Simple Steps for Construction Managers to Ensure High Performing Enclosures

Transcription

1 Simple Steps for Construction Managers to Ensure High Performing Enclosures Brian Stroik Manager Building Envelope Solutions Team Tremco Sealants & Waterproofing Vice Chair Air Barrier Association of America Past Chair National Building Enclosure Council Voting Member ASTM E 06 Building Performance Co-Chair BEC WI Neal Morton Vice President and Managing Director of UIA at Barton Malow Company Guest Lecture, Project Management and Leadership Skills at University of Michigan Dearborn College of Business Construction Neutral, American Arbitration Association

2 Learning Objectives Why Building Enclosures Matter for Energy Efficiency, Sustainability, and Durability Pre-Design and Pre-Construction Activities and Discussions Mock Ups, Lessons Learned, and Quality Assurance Processes Prior Installations Site Validation & Testing / Quality Control Processes During Installations

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4 Per Zurich Insurance: We pay out Hundreds of Millions of Dollars every year in Construction Claims 70% of those are due to Water and Moisture Issues in the Enclosure

5 Building It Right Matters Why An Enclosure Program??? Buildings Consume approximately 40% of our Nations Energy!!! Transportation 20%-40% Building Energy LOST Through the Enclosure! NIST Report 7238 Did You Know: Building Science is Not Taught in most University Architectural Schools (Only Approximately 16 Schools across the Transportation US) There 29.0%39.4% is Not One Enclosure / Building Buildings Science Question on the AIA Exam Building Failure across the US Annually, 31.6% is One of the Largest Insurance Claims Industry Source: USEIA 2016 Slide Courtesy of: Mathis Consulting

6 How Many Products Do We Build With Today? Let s Consider the Following: 3 Different Types of Back Up Walls Block, OSB, Exterior Sheathing 5 Different Types of AVB Fluid, Self Adhered, SPF, Rigid, Mechanically Fastened 4 Different Types of Insulation SPF, Extruded Poly, Poly Iso, Mineral Wool 4 Different Types of Exterior Cladding Brick, Metal Panel, EFIS, Cement Board OVER 116 Wall Configurations This DOES NOT Consider all of the Different Manufacturers of each Item

7 Building Science Why It Has To Be Built Right Photo by: ABAA

8 Building Science Why It Has To Be Built Right Photo by: ABAA

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10 Is There a Way to Reduce or Eliminate These Issues?? Bronze Tone Windows???

11 ASHRAE 1478 Why An Enclosure Program?

12 Steps to Build Your Project Right The First Time 1. Construction Team Matrix 2. Plan / Specification / Detail review / Shop Drawings / Questions 1. 3 rd Party, Manufacturer Involvement, Insurance Company Requirements 3. Superintendent / PM Pre-conference with Subcontractor trade Superintendent / PM 4. Pre Construction Meeting / Enclosure Phase with all Enclosure Sub Contractors 5. Mock ups & Modeling 1. What Materials / Conditions 2. Testing Protocols / Pass Requirements 3. WUFI / Therm Model Exterior Wall 4. Lessons Learned Meeting / Discussion after Total Pass 6. Creation of Quality Assurance Requirement lists By Who?? 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions 8. Review of Material Installation 1. CM QA Personnel / 3 rd Party / BECxCA 9. In Situ Testing 1. What Types of Tests / How Often Who Performs it???

