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Where Did The Concept of
  Backer Board Start?
  In 1964, a tile setter by the name of Paul Dinkel
  had a good idea, for ...
Development of Backer Board

The first exterior jobs of backer were attempted
with great success. Farrell’s Ice Cream was ...
Development of Backer Board
               Queen of Peace Church
                         Millville, OH
Development of Backer Board

Soon after, knowledge of the new material,
and the time savings began to generate great
inter...
Evolving Backer Board
Backer Board was beginning to catch on outside
out the Cincinnati Tri-State Area although it was
a f...
Evolving Backer Board
USG began producing Durock in 1987. Originally
USG only produced 3’ x 5’. It was not long before
Fin...
Evolving Backer Board
The focus for most of the board manufacturers was lighter
weight. Experimentation with the core of c...
Evolving Backer Board
Gypsum (Synthetic Gypsum) was also used in the
attempt to lighten board weights.

The next change ca...
Evolving Backer Board
Fiber cement boards were next in the development
path. Originally, not recommended for exterior,
som...
The Differences
The changes in the evolution of backer board
are evidenced in the materials composition of
each different ...
The Differences
What does Compressive Strength
and Density mean to external uses of
Backer Board?
    The higher the compr...
The Differences
All Concrete Backer Boards absorb some water.
The absorption of moisture is slowed in boards
that have den...
The Differences
Some of the backer boards that are recommended
for exterior use have gone to a glass mat wrapped
exterior....
The Differences
Glass Mesh count also plays a large role in
flexural strength and values.
Woven fiberglass embedded has th...
The Differences
Backer Board   Manufacturer    Compressive   Flexural
                               Strength      Strengt...
Current Accepted Exterior
  Assemblies
                               These two assemblies are similar in
                ...
Advantages and Disadvantages of
Current Assemblies
Advantages:
Quick Assembly
Budget Friendly Materials
Durable
Disadvanta...
Thermal Bridging-Disadvantage
“These ties should be connected to the steel studs with screws. About two
threads hold this ...
Only In Cold Climates – Right?

    The purpose of
    insulation is to
       separate
 one environment from
       the o...
Emerging Sustainable &
   Energy Efficient Design
Insulation Needs to Be Applied on the Exterior of Stud
                 ...
Emerging Sustainable &
Energy Efficient Design

  EIF’s – Right Concept – Wrong Assembly

      Why Did It Experience Fail...
Emerging Sustainable &
Energy Efficient Design

  EIF’s – Right Concept – Wrong Assembly

      Why Did It Experience Fail...
Emerging Sustainable &
Energy Efficient Design
The Solution Is to :
   Insulate the Exterior of the Frame Wall
   Provide ...
Emerging Sustainable &
Energy Efficient Design
  Concrete Backer Board is a Perfect Solution
This is a new
& emerging
tech...
Emerging Sustainable &
   Energy Efficient Design


ProGUARD©
 by T.Clear Corp
Sustainable Energy Efficient
Design – The Time is Now!
 Since the energy crisis of the 1970’s, the U.S.
 has flirted with ...
ProGUARD Insulated Sheathing
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ProGUARD Insulated Sheathing

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The History of Concrete Backer Board,its use in Exterior Construction and New Solutions to Sustainability and Energy Efficiency.

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Transcript of "ProGUARD Insulated Sheathing"

