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ProGUARD Insulated Sheathing
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.
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.
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
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.
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.
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”.
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.
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.
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.
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
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.
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
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
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.
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
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
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
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
Only In Cold Climates – Right?

    The purpose of
    insulation is to
       separate
 one environment from
       the other.
Warm Climates Need Insulation Too!
Emerging Sustainable &
   Energy Efficient Design
Insulation Needs to Be Applied on the Exterior of Stud
                    or Frame Wall
                What about EIF’s?
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
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
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
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
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 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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ProGUARD Insulated Sheathing

  • 2. 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.
  • 3. 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.
  • 4. Development of Backer Board Queen of Peace Church Millville, OH
  • 5. 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.
  • 6. 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.
  • 7. 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”.
  • 8. 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.
  • 9. 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.
  • 10. 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.
  • 11. 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
  • 12. 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.
  • 13. 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
  • 14. 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
  • 15. 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.
  • 16. 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
  • 17. 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
  • 18. 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
  • 19. 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
  • 20. Only In Cold Climates – Right? The purpose of insulation is to separate one environment from the other. Warm Climates Need Insulation Too!
  • 21. Emerging Sustainable & Energy Efficient Design Insulation Needs to Be Applied on the Exterior of Stud or Frame Wall What about EIF’s?
  • 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. 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
  • 24. 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
  • 25. 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
  • 26. Emerging Sustainable & Energy Efficient Design ProGUARD© by T.Clear Corp
  • 27. 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.