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Green Alternative to Concrete Block Gets a Nudge

Wednesday, September 21st, 2011
A Cleaner Concoction MaqCrete mixes cement with various waste products.

A Cleaner Concoction MaqCrete mixes cement with various waste products.

Credit: Courtesy EcoBuilt Efficient Buildings

In May, the Green Building Alliance awarded a $20,000 Innovation grant to EcoBuilt Efficient Buildings, a Pennsylvania-based company that specializes in energy audits. EcoBuilt and Drexel University will use that money over a 12-month period to determine whether a greener alternative to conventional masonry blocks called MaqCrete—which EcoBuilt’s principal, Dennis Crook, has been developing for the better part of three decades—can be mass-produced cost effectively.

The 60-year-old Crook, who runs the company with his wife Siti, is no Johnny-come-lately to the world of efficient construction. His first job in the early 1970s was with an insulation and home improvement company in Newton, Iowa, where his father was an industrial engineer for Maytag. “One of the lessons he taught me is that there’s always a cheaper and better way to do things.”

In 1985, Crook bought an abandoned steam plant in the Overbrook Farms district of Philadelphia, and after years of remediation turned it into a seven-unit housing development that qualified for energy-efficient certification under Owens Corning’s “Thermal-Crafted Homes” program. More recently, his company built a duplex with two 1,680-square-foot homes in Lancaster, Pa., whose HERs were, respectively, 69 and 71.

Crook is a big proponent of improving a home’s thermal package through better construction techniques and materials. MaqCrete’s formula, which received a 20-year patent in 2002, consists of post-industrial waste and/or bio-based plant fibers mixed with Portland cement, but uses about 25 percent less cement than a conventional masonry unit. MaqCrete is 30 percent lighter than masonry block, with an R-23 insulation value. And it’s fibrous, so screws have something to grip onto.

“What’s revolutionary,” says Crook, “is that the product can serve as a whole building system. It’s fire-resistant, non-rotting, and users can attach other products to it,” which would also reduce labor costs.

But Crook hasn’t gotten MaqCrete past the prototype stage, and his latest challenge has been figuring out which binder combination will work best. Enter Drexel.

Dr. Michel Barsoum, a professor in the university’s department of materials science and engineering, says MaqCrete’s commercial fate lies in its meeting or exceeding performance criteria for concrete and cement that have become ingrained over centuries. Barsoum’s own research team has been working for two years on an alternative concrete product made from blast-furnace slag, and what’s kept it from passing ASTM’s C1157 performance standard is that it sets five minutes quicker than conventional cement.

This article was originally posted on Builder Online.

Irwin Tools Names September 16 National Tradesmen Day

Friday, September 16th, 2011

A months-long grassroots campaign by Irwin Tools to thank hardworking men and women trade professionals culminates on September 16, 2011 with the first National Tradesmen Day.

 

Trade worker Delwyn Thornton rings the bell to open the New York Stock Exchange on Sept. 1, 2011 to celebrate National Tradesmen Day.

Trade worker Delwyn Thornton rings the bell to open the New York Stock Exchange on Sept. 1, 2011 to celebrate National Tradesmen Day.

“From media coverage, to our customers continuing to ask how they can get more involved, we’ve had great interest at every level,” says Irwin vice president of marketing Curt Rahilly. “We’re really honoring the tradesman and promoting that having a career as a skilled worker is rewarding. Everyone we meet is excited about it, especially because it’s not about trying to sell something – it’s about looking people in the eyes and saying, ‘thank you.’”

 

Since the team conceptualized National Tradesmen Day back in January, Irwin has held numerous events to bring attention to both the holiday and the workers it honors. As a sponsor of the Bristol Motor Speedway Night Race, Irwin brought 250 tradesmen to the event and held a subsequent contest Thank a Tradesman contest with a VIP Pole Position grand prize. Participation in the contest was telling, Rahilly says.

“We asked people to go to Irwin.com and thank a tradesman that impacted their life. The winner was  Kenny Thompson, who happens to be a concrete finisher. He went on the site and thanked all the tradespeople who helped him build the career he has today,” Rahilly says. “It was really touching to see not just homeowners go online to thank their homebuilders and plumbers, but also to see trade workers recognizing each other.”

