Plastering Prevails In Dry-Stacked Construction
In the competition for market share of building exteriors, plastering contractors can wind up on both sides of the fence when it comes to the use of concrete masonry units.
Whereas, on one hand, masonry walls compete directly with traditional lath and plaster or EIFS cladding, in some parts of the country, such as the Southeast, stucco is utilized practically as the de facto finish for block walls. It would seem that what is one plasterer's bane can also be another's boon.
However, one innovation in masonry construction -- dry-stacked block walls -- may provide plastering contractors the means to grab a greater portion of the exterior market by doing what they do best -- plastering. With dry-stacked construction, reinforced bonding cement applied to the face of the masonry block replaces the mortar and masons normally required by block wall construction.
The four-story, 48,000-square-foot Exel Grand Hotel in Madison, Wisc. is one example of the increased volume of work that plastering contractors can perform in conjunction with dry-stacked construction. The 92-unit upscale limited service hotel was developed and contracted by owner Exel Inn Madison South, LLC. Additionally, the development company performed much of the hotel's construction, which included more than 200,000 square feet of wet trades.
The hotel's exterior walls were constructed with dry-stacked concrete masonry units, an approach which can produce a stronger and more watertight wall in less time than does traditional block and mortar construction. As part of the dry-stacked construction process, the CMU walls were parged on both sides with Retro Bond, a glass-fibered surface bonding cement manufactured by RETRO TEK.
"Typically, on the older properties, we did stucco and brick and mixed the materials on the site," explained David J. Stauffacher, a partner in Exel Inn. "We went to RETRO TEK because the materials are pre-mixed in the factory and shipped to the job site ready to apply."
"Compared to the materials we used in the past, this product pleasantly surprised me with the ease of working with it," Stauffacher said. "It was much smoother and easier to trowel on and work with."
The surface bonding cement, applied to nearly 150,000 square feet of exterior and interior surfaces, provides the structural reinforcement for the block walls. Additionally, the bonding cement results in uniform masonry surface which is ready for a variety of finishes and systems.
At the lower exterior levels, the bonding cement was coated with Retro Swirl finish, a trowel applied acrylic finish coat with elastomeric properties. The finish provided the outer color and contemporary texture on the hotel exterior. "The elastomeric properties of the finish will also bridge any hairline cracks that may develop in the walls from settling or other building stresses," explained Robert Krehl, founder of RETRO TEK.
Entranceways and canopies were covered with RETRO TEK's full soft coat PB EIFS system. The system provided the lightweight seamless cladding with a masonry-look that was needed for these areas.
Window panels were treated with a direct applied system over Dens-Glass® Gold. This permitted the proper reveal for the window and louver treatment. The finish coating was a textured RetroLastic which was tinted to match the color of the louvers. The finish provides a waterproof, protective coating for the all-important window areas and adjoining treatments. The direct applied system was also used at entranceways under the canopies.
The upper exterior elevations of the hotel were clad with 4" and 8" thick pre-manufactured EIFS panels. These panels, called Retro 2000, created the desired two-step reveal at the upper building elevations. The panels were pre-manufactured and finished with a matching Retro Swirl finish, then delivered to the job site ready to hang on the walls. The panels were custom sized, 8' to 12' in length, to accommodate design requirements.
More than 10,000 square feet of panels were installed over a two-day period using Retro Mastic adhesive and mechanical attachment. Just two workers installed the panels 40' above the ground using a sky-track forklift. The use of the panels enabled the crew to efficiently continue working in freezing temperatures.
On the hotel interior, a swirl finish was applied directly over the cured bonding cement. More than 30,000 square feet of the finish was applied, in every room on at least one wall, on the lobby and lounge walls, in the rest-rooms and on the swimming pool area interior walls. A Retro Gemstone finish was also applied to interior walls in the lobby and lounge areas to provide an accent trim. Formulated with colored quartz aggregate in a clear acrylic elastomeric base, the finish produces a granite-like appearance.
"The Exel Grand Hotel project is a beautiful example of how a well designed product line can be responsive to a wide variety of interior and exterior building needs," observed Krehl.
Krehl feels the company's broad product line approach enables them to completely tailor their coating systems. As a result, each building area can be optimized for faster applications, better performance and a more attractive result. "The practical advantages are highly appealing to applicators, architects and building owners since the result adds up to quality, speed and reduced cost," he said.
For the owner and developer of the Exel Grand, the practical advantages of the product are readily apparent. According to Stauffacher, the material will be specified in the development of up to six new hotel projects in the greater Chicago area.
"Whoever does the general contracting for those projects is going to be told expressly that they will use RETRO TEK products exclusively on all of the buildings," Stauffacher said. "That's how satisfied I am with the product."
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