Innovative Column Options for the 21st Century - Ron Blank

Innovative Column Options for the 21st Century

Course Number:

hbg06c

HB&G Building Products

Tim Bobo

PO BOX 589

1015 Brundidge Blvd.

Troy, AL 36081

800-264-4424

334-670-6512

[email protected]

www.hbgcolumns.com

An American Institute of Architects (AIA)

Continuing Education Program

Innovative Column Options for the 21st Century Credit for this course is 1 AIA HSW CE Hour

© Ron Blank and Associates, Inc.® 2006

Please note: you will need to complete the conclusion

quiz online at RonBlank.com to receive credit

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professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement

by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.



Course Format: This is a structured, web-based, self study course with a final exam.

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Discover the innovative column options that are available

today and the variety of materials that are used to create this

classic product. Learn about the current trends that have

affected columns in the construction industry.

Course Description

Become aware of the column design options and the materials they are made from.

Describe the manufacturing process for column materials.

Explain the construction process of the different column material options.

Identify the characteristics of the materials used in column construction.

Explain the current trends and construction standards that have affected column design in the construction industry today

Upon completion of this course the Design Professional will be

able to:

Course Objectives

Columns and the Materials They are Made From

Weatherability

Application

Ease of Installation

Warranty

Quality

Price

Things to Consider When

Selecting a Column:

The five classical orders are:

• Tuscan

• Doric

• Ionic

• Corinthian

• Composite

Since ancient Greek and Roman

times, columns have signified

importance and power. During

these times, decorative columns

were strictly made of stone and

are still impressive today

His

tory

Columns and the Materials

They are Made From

An

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Prestige Facade Entry

His

tory

Pantheon Temple of Athena Roman Coliseum

Today, columns are made from a variety of different materials, and are

one of the most important millwork elements in the residential building

industry. Drive through any residential development and it seems like

columns are on every other house.

Example: Current day residential USA. Notice the resemblance of Greek and Roman ideology in modern day architecture.


They are Made From

The majority of current day columns are made from five basic materials:

• Wood

• Aluminum

• Fiberglass

• FRP (Fiber Reinforced Polymer)

• Stone

Let’s review these materials independently, to understand the history, manufacturing, and installation procedures required for each.

His

tory


They are Made From

Throughout history wood has been the

material of choice for millwork use.

Alternative options did not become

available until the 1960’s. Wood columns

were first introduced to America with a style

of architecture known as Neoclassicism

(circa 1780’s).

Today wood columns, as well as most other

wood millwork elements are being surpassed

with the new synthetic products. Most

column manufacturers would agree that

wood is a small percentage of sales to what

it was only 20 years ago. Wood columns can

be found in any shape, even their knotted,

twisted natural form.

Wood Columns H

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Strips of wood called staves are cut to the desired length of the column.

The strips are notched on each side to allow them to be placed together.

Glue is applied between the staves, and a band is place around the

attached staves. The glue is then allowed to dry.

Wood Columns M

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The manufacturing process of round wood columns is a fairly straight forward process.

1 2 3 4

Once dry, the bands are removed and the column is placed on a lathe.

During this process the column is turned on the lathe, and the column

becomes smooth, close to the look of the finished product. Once the

column is turned, some light patch work is performed, and the column is

ready to be packaged.

Square wood columns are simply four boards, some with surface

etchings, that are glued and nailed together on the job sight.

Wood Columns M

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5 6

Let’s take some time and look into the installation of round wood columns.

Step 1 - Measure full opening less the height of the cap and base. Columns must be installed on level surface or shimmed to level. To get the

height of the cap and base simply place cap on top of base and

measure.

Step 2 - Locate saw kerft at top of column and trim using hand saw or circular saw. Sand or rasp smooth to guarantee even contact with

capital.

Step 3 - Measure from newly trimmed top of shaft to desired length placing marks every inch around column. Next, place a mark around

shaft using a straight edge (something that will bend).

Step 4 - Trim column with a hand saw or circular saw. Slowly rotating column will insure a level cut.

Wood Columns In

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Step 5 - For exterior applications, paint inside of column shaft with non- fibrous, asphaltum- type roof coating. Application must reach a minimum

of 4’ up column shaft. Next, paint the bottom end of shaft with an oil base

wood primer. Also paint top end of column with oil base primer.