Education and Awareness

In addition to showing appreciation for trades across a variety of industries, Rahilly says a major impetus behind the National Tradesman Day has been the need to draw attention to skilled trades as rewarding careers. “We can all appreciate a tradesman coming in to repair an overflowing toilet, but there’s not a lot of encouragement for kids and teens to look at plumbing or other trades as careers,” he says. “As a result, there’s a forecast shortage of skilled labor, so we want to help bring some attention to that issue.”

In keeping with its Nascar tradition, Irwin also took two automotive service technician winners of the 2011 Skills Challenge to the Bristol Night Race. The teens were able to “experience Nascar from a different side,” Rahilly says, by teaming up with one of the race teams and getting some hands-on experience in the pits.

“This was a great resume builder as these students prepare for trade careers,” he adds. “Bristol gives us a great voice to help spread the word.” Irwin has also contributed thousands of dollars in Skills USAscholarship money.

National Attention

To bring attention to National Tradesmen Day outside the Nascar world, representatives from Irwin rang the opening bell at the New York Stock Exchange on Sept. 1. Rahilly called the experience “incredible.”

“When you think about the excitement of the New York Stock Exchange and to be on the floor before it opens, it’s a pretty intense environment,” he says. “When you think about the halls of the most important economic center in the world, and at center stage was a tradesman – that’s a really powerful combination. It added to the excitement when we watched all these executives in suits step aside so a trade professional could open the market.”

Rahilly says Irwin’s sister companies under the Newell-Rubbermaid umbrella, which include Lenox Tools and numerous consumer brands, such as Rubbermaid and Sharpie, have been asking how they can get more involved in the National Tradesmen Day initiative. “The whole company is excited about it because it’s recognizing the people that build our country and keep us up and running,” Rahilly says, sharing a conversation he had with a rail worker recently.

“I was talking to a young guy during one of the races we attended and he told me he fixes track on the railroad,” Rahilly recalls. “He told me the line he works on starts in Florida and ends in New York, and he works on a 50-mile section. I said to him, ‘what you really do is connecting family and friends on the East Coast. You’re allowing transportation to flow smoothly so people can get together.’ He told me he had never thought of it in that perspective before, and that was really powerful.”

To celebrate National Tradesmen Day on Sept. 16, Irwin will host pizza parties and events in parks around the country, including a Hispanic marketing effort in San Diego. Rahilly says in years to come, Irwin hopes to make National Tradesmen Day a global celebration, reflecting the company’s international history and reach.

Mark your calendars for next year’s National Tradesmen Day on Sept. 21. Going forward, the holiday will be marked annually on the third Friday of September. —Lauren Hunter, associate editor, Remodeling magazine

This article was originally posted on Remodeling Online.

Weyerhaeuser Drops iLevel Brand Name

Wednesday, September 7th, 2011

Weyerhaeuser Co. announced today it will abandon the “iLevel by Weyerhaeuser” name it has used for the past five years to brand its wood products businesses and instead will simply call them “Weyerhaeuser.” The transition will begin on Sept. 6.

The Federal Way, Wash.-based company said in a news release that it is making the name change “to simplify customer contacts and leverage the widespread recognition of the Weyerhaeuser identity.”

That was the same reason Weyerhaeuser gave in April 2006 when it publicly unveiled iLevel. The company said then it was doing so to integrate five divisions that produced the bulk of the company’s structural frame products. The idea at that time was to provide a single point of contact who would replace a multitude of sales reps and marketers, each assigned to tout particular product lines.

“Our customers and vendors know us best as ‘Weyerhaeuser,’ so we are returning to what is most familiar to them,” Larry Burrows, Weyerhaeuser’s senior vice president of wood products, said in today’s news release. A company spokesperson, responding to an e-mail from ProSales, called the Weyerhaeuser and Trus Joist names “more meaningful” than iLevel. “Many times when customers hear ‘iLevel,’ they think of Weyerhaeuser or Trus Joist products, so the intent is to make the brand recognition easier for customers,” he said.

The company said it also “will enhance promotion” of its Trust Joist brand of engineered lumber products. It didn’t elaborate.

