PRINCIPAL'S NOTE

The Facts About Toxic Drywall

During the construction boom at the beginning of this decade the construction industry experienced shortages of many construction materials and began to import products from around the globe. In the last year, we have begun to discover the ramifications of importing some of these products. The most talked about is Chinese-manufactured drywall containing high sulfur content and found to cause a threat.

As construction materials ran short, contractors began ordering materials from around the globe in an effort to meet demand. Cement from Brazil was being off loaded in Florida at a rate of 1 million pounds a day. Roofing materials were being imported from across the world. Drywall began streaming into the US from China. Further increasing the demand for imported goods was its low cost. Often, imported goods were able to compete with US produced products, even with the added costs of shipping.

This supply and demand issue set the stage for the introduction of Chinese-made Drywall into the US.

The Toxic Ingredient
In an effort to lower costs and increase production, some Chinese manufacturers began adding ‘Fly Ash’ and other ingredients to their products.

Fly Ash has nothing to do with buzzing pests - it is a residue of coal combustion and has been used successfully in the US for decades as an admixture in concrete design as a supplement for cement. The ash is added into concrete as a replacement for some of the cement making the concrete more affordable, while still maintaining structural qualities. Once the Fly Ash is integrated with the mix it hardens with the concrete and solidifies.

Coal contains a small percentage of sulfur and other minerals. When burned and consumed these minerals remain in the ash. When used in concrete mixes, the minerals do not escape when solidified. However, in the production of drywall, the use of Fly Ash does not result in solid form and can escape in the form of gases. These gases can be toxic.

First Indication
The first indication of potential toxic drywall problems began in Florida, Alabama and Virginia, which all experienced peak construction during the boom years from 2004 to 2007. It was not until August 2008 that the Environmental Protection Agency (EPA) was officially acknowledging the problem.

After an extensive investigation, the bulk of the known problems with tainted drywall was traced to a manufacturer called Knauf Plasterboard Tianjin Co. Ltd. Initially, the company refused to take any blame and said the toxic drywall came from another unnamed company. As the problem grew and testing began, the company acknowledged that it had shipped some bad drywall, but identified a single gypsum mine in Tianjin, China, which is no longer being used as a material source. Unfortunately, early indications are that the problem may not be limited to just this mine or manufacturer.

The Toxins
The toxic drywall has been found to contain significant levels of several chemicals believed to be harmful or damaging including:

• Iron disulfide
• Hydrogen sulfide
• Sulfuric acid
• Sulfur dioxide
• Carbon disulfide

Recently completed studies by one environmental testing firm found that hydrogen sulfide gas is the essential component that causes copper and silver corrosion, which is believed to be causing corrosion of other building materials such as electrical and mechanical components, but may also effect interior finishes and furnishings. In November 23, 2009 a report issued by the U.S. Consumer Product Safety Commission (CPSC) concluded that there is a higher rate of corrosion in the complaint buildings where Chinese manufactured drywall products are present.

How To Tell If You Have Toxic Drywall
There are some telltale signs that your building’s walls may be tainted from toxic Chinese drywall:

• The smell of sulfur, often likened to rotten eggs.
• Corrosion on metal faucets, drains, mirrors, picture frames and even jewelry. Visible signs include pitting or any kind of spot or discoloration.
• Corrosion on copper in your building. Visible signs including the darkening of the copper.
• Failing or poorly working appliances, especially if they are relatively new.

Respiratory Health and Toxic Drywall
With conclusive evidence that Chinese-produced drywall is responsible for structural failure of affected buildings, the next logical question is the health of the inhabitants. There are still several ongoing tests and studies being done to determine the danger due to exposure from tainted drywall. While there is no conclusive evidence of related respiratory illness, it may still be advisable to take certain precautions if you are in a building affected by toxic drywall. These steps include:

• Keep windows open as much as possible, or spend time outdoors in fresh air.
• Keep inside temperatures as low as possible, but comfortable for occupants.
• Run the air conditioner or a humidifier.
• Get your drywall tested!
• No smoking, specifically no smoking in the affected building.

ABB Forensic Services
ABB has experience with toxic drywall investigation, litigation support and remedial repair assistance. ABB has specialized equipment that can perform non-destructive testing of your drywall. If your building is exhibiting any symptoms of toxic drywall, please call ABB for a complimentary initial assessment.

Check out: http://www.abbae.com/chinese-drywall.html

EIFS 101

Have you always wanted to know more about EIFS and how it works? Wonder if it’s a good fit for your project? Here are some of the most common questions answered by ABB’s in-house certified EIFS experts.

What is an EIFS system? Are there geographic limitations to its use?
Exterior Insulation and Finish Systems (EIFS) are a type of building cladding commonly used on both commercial and residential structures. Originally developed in Europe after World War II as a means of repairing bomb damaged masonry buildings, today’s EIFS is substantially different. It is recognized more as a North American development, where it was first applied to framed and sheathed walls, instead of masonry or concrete.