Step 6 - Using a jack post lift beam, remove existing column or post. Beam should not be lifted more than ½’’ inch.

Step 7 - Determine top centerline and mark on beam using a straight edge. Next, hang a plumb line from top center line to determine bottom

center line. Mark center point of column. Using a large square, draw a

center line perpendicular to the outside edge of substrate. Draw another

line parallel to outside edge.

Step 8 - Place marks at center line of all four sides of each capital and base. When installing shaft, capital and base, all four sides will line up

evenly insuring a perfectly aligned column.

Wood Columns In

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Step 9 - Center base on bottom of column shaft and apply using nails or screws. Place column shaft with applied base into place and align base

with marks.

Step 10 - Center capital on column shaft and align with marks. Toe nail or screw through shaft into capital. Nail or screw through capital into beam in

4 corners of capital. Nail or screw through base into substrate in 4 corners

of base.

Caulk seam at top of column shaft and at bottom. Use a high quality paintable exterior caulk for best results.

The proper painting of wood columns must be met to comply with manufactures warranty. When using wood columns for exterior use, the column must be painted with a high quality oil base primer and top coat.

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Aluminum Columns

Aluminum is the most abundant

element in the Earth’s crust and

constitutes 7.3% by mass. Aluminum

was discovered in 1808 by Sir

Humphry Davy and today is produced

more than all other nonferrous metals

combined.

Aluminum was introduced to the

construction market in the mid- 1960’s

and is featured in a variety of different

millwork applications including siding,

rail systems and columns. The

following picture showcases

aluminum columns in every day

applications.

His

tory

Aluminum columns are produced by a process known as sheet and plate. Sheet and plate manufacturing occurs when aluminum is passed between rolls under pressure. When the raw aluminum is rolled, it becomes thinner in the direction in which it is moving. Sheet is the most widely used form of aluminum.

Construction applications also include siding and gutters. The following pictures show the sheet and plate process; Picture one is the raw aluminum billets. Picture two showcases the rolling machine rolling the billets into a sheet form. The last pictures shows aluminum once it is rolled.

Aluminum Columns M

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Although available in pre-manufactured shafts, aluminum columns are traditionally sold in sheet form with locking or mechanical joints. These columns are generally acceptable to load bearing or wrap around installations. To assemble an aluminum column in a load bearing application:

Step 1- measure the required height and cut aluminum staves with a hacksaw prior to assembly. ( add ¼ inch to measurement for new construction and subtract ¼ inch for wrap around construction.

Step 2- assemble staves by rotating together Step 3- assemble final interlock by rapping with the hands, starting at one

end of the column. For a wrap around assembly steps 2 and 3 are preformed around support.

Aluminum Columns In

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Step 4a- cut base with a hacksaw along diagonal, splitting lugs on underside of base. Place ½ of split base around column, so edge is parallel to edge of structure. Fasten column top and bottom with two angle brackets.

Step 4b- Place second ½ of split base and cap around column and drill three 1/8’’ holes through base and cap and into column, in line with ribs. Fasten with screws as in figure 5b supplied in base of master carton.

Step 5a- For Primary Support slide cap and base on column ends. To avoid scratching of column, slide base on until bottom is flush with end of column. Raise structure ½’’ to permit plumb installation of assembled column. Lower structure to secure column.

Step 5b - Drill three 1/8’’ holes through base and into column, in line with ribs. Fasten with screws supplied.

The normal weight of the porch roof is enough to hold the columns in place. In a coastal area special fasteners such as rods or cables may want to be used.

Aluminum Columns In

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In 1880, Herman Hammesfahr was

awarded a patent for a type of

fiberglass cloth. As early as 1942,

Owens-Corning was producing

fiberglass airplane parts for the war

effort. Fiberglass is fairly new to the

architectural world and was first

introduced to millwork in the 1970s and

is used in ornament, molding and

columns today. Fiber-wound fiberglass

is the first generation of synthetic

columns, not to be confused with fiber

reinforced polymer (FRP) columns that

we will discuss later. Fiberglass columns

are generally thin wall shafts, light in

nature, and are characterized by a slick

exterior finish, similar to modern day

boat hulls.