Weyerhaeuser will retain its individual names, such as TimberStrand, Parallam, and Microllam wood products and Stellar and Forte software. Companies also will still have access to their same sales representatives, it added.

iLevel’s five-year lifespan encompassed some of the most tumultuous times in Weyerhaeuser’s 111-year history. When iLevel was created, its combined units accounted for more than one-third of the company’s $22.6 billion in revenues. Company representatives in 2006 described iLevel as the integration of disparate divisions that together would produce a new level of innovation, service, and efficiency to dealers, builders, and the overall business.

“It’s a new game [in home building], and it shows our willingness to change and lead based on what the market needs,” Scott Elston, director of national accounts, said then. “It’s hard to say what iLevel means to anyone right now, but that’s what we intend to create.”

Since then, the housing game has changed considerably, and so too has Weyerhaeuser. In the wake of the housing crash it shed operations and properties and became a real estate investment trust. By 2010, annual sales had shrunk to $6.6 billion, and revenues through June 30 of this year are on about the same pace. The wood products segment now is about half of the entire business.

This article was originally posted on ProSales Online.

 

Green Building Materials Demand to Grow 13% Annually Over Next 5 Years

Thursday, May 26th, 2011

Demand for green building products–buoyed by increased availability, environmental concerns, stricter building codes, and a rebounding construction industry–is expected to increase by 13% annually to create a $71 billion market in 2015, states to a forecast by the Freedonia Group, a Cleveland-based research firm.

According to the study, concrete made from recycled materials is expected to soar by 24% annually between 2010 and 2015. Meanwhile, green floor coverings, which include Green Label Plus-certified carpets and products made from fast-growing natural resources such as bamboo and cork, are expected to grow by nearly 12% annually through 2015. The study predicts, however, that flooring will not grow at the same pace as some other green building materials, in part because many flooring products already are considered green.

Through 2015, sustainable doors are predicted to increase by 12% annually, green windows will grow by 8% each year, and insulation and other green building products will jump 14% annually, the Freedonia Group study says. Nevertheless, green roofing materials will see the smallest annual growth (4.1%).

Brendan Rimetz is assistant editor for ProSales.

This article was originally posted on ProSales Online.

Forestry Group Aims To Boost Sustainability Practices

Wednesday, March 30th, 2011

The American Forest & Paper Association (AF&PA) released today five goals for the forest products industry to be more environmentally sustainable, including work to increase the amount of fiber procured from certified forest lands and to promote polices worldwide that reduce illegal logging.

AF&PA promoted its Better Practices, Better Planet 2020 document as a “continuing commitment to sustainability” that the association concluded was not being recognized by the public as much as it should. Along with its intent to buy more fiber from certified forest lands, the association also set these goals for 2020:

  • Increase the paper recovery for recycling rate to more than 70%.
  • Boost by at least 10% the industry’s energy efficiency in terms of purchased energy use.
  • Reduce “the intensity” of industry greenhouse gas emissions by at least 15%.
  • Improve the industry’s safety incidence rate by 25%.

“Sustainability has become a bit of a buzzword. For us, it’s the whole story,” Jim Hannan, chairman of AF&PA’s board as well as president and CEO of Georgia-Pacific LLC, said in an interview withProSales. “We rely on natural resources, renewable resources, and recycling as our business model. It doesn’t disconnect from our vision–it’s embedded in our vision. We just haven’t told our story.”

“Sustainable forestry is the key to our existence,” AF&PA president and CEO Donna Harman added. She said the new document shows how the industry is “raising the bar” in its commitment to the subject.

Unlike the other commitments, AF&PA’s goal of increasing the amount of fiber procured from certified forest lands doesn’t give a numerical target. It does note that all AF&PA members that own forestland must conform “to a credible sustainable forest management program,” while members that source wood fiber from the forest must comply with “sustainable procurement principles.”

But AF&PA’s call for members to participate in forest certification programs refuses to play favorites among the several wood-certification schemes available worldwide. That list includes the Sustainable Forestry Initiative (SFI); the Programme for Endorsement of Forest Certification (PEFC), which boasts a global scope; and the Forest Stewardship Council (FSC), another global program that is the only certification scheme recognized by the U.S. Green Building Council (USGBC) for points in its LEED green-building program.