  1. 1. Where Did The Concept of Backer Board Start? In 1964, a tile setter by the name of Paul Dinkel had a good idea, for faster easier construction: Concrete Backer Board In a collaboration with a lather/plasterer, Ted Clear, the two men produced the first concrete backer board by hand, in molds. The first concrete backer was named “WonderBoard©” by the cousin of Paul Dinkel, Howard Mees, Mees Distributors , Cincinnati.
  2. 2. Development of Backer Board The first exterior jobs of backer were attempted with great success. Farrell’s Ice Cream was the first commercial exterior use of concrete backer board. No longer in existence, it was located in Springdale, OH. It was surfaced with ceramic tile. The first exterior direct applied stucco application was Queen of Peace Church, Millville, OH. It was finished with a direct applied stucco and embedded marble chip finish.
  3. 3. Development of Backer Board Queen of Peace Church Millville, OH
  4. 4. Development of Backer Board Soon after, knowledge of the new material, and the time savings began to generate great interest. Demand began to outpace hand production. Ted Clear invented the automatic process to manufacture concrete backer. Fin Pan, Inc. was begun to manufacture “WonderBoard”. Modulars, Inc. went into sales and marketing. The year was 1974.
  5. 5. Evolving Backer Board Backer Board was beginning to catch on outside out the Cincinnati Tri-State Area although it was a few more years before other boards began. Backer Board was produced in various sizes to fit specific applications: 3’ x 5’ was produced for a tub surrounds 3’ x 64” was produced order to be used for standard stud spacing. 3’ x 4’ was produced for use on floors – 8’ was not available originally and extremely heavy 3’ x 5’ is still the most popular size for residential construction. Fin Pan still manufactures the various sizes for ease of installation and less waste on the jobsite.
  6. 6. Evolving Backer Board USG began producing Durock in 1987. Originally USG only produced 3’ x 5’. It was not long before Fin Pan and USG both developed an 8’ backer. USG developed the 4’ wide format and Fin Pan developed the 3’ wide. During this time, the “WonderBoard” name was sold by Modulars Inc. and rights given to Custom Building Products to produce. Fin Pan, Inc. named its board “Util-A-Crete”. It is produced to the same quality standards as the original “WonderBoard”.
  7. 7. Evolving Backer Board The focus for most of the board manufacturers was lighter weight. Experimentation with the core of concrete backer boards lead USG and Custom to introduce other materials into their cores in the attempt to lighten and reduce raw material cost. Some manufacturers reduced the glass mesh count to reduce cost. The result is less flexural strength. Bottom (Fly) Ash from coal fired electric plants and crushed slag from steel factories were introduced into some board, evidenced by the “coffee staining effect” or ferrous (rust) leach. Fly Ash (top ash) also were introduced into some board. A cleaner and uncontaminated material fly ash bonds well with Type 1 Portland Cement and does not produce rust staining.
  8. 8. Evolving Backer Board Gypsum (Synthetic Gypsum) was also used in the attempt to lighten board weights. The next change came from a company based in Canada, Unifix. Unifix introduce polystyrene bead to its core. A lightweight and easily cutable material, gained popularity and the attention of National Gypsum Company. National Gypsum acquired Unifix US and PermaBase was launched. Type III Cements requiring high temperature curing (oven) also is used in some boards as well as entrained air to make them lighter.
  9. 9. Evolving Backer Board Fiber cement boards were next in the development path. Originally, not recommended for exterior, some fiber cement boards are still not recommended for exterior applications. James Hardie does not warrant nor recommend HardieBacker for exteriors Not to be forgotten, gypsum cored boards with fiber glass wrapped skins began to emerge with the success of DensGlass Gold for exteriors.
  10. 10. The Differences The changes in the evolution of backer board are evidenced in the materials composition of each different type of backer and the effect on board properties. (Published Values*) Backer Board Manufacturer Compressive Flexural Strength Strength Util-A-Crete Fin Pan, Inc. >2600 psi >1500 psi ProTEC Fin Pan, Inc. >2600 psi >1260 psi Durock USG 2300 psi 750 psi FiberRock PermaBase Nat’l Gypsum 2250 psi 750 psi WonderBoard Custom 1250 psi >750 psi Bldg.Products
  11. 11. The Differences What does Compressive Strength and Density mean to external uses of Backer Board? The higher the compressive strength, the higher the density. The higher the density, the slower the absorption rate. The slower the absorption rate, the better the performance in freeze thaw conditions.