EIFS provides both weather resistance and architectural appeal. Basic EIFS is a thin “lamina” of cementitious material applied directly over a fiberglass “screed”. This is applied over rigid foam insulation which is attached to sheathing such as exterior rated gypsum board. Preferably, a waterproofing barrier is applied to the exterior sheathing prior to application of the EIFS.

Occasionally you will hear EIFS referred to as synthetic stucco; however, EIFS and traditional stucco are very different so it is important the two are not confused.

There are no significant limitations to where EIFS can be used. It works in most climate types and conditions, provided the appropriate type is selected and is properly installed.

What is the advantage of using an EIFS system?
Economics play a major role in selecting an EIFS system over another type of exterior cladding. In addition to being typically less expensive, it is also readily available. The cementitious lamina is mixed on site and field applied, so there are less transportation costs involved. In comparison, other types of cladding systems need to be ordered with a significant amount of advance notice and cannot be built on-site. Most of the foam insulation used in EIFS assembly can be locally sourced, again providing economic benefit. EIFS also gives designers and installers increased flexibility and creativity without breaking the bank; it is architecturally easy to work with. Lastly, EIFS improves energy efficiency as compared to some other systems. The increase in energy efficiency continues to be one of the driving forces behind EIFS popularity.

How do you determine which type of EIFS system will work best for a particular project?
The answer here truly is "it depends". Decision-making factors are the owner’s goals and budget, there is no single solution for all situations. Specific systems vary from manufacturer to manufacturer but EIFS can generally be condensed into four basic categories:

What are the cons or caveats to using an EIFS system? What types of projects are best suited for EIFS? Under what circumstances would an EIFS system not necessarily be the most effective choice for a building?
EIFS can be a very effective system for almost any low or mid rise building and is cost effective. However, anytime you rely on 1/8” of cement over foam to keep water out of a building things can go wrong. Barrier EIFS and DEFS systems have no backup, so if there are any problems, water is going directly into the wall cavity. This causes corrosion, premature failure of components, and worse yet, mold. EIFS systems are theoretically trying to emulate traditional stucco at less expense. But if you think about it, stucco systems always have a weather resistive barrier as a back-up. In fact, it is a building code requirement for stucco systems. With this in mind, our firm never recommends using DEFS or a standard barrier EIFS because they have no WRB backup. Instead, we always recommend owners use a water-managed EIFS assembly thereby making it an effective choice to protect their investment.

Many reports describe problems with moisture buildup in an EIFS system. What causes these problems in an EIFS system and how can they be prevented?
To be fair, water intrusion into buildings is a problem with many types of cladding systems, not just EIFS. Moisture buildup in wall systems is especially prevalent in regions with hot and humid climates regardless of the type of cladding. Moisture problems can be associated with material defects and design errors; however, the overwhelming majority of these problems are caused by construction defects and poor craftsmanship. This is particularly true of DEFS and classic EIFS since there is no WRB as a back-up. Even the smallest of construction errors can allow water directly into the wall cavity. The good news is prevention can easily be obtained. If expired material arrives at the job site, reject it. Consult with knowledgeable designers and building envelope specialists. Insist on quality and be sure to include a quality assurance program in your project.

From a contractor’s standpoint, what must be done to ensure that an EIFS system performs successfully?
Construction is a tough business and translating design intent from “mouse clicks” to “bricks” is often a dilemma for contractors. It is not an enviable position and we respect the challenges they face. Nonetheless, installing EIFS (or anything else) correctly and in compliance with the construction documents is ultimately the contractor’s responsibility. If we could offer one piece of advice to contractors, it would be to invest in better training for your crews, and then as a follow up, hold your craftsmen accountable to installing a quality product. It has been our observation over the years that this is single-handedly the biggest thing contractors could do to improve the performance and reduce risk.

Any reassuring words for owners/developers who are considering an EIFS system?
First, don’t be afraid of EIFS. It is a perfectly acceptable cladding system. That said, do your homework. As you can see from our comments above it is more complicated than it may appear. Always use a water-managed EIFS system that incorporates a weather resistive barrier as a back-up. Second, get your designer or a third party to provide observations in the field to verify the installation is in compliance with the construction documents and manufacturer requirements. Since most construction defect litigation is attributable to poor craftsmanship, this is the single best thing owners can do to protect their investments. Last, plan for and resolve your warranty and insurance concerns at the front end of the project. Comprehensive labor and material warranties are available from the EIFS manufacturers, but you have to ask for them in advance!

ABOUT ABB

Allana Buick & Bers, Inc. (ABB) s dedicated to providing comprehensive and innovative consulting services with award-winning expertise in building envelope design, architectural engineering, energy efficiency and construction management. ABB is customer-focused, providing expert advice using advanced technologies for time-enduring solutions. This publication is published several times a year. For more information, call (800) 378-3405 or email bd@abbae.com.

Contributing Writers: Karim Allana / Dana Bergeman / Bradley Kempthorne

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