Many AF&PA members are known to prefer SFI, and the association’s list of certification programs not only cites SFI first but also notes–as part of its list of members’ past accomplishment–that more than 7,000 loggers have completed SFI-supported training on forestry best management practices.”

Late last year, a subset of USGBC members failed to give enough votes to a proposal to set benchmarks by which wood certified by other schemes besides FSC would qualify for LEED points. A letter from 14 environmental groups that FSC distributed during the voting argued that allowing SFI’s and related groups’ standards to qualify for LEED points would amount to sanctioning “status quo forestry.” SFI also urged voters to reject the idea, but for much different reasons. (Story)

Asked whether tacitly endorsing a number of certification schemes would open it up to criticism, Hannan replied: “I understand people may have different opinions about that. We think it doesn’t make sense to pick one program only. For us, we think that’s the right approach.”

AF&PA said it plans to report the industry’s progress through an annual report on paper recovery and a biennial report on sustainability.

This article was originally posted on ProSales Online.

Japan Earthquake Unlikely To Affect N. American Timber Prices for Months, Experts Say

Thursday, March 24th, 2011

Aside from a runup in timber companies’ stock prices, the earthquake and tsunami that devastated northern Japan are more likely to have a long-term than a short-term influence on the price and availability of North American lumber, a number of experts tell ProSales.

One of the unknowns is when a devastated Japan will be able to get back into a position to rebuild, they say. Another is whether Japan will revise its building codes in ways that will favor North American lumber. And a third involves how timber companies will weigh potential opportunites in Japan against already hot sales in China.

Japan imported $10.4 billion worth of wood products last year, putting it No. 3 on world rankings, Bob Flynn, director, international timber, for the RISI research firm noted earlier this month at a conference in Amsterdam. “Because Japan was already such a large import market for wood products, any jump in demand due to reconstruction efforts will have significant global impacts on the markets,” RISI reported. “Although the news media reports today that investors are already flocking to timber stocks because of this anticipated reconstruction effort in Japan, we caution that the timing of market impacts may not be so immediate. Given the scale of the damage to infrastructure in northeast Japan, it will likely take months before any meaningful reconstruction effort can be organized and implemented.”

Even when it does recover enough to be able to start rebuilding, Japan’s purchase patterns are likely to be slow and limited, the experts said. John Bavester of Progressive Affiliated Lumbermen, a Grand Rapids, Mich.-based co-op, noted that it took several years for rebuilding to take place in areas like south Florida and New Orleans after hurricanes Andrew and Katrina roared through. Some experts figured it will be a year before Japanese buying affects the market, just as it did after the Kobe earthquake in 1995.

Others noted that mills and dealers that handle southern yellow pine and eastern white pine are unlikely to see any impact at all, as virtually all of Japan’s North American imports involve West Coast timber in general and wood from British Columbia in particular.

“But, when the reconstruction effort does kick in, which suppliers are most likely to benefit?” RISI asked in its commentary. “Sawmills in Japan (outside of the region of damage) will no doubt try to accelerate production, and this will require increased imports of softwood logs. The United States and Canada accounted for over 70% of Japan’s softwood log imports in 2010, and it is logical to assume that suppliers in North America will see the greatest increase in demand from Japanese customers For New Zealand log exporters, Japan was only the fourth largest market in 2010 (trailing China, Korea and India) and Chinese buyers this year are again sucking up most of the available sawlogs in New Zealand. Japanese buyers had already turned away from Russian log suppliers, given the uncertainty and greater cost resulting from the Russian log export tax. While it is possible, given the magnitude of the situation in Japan, that buyers might decide to return to importing more Russian logs, it is most likely that the long-term, reliable log suppliers in North America will see the largest uptick in demand.”

RISI also asked rhetorically whether Canada’s sawmills will be able to accommodate a surge in demand from Japan given how much wood the Canadians are selling to China. It even asked whether Canadians will want to meet short-term demand from Japan at the expense of long-term sales to China.

Another long-term question concerns whether Japanese building codes and practices will change as a result of the earthquake. Typically, the experts said, every disaster such as an earthquake, tsunami, or hurricane teaches contributes to building science and ultimately leads to adjustments in codes. Some experts speculated that the latest earthquake would make Japanese more amenable to wood construction rather than building with concrete. If that happens, West Coast timber companies definitely would benefit.