13 Phase Project Matrix Owner Built-In Quality Linear Responsibility Chart Design Team CM/GC Project Name: Project Number: Architect Consultants PM FE Supt Action Pre Construction Quality Team Trade Contractors Suppliers & Vendors BECx Agent Jurisdiction Authority AHJ/ OSPD Bldg Inspector Define Purpose & Value R A A Document the Design Criteria R A A A I A A V Develop Design Drawings & Specifications A R R A A I A C I I Identify fabrication & installation instructions I R S A I R R I I Recognize preconstruction expectations: Owner & Boldt R Continually perform Constructability Design Review (required 50% & 90% complete) I S S R I I I R R I I Quality Team reviews specs for special requirements R R I R A S I I Request & review contractor's Quality Manuals S S R S S I I Develop Conditions of Satisfaction list S S S R R I R V I Create Quality Control Requirements Lists R A I R R V Host Project Manager Pre-Construction Meeting to identify and agree on Project Scope S S R R A I R S C I Develop Hold-Point list for Production Planning I I I R R A I A A I I I Constructi on Construction Host Superintendent Pre-Construction Meetings to identify & agree on Conditions of Satisfaction R S A I Develop Mock-up or First-Run-Study S S S R R S R R S V V Review Work Sequence for Constructability A R R R S R Instruct & train trade workers on special requirements and techniques A A I A R R I I Trades Self-Inspect work as installed A A A A R S V Use Task-based Quality Checklist for verification A A A A R S V Inspect early work to assure compliance with Conditions of Satisfaction A R S S S S S V R Perform Hold Point Inspection at Handoff Points: Stud Frame;MEP rough-in;finishes (In-wall, Above-Ceiling) S S S R A S R S I V Perform Root Cause Analysis for frequent Findings C C R R C S R S I I Conduct Indoor-Air-Quality Audit I R S S A V Field Inspections performed and results distributed by A&E, Boldt, IOR, and Third Party I R R A R A R A I V Post Constructi on Post Construction Process IOR forms & Statement of Conformance I S S S S S I S S S R A&E provide Certificate of Completion I R R A A A S S S S S I Obtain Occupancy Permit S S S S S S I S S S R R Closeout project; finalize O&M and Turnover documents for Owner R R I S A S V V Conduct Post-Construction Interview R R

14 1. Construction Team Matrix Who is Responsible for What Project Title: Job Name: Job Number: Start date End date Info. By: Modified By: Chart Rev. Date: Project RACI Chart Delivery or Program Oriented Delivery or Program Oriented Categories Items ê or Items ê R = Responsible, A = Assisting C = Consulted, I = Informed Location Field ==> Office ==> Field PM PM Position Person(s) Jason Krueger Assigned General Field Supt Field Engineer Supt Engineer Field Engr Field Engr Field Safety Field Safety Engineer Engineer Admin Team Leader MEP Field Engineer Craft Foreman Subcontractor Foreman PM PM Admin Team Leader MEP Field Engineer Boldt Craft Foreman Sub-contractor Foreman PM PM Estimate R C I I I I C I I R Estimate Owner Inter-action / Correspondence R A A A A A A A I R Monthly Owner Reports A C C I I R I I I R Owner Inter-action / Correspondence Field Daily Reports I R I I I I I R R I Monthly Owner Reports Self-Perform Crew Time Reported I I I I R I I R I Field Daily Reports Document Distribution C C C I I R I I I Contracts and PO's - Issue R I I I I A A I C Contracts and PO's - Invoices R I I I I R A I C Scope Revision - Contracts and PO's R A A A I A A I C Self-Perform Crew Time Reported Scope Revision - Boldt / Owner Contract R C I I I A I I R Document Distribution Commissiong / Work Closeout A R R R A A R R R A Closeout - documents and Manuals C C R R I R R I C Contracts and PO's - Issue Safety Program R R R R R R R R R R Contracts and PO's - Invoices Safety Site Review R R A A R A A R A R Scope Revision - Contracts and PO's Scope Revision - CM / Owner Contract Project Master Schedule (Strategic and lookahead) R R C C I I I C C A Construction Equipment Schedule A R I I I I I C C C Commissiong / Work Closeout Pull Schedule R A C C I I I C C A Weekly Last Planner meetings C R A A I I I A A C Closeout - documents and Manuals Boldt Mgmt Daily Huddle R A A I I I I A I I Field Daily Huddles at start of work C R I I I I I A A I Productivity Targets R C A A A I I R I C Safety Program Productivity Collect & Report C C R R A I I A I C Safety Site Review Site Rsponsibility: Construction Layout, Position Control C R C C I I I A A C Temporary Services C R A I I I I A C I Waste & Recycling I R A I I A I A C I Project Master Schedule (Strategic and Submittals, Strategies and RFI's for: lookahead) Subcontractor Site Coordination C R A I I I A A C C 2. Earthwork, Sitework A A R I I I I I R C Construction Equipment Schedule 3. Concrete work C A R I I I I A R C 4. Masonry work R A A/I R I I I R I C Pull Schedule 5. Steel, Structure A A R I I I I R I C 6. Wood & Plastics, Carpentry A A R I A I I R I C Weekly Last Planner meetings 7. Thermal & Moisture Protection R A A R A I I I R C CM Mgmt Daily Huddle 8. Doors & Hardware A C R A A I I R I C 9. Curtainwall R A I R I I I I R C Field Daily Huddles at start of work 9. Finishes - Floors, Walls, Cielings A A R I I I I A R C 10. Specialties R C I R I I I R I C Productivity Targets 14. Conveying Systems R A R I I I I I R C 15. Plumbing, Piping, HVAC R A A I I I R I R C Productivity Collect & Report 16. Electrical R A A I I I R I R C