Fiberglass Columns H

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Fiberglass columns are manufactured using a filament winding process.

During this process, continuous glass fibers, epoxy and/or resin, are spun

up and down a column shaped lathe in two directions at 90 and 45

degrees (notice this process in the first two pictures). This allows for

strength, durability and the light weight nature of fiberglass columns. The

epoxy or resin is the glue that holds the glass strands in place and

provides a workable finish (bottom right picture shows the fiberglass

column once the spinning process is complete).

Fiberglass Columns M

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In 1936, Carlton Ellis of DuPont was awarded a patent for polyester

resin. Resin was introduced to the construction market in the early

1990’s and is used mainly for columns and some large décor. Resin is

the main component in FRP columns. As mentioned earlier, FRP

columns differ from fiberglass. FRP (Fiber Reinforced Polymer)

columns can also be specified as GFRC (Glass Fiber Reinforced

Composite), using ¼ to ½’’ chopped fiberglass as a tensile

reinforcement, not as a structural component. The following pictures

show resin columns in the field.

FRP Columns H

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FRP columns are manufactured by a process know as spun cast.

During the spun cast process, the resin material is spun inside a mold

housed by a cage. Centrifugal force takes the resin to the outside of

the mold. The process starts with a positive mold made from wood or a

polymer product. (left.) The negative mold is made from the positive

mold. (middle.) The bottom right picture shows the cage that houses

the negative mold.

FRP Columns M

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FRP Columns

The FRP composite (containing resin, filler, chopped glass, and a

catalyst) is poured into the mold and allowed to spin. It typically

takes around 15 minutes to spin an 8x8 FRP column. Larger columns

take a greater amount of time.

After the spinning process is complete, the mold is then opened,

and the shaft is allowed to cool. (note center picture.) Keep in

mind, resin columns are a chemical reaction between the plastic

and catalyst producing heat. After cooling, the column is taken to

the finishing stage where it is patched, sanded, and packaged for

shipping. Bottom right picture shows a typical finishing procedure.

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When installing FRP, as well as fiberglass columns,

Step 1- measure the opening in four places; front, back, left and right. Mark column accordingly. If column is too long, shorten length from

bottom.

Step 2- Use an abrasive saw (masonry or carbide tip blade). Fine trim top and bottom with rasp to assure flat surface contact.

Step 3- Slip base over top of column shaft and allow to slide to base of shaft. Slip cap over shaft and allow to rest on neck mold. Some

sanding may be required.

Step 4- Apply construction adhesive to top and bottom surfaces of column.

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FRP Columns

Step 5- Put assembly in place and plumb. Make sure load is centered over column shaft and evenly distributed around the bearing surface.

(Ensure concentric loading of the column 100% of bottom must contact

substrate and 75% of the top)

Step 6- Mark and drill holes in floor and column shaft for corner brackets. Install brackets at bottom and top of column.

Step7- Apply construction adhesive to top of cap, press against structure, and screw or nail into place.

Step 8- Also apply construction adhesive to bottom of base and nail or screw to floor. Cap and base will cover up angle brackets on column

shaft.

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FRP Columns

On square FRP columns, the neck mold is mitered and glued with

construction adhesive and screwed to the column shaft. Cover

screw holes with latex caulk. Resin and fiberglass columns can also

be split to wrap around existing load bearing structures, and once

split, are not load bearing.

FRP columns require priming and finish painting. Most column

manufacturers recommend a high quality latex primer and finish

coats per paint manufacturer’s recommendations.

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FRP Columns

Stone Columns

Cast stone is basically a manmade limestone and dates back to around

500 BC. Structures from the Roman Empire were built using cast stone

parts and are still in existence today. Cast stone columns are primarily

used in upper scale homes, commercial buildings, and churches. This is

because of the higher price associated with cast stone columns. I will

discuss this further when we cover column comparisons.

His

tory

Cast stone columns are produced by mixing crushed stone that has been

compressed under extreme pressure into a pre-designed shape or form

to create a man made limestone. The process is called hand-forged

stone. This process is very similar to that used when a child builds a sand

castle, by pressing moist sand into a bucket, only on a much more

permanent scale. The final result of the process is a hand forged

limestone that is very difficult to distinguish from natural limestone. Top left

picture shows the making of the mold.