This article originally appeared on ProSales Online.

Wood Production Hits Historic Lows

Wednesday, September 22nd, 2010

Sawmills in the western United States produced just 10.39 billion board feet (bbf) of lumber in 2009, 20% below 2008′s rate and the lowest annual production since the Western Wood Products Association (WWPA) began keeping statistics, WWPA announced Thursday. Meanwhile, southern production dropped 19.5% to 11.79 bbf, the lowest number since 1986, and imports shrank 30% to 8.9 bbf, the lowest since 1976.

Output from Western lumber mills has fallen 46% since 2005, and current output hasn’t been this low since 1982, when 13.7 bbf of lumber was produced, the WWPA said. It based its numbers on a survey of 170 mills in 12 states. The dollar value of 2009′s production fell 26% from 2008 to reach $2.69 billion. Five years ago, the 19.3 bbf of lumber those mill produced fetched $7.7 billion.

Overall demand for lumber totaled 31.3 bbf, less than half what it was in 2005, the Portland, Ore.-based WWPA said. And of that total, the amount of wood used for residential construction dropped in 2009 to 7.3 bbf vs. 27.6 bbf in 2005.

Look for Lumber Prices To Sink Soon –Economist

Tuesday, April 27th, 2010

Lumber prices are near their peak and likely will begin dropping “fairly sharply” in May or June, a veteran timber economist predicted today.

Paul Jannke, a principal of Forest Economic Advisors, said the three key factors that powered the recent runup in prices–modest rises in consumption, low inventories at dealers, and wet weather–all are short-term phenomena. The North American timber industry’s latent production capacity “far outstrips any rise in the level of demand for the next few years,” he said in a webinar sponsored by Citi Investment Research & Analysis.

“In May, perhaps June, we’re going to see prices come off, and come off fairly sharply,” he continued.

After years in which lumber prices were as low as just about anyone can remember, they have shot up in the past 12 months, particularly since January. Random Lengths’ framing lumber composite price as of April 23 stood at $365 per 1,000 board feet, up 72% from a year ago, while its structural panels composite price was 91% higher at $463 per 1,000 square feet.

Jannke, who has spent 15 years studying timber markets, agreed that the rise in consumption lately has boosted demand. But what’s more important, he said, were the extreme low levels that building material dealers and suppliers have been carrying lately. Those parties reduced their stocks by roughly 4 billion board feet, he said, so just replenishing their stocks in anticipation of the spring building season would have caused an upsurge in calls to mills.

In addition, wet weather in the South and the usual fallow period that comes with the North’s spring thaw meant that timber companies couldn’t go into the woods when demand began to rise, Jannke said. But now the timberlands are drying out, so that factor will evaporate, and buying this summer will be done with an eye toward construction projects starting around September, when construction activity begins to taper.

Adding to these factors is the tremendous latent capacity in the industry, Jannke said. He noted that mills that ran two to three shifts per day during the housing construction boom are down to just one shift a day, if they’re open at all. It takes months to open a mothballed mill, he said, and six months to open a mill that was totally shut.

At the same time, reduced consumption has meant harvests trail the growth rates on North American timberlands. In fact, Jannke noted, nearly a full year’s worth of harvest will be deferred between 2008 and 2012.

“The fiber’s available,” he said. “That’s another factor why prices in 2011 are likely to be … within a 5% range of where we are this year.”

Looking deeper into this decade, Jannke noted there’s sustainable demand for up to 1.7 million new units of housing in the United States this year; last year’s starts rate was not even one-third that level. The industry isn’t tooled up yet to supply the lumber needed for such volumes, but by mid-decade it should be. However, it might come from different places than it did a decade previously.

British Columbia, which supplies 20% to 25% of the lumber used in North America annually, suffered peak annual damage from the Mountain Pine Beetle in the middle of the last decade. Given that beetle-kill wood can be turned into lumber for up to about 10 years afterward, British Columbia’s productivity likely will drop by about 3 billion board feet starting around 2015, he said. Meanwhile, other factors have already led to reduced production from Eastern Canada, which also supplies just over 20% of North American. lumber demand.

