" of all new subdivisions will be TNDs in another decade.” 1. The Town Paper: www.tndtownpaper.com 2. Congress for New Urbanism: www.cnu.org 3. New Urban News: www.newurbannews.com New Urbanism Neighborhoods Market Trends Hanley-Wood (Largest publisher of building related magazines and home plans) annually publishes the BUILDER 1001 Plans from The Finest Designers which details the best selling plans of the year. Total of 1004 home plans from across the country 87% of the homes (875 plans) used columns (round and square) A total of 6092 columns were used in these plans 37.3 % were ROUND 62.7% were SQUARE (including square posts) 25.6% (round and square) were used in the interior of the homes Conclusion: 87% of the homes featured as top sellers across the U.S., ranging from $100,000 to $2-$3 million residences, continue to use columns in their design. 2005 Publication Market Trends 56% Front Porch 49% Patio 35% New Urbanism Neighborhoods Deck Fencing (avg. length: 139 ft.) 23% Landscape wall (avg. length: 48 ft.) 0% 14% 10% 20% 30% 40% 50% 60% In a recent National Association of Home Builders (NAHB) study, new home buyers were asked what outdoor features were considered the most important when purchasing a new home. As you can see from the chart, almost 60% of the buyers polled considered a front porch to be the most important outdoor feature of their new home. There is nothing like the sense of comfort and peace a front porch can bring. PVC columns New Urbanism Neighborhoods PVC columns are an up and coming material in the column industry. PVC box columns are prefinished and available in preassembled or wrap around applications. PVC columns are non load bearing, wrapping around a structural post and are ideal for remodeling or hurricane zones. Preassembled columns are prebuilt around an existing structural component. PVC column’s can be manufactured to fit a variety of different looks from panel square, to tapered square columns. PVC columns are less expensive than comparable square fiberglass columns and easier to install. Look for PVC columns to become a major factor in the column industry over the next several years. PVC columns New Urbanism Neighborhoods PVC Box Columns Course Summary The Design Professional will now be able to: Become aware of the column design options and the materials they are made from. Describe the manufacturing process for column materials. Explain the construction process of the different column material options. Identify the characteristics of the materials used in column construction. Explain the current trends and construction standards that have affected column design in the construction industry today An American Institute of Architects (AIA) Continuing Education Program HB&G Building Products Tim Bobo PO BOX 589 1015 Brundidge Blvd. Troy, AL 36081 Innovative Column Options for the 21st Century 800-264-4424 334-670-6512 Credit for this course is 1 AIA HSW CE Hour www.hbgcolumns.com tbobo@hbgcolumns.net Course Number: hbg06c Please note: you will need to complete the conclusion Innovaive Column Options for the 21st Century quiz online at RonBlank.com to receive credit © Ron Blank and Associates, Inc.® 2006