Once the mold is made, the aggregates used are washed, screened,

graded, tested, and placed in a bin. (top middle picture)

During the mixing process, the aggregate is ground until every particle is

surrounded by Portland cement. Mineral oxides are added to achieve

the desired color (top right).

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Stone Columns

In the casting stage, the mix is placed into a mold and vibro-tamped

by machine to include every detail of the mold (bottom left). The curing

stage is the last step in the order. During this time, hot steam, carbon

monoxide, and carbon dioxide are applied to speed up the curing

process (bottom right).

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Stone Columns

Stone Columns

Cast column installation is quite simple, yet very time consuming

and requires a good mason. From a clean, level and structurally

sound substrate, assemble cast pieces from the bottom up. Each

component is anchored to the adjacent piece with a combination

of pins and epoxy and/or mechanical fasteners. A ¼” mortar joint

is required when fitting all pieces together. As you move vertically,

pins should be drilled and epoxied into each piece and stacked

on top of one another.

¼” spacers will assist in maintaining

the required mortar joint. Each layer

is also fastened to the structural post.

Fasteners are available for almost any

application.

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Stone Columns

Wood, two steel spacers, and concrete are indicated in the bottom middle photo. The process described should be repeated for all remaining pieces. A

few finishing notes need to be pointed out.

Most manufactures require a variation of 3 finishing requirements:

(1.) Extreme care should be taken to cover and seal the top of the column if it is exposed to weather and elements.

(2.) When joints abut other materials, a sandable caulk should be used

instead of grout to eliminate excessive cracking during expansion and contraction of the adjacent materials;

(3.) A sealer should be applied to all exposed surfaces according to manufacturer’s recommendations

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Comparison of Materials

Wood Aluminum Fiberglass

FRP Stone


So far we have explored the manufacturing and installation

processes of the different column materials. The next couple of

slides will showcase the comparison between column

materials with a series of graphs and field pictures, both good

and bad. All of today’s column materials have their

advantages and disadvantages. One material might be strong

in a certain area but weak in another. The following

characteristics all need to be considered when specifying a

column.

Wood columns have the look, feel and versatility, but lack the

durability. With wood, rotting and warping are quite common

unless proper installation and upkeep are met.

Aluminum columns are lightweight, easy to install, and prefinished.

With aluminum however, appearance and proportion are not

always correct. Aluminum columns also scratch and dent fairly

easy.

Fiberglass columns are rot and insect resistant, lightweight and

have an appealing price. On the downside, fiberglass columns

have a thin wall that bring structural integrity and durability into

play. Because of the slick finish associated with fiberglass, the

columns can be difficult to paint.


FRP columns are also rot and insect resistant, carry a lifetime

warranty, and have a wood like feel. FRP materials were also one

of the first fire retardant elements to come out of the plastics

industry. On a negative note, resin columns have limited finishes,

and must be painted with a light color paint. Mold cost and

painting are also issues when working with resin columns. It can

cost upward of 10 thousand dollars to produce a new mold. All

dust must be removed prior to painting a resin column.

Stone columns have the authenticity and durability, as well as fire

retardant capabilities. With stone, cost, weight and installation time

are all negative factors to be considered.


Disadvantages

Advantages

Aluminum

Fiberglass

FRP

Wood

Stone

Lightweight, Prefinished

Ease of Installation

Rot and Insect

Resistant,

Lightweight

Rot and Insect Resistant,

Lifetime Warranty

Wood like Appearance, Fire Retardant

Limited Finish,

Mold Cost,

Painting

Look and Feel, Versatility Rot and Warping, Upkeep

Availability, Painting Methods,

Warranty

Appearance/Proportion,

Durability,Structural Integrity

Structural Integrity, Durability,

Wall thickness,

Painting

Authenticity, Durability Cost, Weight,

Non Load

Bearing Fire Retardant

Comparison of Materials C

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The pictures on this slide showcase

the importance of installing wood

columns properly. The bottom right

picture shows how the base on a

wood column is vented to allow for

proper ventilation. Top right shows

a base that was not vented and

how the column has deteriorated

as a result. The staves will separate

if the column is not properly vented

and/ or maintained. Improper

installation will allow moisture to

wick its way into the shaft, and the

column will rot from the inside out.