  12. 12. The Differences All Concrete Backer Boards absorb some water. The absorption of moisture is slowed in boards that have denser cores. The introduction of dissimilar materials, like polystyrene can leave pathways to transmit water. A more homogenous core will allow materials to bond more thoroughly, become dense and resist the absorption of water. The perceived drawback is that the board is heavy and more difficult to cut. A moisture barrier is needed with all concrete based backer boards
  13. 13. The Differences Some of the backer boards that are recommended for exterior use have gone to a glass mat wrapped exterior. Advantages: Protects hygroscopic core Protects against core damage Resists Freeze Thaw Disadvantages: Screw Penetration may cause moisture migration and core degradation Can not direct apply finishes
  14. 14. The Differences Glass Mesh count also plays a large role in flexural strength and values. Woven fiberglass embedded has the highest flexural strengths. They provide the best tension and compression assembly translating to flat backer board. Some manufacturers have an 8 x 8 count weave, some 8 x10, 8 x 12 and some 10 x 16. Flexural strength numbers directly correlate to weave counts.
  15. 15. The Differences Backer Board Manufacturer Compressive Flexural Strength Strength Util-A-Crete Fin Pan, Inc. >2600 psi >1500 psi ProTEC Fin Pan, Inc. >2600 psi >1260 psi Durock USG 2300 psi 750 psi FiberRock PermaBase Nat’l Gypsum 2250 psi 750 psi WonderBoard Custom 1250 psi >750 psi Bldg.Products
  16. 16. Current Accepted Exterior Assemblies These two assemblies are similar in their details. One has a polystyrene insulation board in the assembly In the assembly: Gypsum Board (Int.) Stud Framing & Cavity Cavity Insulation Structural Sheathing Moisture Barrier Concrete Backer Board Mesh Joint Tape Low Density Polystyrene Insulation Mesh Reinforcement Base Coat Textured Finish
  17. 17. Advantages and Disadvantages of Current Assemblies Advantages: Quick Assembly Budget Friendly Materials Durable Disadvantages: Studs Are Un-insulated Allowing Heat/Cold Transfer Can Increase HVAC Loads on the Building Envelope- Energy Inefficiency Low Density Polystyrene May Not Resist Damage Compromising Exterior Finish Cavity Insulation May Become Saturated Many Layers of Labor To Install
  18. 18. Thermal Bridging-Disadvantage “These ties should be connected to the steel studs with screws. About two threads hold this screw in the 16-gauge outside flange of the metal stud. Thermal bridging at the stud could cause condensation to form at the inside face of this outside flange in the cold weather months. A rust or a galvanic cell reaction could develop at the juncture between the screw and the stud. The connection between the two could eventually deteriorate and become loose, which means that the masonry tie and the brick veneer also could become loose, causing cracks in the horizontal (bed) joints of the brick veneer. Cracks lead to water penetration through a brick veneer and provide an avenue for moisture to get inside the building, All associated problems could then be blamed on the masonry contractor who installed the brick veneer and masonry ties. However, it is actually a design problem.” Masonry Construction , Jan, 2003 by Michael Gurevich
  19. 19. Only In Cold Climates – Right? The purpose of insulation is to separate one environment from the other. Warm Climates Need Insulation Too!
  20. 20. Emerging Sustainable & Energy Efficient Design Insulation Needs to Be Applied on the Exterior of Stud or Frame Wall What about EIF’s?
  21. 21. Emerging Sustainable & Energy Efficient Design EIF’s – Right Concept – Wrong Assembly Why Did It Experience Failures? Surface could be “Spongy” and Damage Prone Leading to Water Intrusion and Gypsum Degradation. Too many site applied layers to be reliable
  22. 22. Emerging Sustainable & Energy Efficient Design EIF’s – Right Concept – Wrong Assembly Why Did It Experience Failures? Surface could be “Spongy” and Damage Prone Leading to Water Intrusion and Gypsum Degradation. Too many site applied layers to be reliable
  23. 23. Emerging Sustainable & Energy Efficient Design The Solution Is to : Insulate the Exterior of the Frame Wall Provide Wind and Moisture Barrier Remove Hygroscopic Materials From the Assembly Provide a Durable Damage Resistant Surface That Will Accept Direct Applied Elastomeric, Faux Stone, Exterior Rated Ceramic Tile or Brick Veneer Move the Dew Point Outside the Wall Cavity
  24. 24. Emerging Sustainable & Energy Efficient Design Concrete Backer Board is a Perfect Solution This is a new & emerging technology Provides in a pre-assembled panel… Insulation Vapor and Durable Surface Wind Barrier
  25. 25. Emerging Sustainable & Energy Efficient Design ProGUARD© by T.Clear Corp
  26. 26. Sustainable Energy Efficient Design – The Time is Now! Since the energy crisis of the 1970’s, the U.S. has flirted with energy efficient materials. When times are flush, energy efficient design gets forgotten – immediate cost rules! The use of Concrete Backer Board has developed over the course of the last 40 years to be a material of choice in sustainable design. Emerging technologies and materials will continue to contribute to not only sustainable but energy efficient design.
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