15 2. Plan / Specification / Detail review / questions by 3 rd Party

16 2. Plan / Specification / Detail review / questions by 3 rd Party

17 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

18 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

19 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

20 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

21 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

22 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

23 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

24 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

25 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings

26 2. Plan / Specification / Detail review / Shop Drawings / Questions by 3 rd Party Manufacture Technical Support / Shop Drawings Actual Project Installation 26

27 3. Superintendent / PM Preconference with Subcontractor Trade Superintendent / PM

28 4. Pre Installation Meeting / Enclosure Phase with ALL Enclosure Sub Contractors

29 4. Pre Installation Meeting / Enclosure Phase with ALL Enclosure Sub Contractors

30 5. Mock ups & Modeling 1. Model Exterior Wall 1. Therm 2. WUFI 3. equest WUFI Therm Caution Output is only as good as the Input!!!!!

31 IBC 2015 Section Vapor Retarders as described in Section shall be provided in accordance with Section and or an approved design using accepted engineering practice for hydrothermal analysis

32 Mock Ups

33 5. Mock ups & Modeling

34 Mock Ups / First Run Studies of Building Enclosures 93% of Tested Mock Ups Fail!!! National Testing Lab 2009

35 5. Mock ups & Modeling

36 Let s Do Some Brian Math Simple # s Parapet to Wall New Z Furring Air Barrier System Parapet to Roof Thru-wall Flashing Curtainwall / Wall Tie in Wall To Foundation Transition Roof Scupper Lintel Brackets Punched Window / Wall Tie In Let s Say you have a $14 M Project On Site Simple Wall Mock Up = $12,500. Mock Up = 0.09% of Construction Costs SO Less than 0.1% of Construction Costs To: Validate Design Assist Construction Sequencing Validate Materials to be Used Validate Performance Discover Potential Installation Issues Provide Custom Training Program for Installers Material Compatibility

37 Common Tests Performed Air Leakage Windows - ASTM E 283 / ASTM E 783 Uniform Load Deflection - ASTM E 330 Static Water - ASTM E 331 / ASTM E1105 Smoke or Bubble Gun - ASTM E 1186 Dynamic Water - AAMA Hose Test - AAMA Thermal Cycling - AAMA Used to Determine Condensation Resistance Thermograph - ASTM C 1060 Sealant Pull Test - ASTM C 1193 Horizontal Flood Testing (Roof Test) ASTM D 5957 Air Barrier Adhesion Tests ASTM D 4541 Lab Mock Up E 2099 ASTM Work Standard Spec and Test Field Mock Ups

38 When Should You Test Your Mock Up Up!!!

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40 When Should You Test Your Mock Up Up!!!