As a result of those drops, there will be increased demand for lumber from the U.S. Pacific Northwest and the South, Jannke predicted. For both regions, “We’re going to see very solid pricing in the middle of the decade,” he said.

This article originally appeared on PROSALES Online.

Building Product Prices on the Rise

Wednesday, April 21st, 2010

Although home prices continue to fall and sales of new and existing homes are up only slightly this year, manufacturers are ratcheting up prices of building products and materials, according to industry analyst Ivy Zellman.

“Wallboard, concrete, and lumber are all going up,” Zellman told several hundred people attending an Urban Land Institute conference in Washington, D.C., Tuesday. Zellman has been a home building and building products equity research analyst since 1992. “Building product manufacturers are pushing hard and homeowners are going to feel the squeeze.”

Zellman said that four large manufacturers that she surveyed recently but declined to name are making 20% profit margins, although sales of existing and new homes are at their lowest levels in decades. She said that even though manufacturers have “lots of capacity,” she expected prices to continue to rise as the housing industry recovers from the recession. – Jean Dimeo

Coming Soon: Peak Lumber?

Wednesday, March 31st, 2010

You’ve heard of “peak oil,” when the world starts consuming more oil each year than it can add to its discovered and proven oil reserves in the ground. Well, now there’s “peak lumber” — not everywhere, but at least in the Canadian province of British Columbia. The reason? Beetles. That’s according to a study released last week by a research team from three Canadian consulting firms in the timber industry.

“A new report on the mountain pine beetle epidemic describes it as one of North America’s largest natural environmental disasters that will put an estimated 16 major sawmills out of business in B.C. and lead to long-term lumber shortages in the United States,” the Vancouver Sun reported on March 18 (“Pine beetle epidemic will have continent-wide economic impact: report,” by Gordon Hamilton). “Canadian lumber production is not expected to recover for the remainder of the century, one of the report authors said.”

The full report, authored by experts from International WOOD Markets Group Inc. (in Vancouver), Management Decision and Technology Ltd. (in Ladysmith, B.C.), and Murray Hall Consulting (in Maple Bay, B.C.), is only available to subscribers (view a PDF brochure here). But the broad outlines are clear from press reports such as this story on bclocalnews.com (“Forest future gloomy: 100 Mile better shape,” by Joan Silver). “After some expected gains in the lumber markets between 2010 and 2013, the B.C. Interior lumber industry will need to begin reducing production and/or closing mills, and this impact on the U.S. market will soon be profound,” said study co-author Russell Taylor, adding, “It’s not doomsday, but it’s a bitter pill to swallow.” Co-author Gerry Van Leeuwen said, “The end result appears to be an almost 50 percent reduction in the long-term timber harvest and lumber production in the B.C. interior from its peak in 2005 — all from the mountain pine beetle epidemic.” In the short run, industries that rely on biomass and wood waste, such as wood-burning electric generation facilities or wood-based ethanol producers, may benefit; but in the long run, even those industries will be hurt by a drop in supplies of sawmill byproducts like chips and sawdust.

In the U.S., prices will likely rise. However, that effect will be moderated by industry trends toward the more efficient use of lumber. Value-optimized framing methods can reduce framing lumber requirements in a typical house by as much as 30% (see “Frugal Framing” in the February 2007 issue of Builder magazine). And for big members like floor joists and rafters, there’s always LVL and wood I-joist lumber. Weyerhaeuser, a major LVL supplier, has closed i-Level facilities in Southern and Western states in 2009 in an effort to adapt to slumping demand. But when demand returns and prices rise, companies like Weyerhauser are well equipped to meet the need from Southern and Eastern timber — produced by trees that are still putting on wood right now. (Trees, apparently, pay no attention to the economy.)

But for British Columbia, this is a catastrophe. This YouTube video explains the science reasonably well: climate change is bringing warmer winters to the region, allowing the bugs to overwinter and expand their range. As the beetles overpopulate the forest, what was a nuisance pest has become a forest killer. (The threatening, apocalyptic music in the video wasn’t really necessary — the plain facts alone are bad enough.)

This article originally appeared on Builder Magazine Online.