Comparison of Materials W

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With wood, rotting and warping is

inevitable unless proper

maintenance is met, as the top left

picture shows. Wood square

columns built in the field are also

common and tend to separate

very quickly. An 8x8 stone column

tips the scales at around 400

pounds and can split as a result if

not installed properly as the bottom

image demonstrates. Compare this

to a 8x8 FRP column that weighs

around 65 pounds, wood 35

pounds, and an aluminum column

at a feather weight of around 15

pounds.


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I want to point out some extreme characteristics associated with the

different column materials in the form of application pictures. The top left

picture shows an aluminum column and the lack of proportion. Notice how

the shaft diameter does not match the size of the cap and base. Top middle

also shows an aluminum column with the noticeable seam in the middle

and unsightly hardware holding on the base. Top right picture shows a

fiberglass column. Notice how thin the wall thickness is when compared to

the FRP column in the bottom left picture. The last picture shows paint

peeling on a FRP column. The only time paint will not adhere to a FRP

column is if the resin dust is not completely removed from the column.

Comparison of Materials A

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This slide showcases examples of FRP columns installed in the field. Top left

shows a column that is not concentrically loaded. Notice how the left side

of the column is not contacting the substrate. Top middle shows the same

column, and the cracks that have occurred as a result. Top right picture

shows how a resin column will also bow if not concentrically loaded.

Comparison of Materials FR

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Bottom left shows a square column that has not been properly cut to

match the substrate. Notice the shim at the bottom that has been installed

to make it work. This column will more than likely crack over time. Middle

picture shows a stone base that has been installed around a square FRP

column. This is not a recommended installation procedure. Over time, the

stone acted like an oven and caused the column to bow inward from

corner to corner. Last picture shows how to install a threaded rod in the

middle of a column if it is installed in a hurricane zone. This allows for

hurricane code, 120 mile per hour wind uplift. The rod runs through the

entire length of the column, and pulls the roof into the substrate. The

increased number of hurricanes over the last several years have raised the

standards of national building code, and columns are no exception.

Comparison of Materials FR

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3

3.5

Aluminum Fiberglass Wood FRP Stone Wood Site Built

In the construction business, time is money. Builders are seeking products

that install quickly and easily to reduce labor cost. This chart shows

installation time of the different columns and does not include finishing.

Wood site built columns are the most time consuming of the bunch, with a

time around 3.5 hours. Site built columns are wood square that are built and

installed on the job site. Aluminum columns are put together in staves and

take around an hour and a half to install. Resin and fiberglass columns both

come in one piece with separate cap and base. Both take about 45 minutes

to install. Both round wood and stone columns take around an hour and forty

five minutes to install. We consider stone installation time to be a very

conservative number taken from a stone manufacturer.

Comparison of Materials In

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20

40

60

80

100

Aluminum Fiberglass Wood FRP Stone

The warranty of a product is very important in today’s construction

market, and columns are no exception. Callbacks are the worst enemy to

the contractor that, in turn, can point back to the design professional. A

one year warranty is the norm throughout the industry on wood columns.

Aluminum and fiberglass both carry a standard 10 year warranty. Stone

and FRP columns are the leaders in the group with a standard lifetime

warranty.


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$0.00

$50.00

$100.00

$150.00

$200.00

$250.00

$300.00

$350.00

$400.00

$450.00

$500.00

Aluminum Fiberglass Wood FRP Stone

The retail price of an 8x8 aluminum column is around $ 85, the least

expensive of the bunch. Fiberglass comes in next with a retail price

around $120. Wood 8x8 columns retail around $135 followed by FRP at

around $150. Stone columns are very expensive and retail around $450.

FRP columns offer the look and feel of wood without the maintenance.