41 5. Mock ups & Modeling 1. Lessons Learned Meeting / Discussion after Total Pass

42 6. Creation of Quality Assurance Requirement lists

43 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions Project ABC Located in Your Community

44 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions ABC Project in XYZ City

45 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions

46 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions Roll Transition Membrane sealant

47 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions

48 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions

49 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions

50 7. Tradesmen Training from Mock Up Lessons Learned / Shop Drawings / Installation Directions

51 8. Review of Material Installation 1. CM QA Personnel / 3 rd Party / BECxCA / A/E 1. Building Enclosure Consultants / A/E 2. Air Barrier Association of America 3. Manufactures Technical Review

52 8. Review of Material Installation

53 8. Review of Material Installation

54 8. Review of Material Installation 1. CM QA Personnel / 3 rd Party 1. Building Enclosure Consultants 2. Air Barrier Association of America 3. Manufactures Technical Review

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57 8. Review of Material Installation

58 Visual Inspections Be a Kid Again Always Ask Why. ROOT CAUSE!!!!! 4 story curtain wall with Brown Spots

59 8. Review of Material Installation 45 Staples

60 8. Review of Material Installation

61 8. Review of Material Installation

62 8. Review of Material Installation

63 9. In Situ Testing How Much Does It Cost When your Enclosure Has a Failure??? Cost Close to Area of Your Issue Down Reputation?? Initial Meeting to Discuss Issue / Path Forward OWNER, CM, Architect, Consultant, Installers, Manufacturer Is Your Removal of Material Owner Happy??? Testing to Validate Issue & Location(s) of Issue(s) Meeting to Discuss Repair Rework / Refinish the Area Testing to Validate Issue & Location(s) of Issue(s) Have Beed Repaired Reopen Area For Owner Use

64 9. In Situ Testing 1. What Types of Tests Air Leakage Windows - ASTM E 783 Static Water - ASTM E 1105 Smoke or Bubble Gun - ASTM E 1186 Dynamic Water - AAMA Hose Test - AAMA Thermograph - ASTM C 1060 Sealant Pull Test - ASTM C 1193 Horizontal Flood Testing (Roof Test) ASTM D 5957 Air Barrier Adhesion Tests ASTM D How Often Recommend Testing at 10%, 50%, 75%, 95% of completed work

65 9. In Situ Testing ASTM E 1105 Static Water Test

66 9. In Situ Testing Smoke or Bubble Gun - ASTM E 1186

67 9. In Situ Testing AAMA Dynamic Water

68 9. In Situ Testing Adhesion Testing ASTM D 4541 Attach a 2¼" to 4" steel or plywood disc to the air barrier material, Cut around the material so you are pulling on a specific area of the material to not damage more material around the area of the test The force shall be applied to the pad by turning the handle not be more than one revolution per minute (rpm) ABAA Recommendations is to achieve 16psi min.

69 9. In Situ Testing

70 9. In Situ Testing Whenever Using SPF Only Specify an Absolute Minimum Thickness

71 Rework Costs including labor, materials, equipment and subcontractors can run from 2% to 20% of a project's total contract amount. ENR Issue: 12/03/2012 Contractors Confront the Growing Costs of Rework Let s Do Some Brian Math Simple # s 2% = $2M $100M = $20M $50M 2% = $1M $50M = $10M In Rework In Rework = WASTE = Lost Income You put that in your Bid, Right????

72 Learning Objectives Why Building Enclosures Matter for Energy Efficiency, Sustainability, and Durability Pre-Design and Pre-Construction Activities and Discussions Mock Ups, Lessons Learned, and Quality Assurance Processes Prior Installations Site Validation & Testing / Quality Control Processes During Installations Baby Steps It Will NOT Happen Overnight!

73 Thank You For Your Time Brian Stroik Vice Chair Air Barrier Association of America Past Chair National Building Enclosure Council Voting Member ASTM E06 - Building Performance Tremco Sealants & Waterproofing Manager Building Envelope Solutions Team (414) Bstroik@tremcoinc.com Neal Morton Vice President and Managing Director of UIA at Barton Malow Company Guest Lecture, Project Management and Leadership Skills at University of Michigan Dearborn College of Business Construction Neutral, American Arbitration Association (248) neal.morton@bartonmalow.com