Lightweight Concrete MasonryNovember 16, 2009

OutlineProperties and Benefits of Lightweight Concrete MasonryLightweight Concrete Masonry Markets Market share Lightweight OpportunitiesThe Future

LW-CMU PropertiesFire rated Energy efficient – higher R value, makes insulation more efficientSound absorption – 2X NW CMUHigh strengthLow shrinkageLow absorptionSharp edges and corners

Benefits of LW CMUDesigner benefitsOwner benefitsMason contractor benefits

Designer BenefitsFire resistanceHigh strength to weight ratioEnergy efficiencySustainable design

Sustainable DevelopmentLightweight Concrete Masonry and Green BuildingsLEED Certification with Lightweight CMU LEED Credits can be earned in 3

categories Materials and Resources Energy and Atmosphere Innovation and Design

Owner BenefitsHigher qualityLower installed costLower life-cycle cost

Higher QualityBetter fire resistanceGreater energy-efficiencyMore design flexibility Fewer shear walls More and larger openingsGreater comfort and safety for occupantsIncreased worker productivity

Initial Wall Costs

Heavy Weight SmartWall Systems

Block

Direct Labor

Fixed Labor Overhead

Block Delivery

Total Initial Wall Cost

Paint & Waterproofing

Medium WeightLightweight

Total Life Cycle Wall Costs

Heavy Weight SmartWall Systems

LCC Energy Savings

Total Wall Cost

Structural Efficiency

Improved Fire Resistance

Initial Wall Cost

“Typ.” Lightweight Lightweight

Mason Contractor BenefitsLighter weightIncreased efficiencyMore production with less effortImproved competitiveness for masonryMore jobs

Why is this man smiling?

Lightweight Concrete Masonry

QualityValueEnergy EfficientFire SafeLabor-friendly

Concrete Masonry Units ASTM C90Classification

Light-weight

Medium Weight

Normal Weight

Density <105 pcf 105-125

>125 pcf

8X8X1612X8X16

<30 lb<40 lb

32-35 lb44-48 lb

36-38 lb50-54 lb

Productivity vs. Weight

Lower WeightBenefit – less effort

Example – 200 units/day MW (32 lb) - 6400 lb. LW (27 lb) - 5400 lb. (1000 lb. less /

day) (16% reduction)

Lower WeightBenefit – increased efficiencyExample – 200 units/day + 15% increase, or 230 units/day MW - 6400 lb. (@ 200 units/day) LW - 6210 lb. (190 lb. less / day) (3% reduction)More production with less effort!

Labor Savings Productivity Means

Faster Completion >> Quicker Occupancy

Lower Direct Labor CostsLower Contractor Overhead Costs

Better Ergonomics w/ Lighter UnitsLess Fatigue & Fewer InjuriesLower Workman’s Compensation

Increased ProductivityDoes NOT mean working FASTERDOES mean less fatigue permits the mason to maintain his/her NORMAL pace longer Result: More production with less

effort Benefits are even more significant

with 10-inch and 12-inch units

Improved CompetitivenessInstalled wall cost is driven by labor cost 3:1 Labor:block costAs block weight is reduced, installed cost is reducedSome of the cost saving goes to lower bid pricesLower bids make masonry more competitive vs. other wall systems

More JobsLower bid prices mean more projects for masonryMore projects mean more jobs!

OpportunitiesMason Contractors Will recognize productivity benefits Will recognize safety benefitsExamples Minneapolis, MN Atlanta, GA Lansing, MIShould reflect reality in bids and Wall Cost Guides

OpportunitiesArchitects Will specify lightweight to get the

benefits Will allow lightweight substitution Will look for promised cost savingsExamples Minneapolis, MN Atlanta, GA Lansing, MI

The Future

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