Comparison of Materials Pro

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Market Trends

In the early 1980’s traditional architectural forms reappeared in

mass with the idea of Urbanism. The idea of Urbanism portrays the

community as a whole. This translates into equality between all

demographics. Where the 1950-70 Suburban neighborhoods

sought space, particularly private rear lawns, as a feature of

necessity, Urbanism’s direction is toward the public street. Unity, in

lieu of individualism, is a primary focus. A front porch and columns

are a major factor associated with these developments. Someone

has done something right since Traditional Neighborhood

Developments, or TND’s, are appearing throughout the U.S. in

staggering numbers. The poster child for the TND movement was

Seaside built outside of Panama City Florida in the early 1980’s.

According to The New Urban News, today there are over 400

developments in 48 states, including Canada.

Other examples: Argon in Pensacola, in Florida, and The Waters

outside of Montgomery, Alabama.

The following slide displays images of these developments.

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Seaside

Argon The Waters

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“It Takes a Village to Lure Buyers Back to Town”

By JIM CARLTON, Wall Street Journal, March 8, 2006; Page B1

“Built to look like charming villages, with old architecture and

homes clustered within walking distance of a town center, only a

handful of TND communities were built from the 1980s to mid-1990s. But

now, roughly 500 of the communities comprising tens of thousands of

homes have now sprouted up across the U.S., according to estimates

by New Urban News, an industry trade publication in Ithaca, N.Y. Jim

Constantine, director of community planning for Looney Ricks Kiss

Architects in Princeton, N.J. projects as many as "20% to 30%" of all

new subdivisions will be TNDs in another decade.”

Market Trends

1. The Town Paper: www.tndtownpaper.com 2. Congress for New Urbanism: www.cnu.org

3. New Urban News: www.newurbannews.com

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http://www.newurbannews.com/

Hanley-Wood (Largest publisher of building related magazines and

home plans) annually publishes the BUILDER 1001 Plans from The Finest

Designers which details the best selling plans of the year.

Total of 1004 home plans from across the country

87% of the homes (875 plans) used columns (round and square)

A total of 6092 columns were used in these plans

37.3 % were ROUND

62.7% were SQUARE (including square posts)

25.6% (round and square) were used in the interior of the homes

Conclusion: 87% of the homes featured as top sellers across the U.S.,

ranging from $100,000 to $2-$3 million residences, continue to use columns in their design.

2005 Publication

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14%

23%

35%

49%

56%

0% 10% 20% 30% 40% 50% 60%

Landscape wall (avg.

length: 48 ft.)

Fencing (avg. length:

139 ft.)

Deck

Patio

Front Porch

In a recent National Association of Home Builders (NAHB) study, new

home buyers were asked what outdoor features were considered the

most important when purchasing a new home. As you can see from the

chart, almost 60% of the buyers polled considered a front porch to be the

most important outdoor feature of their new home. There is nothing like

the sense of comfort and peace a front porch can bring.

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PVC columns

PVC columns are an up and coming material in the column

industry.

PVC box columns are prefinished and available in preassembled

or wrap around applications.

PVC columns are non load bearing, wrapping around a structural

post and are ideal for remodeling or hurricane zones.

Preassembled columns are prebuilt around an existing structural

component.

PVC column’s can be manufactured to fit a variety of different

looks from panel square, to tapered square columns.

PVC columns are less expensive than comparable square

fiberglass columns and easier to install.

Look for PVC columns to become a major factor in the column

industry over the next several years.

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PVC Box Columns

PVC columns N

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Become aware of the column design options and the materials they are made from.

Describe the manufacturing process for column materials.

Explain the construction process of the different column material options.

Identify the characteristics of the materials used in column construction.

Explain the current trends and construction standards that have affected column design in the construction industry today

The Design Professional will now be able to:

Course Summary

Innovaive Column Options for the 21st Century

Course Number:

hbg06c

HB&G Building Products

Tim Bobo

PO BOX 589

1015 Brundidge Blvd.

Troy, AL 36081

800-264-4424

334-670-6512

[email protected]

www.hbgcolumns.com



Innovative Column Options for the 21st Century Credit for this course is 1 AIA HSW CE Hour

© Ron Blank and Associates, Inc.® 2006

Please note: you will need to complete the conclusion

quiz online at RonBlank.com to receive credit

Innovative Column Options for the 21st Century - Ron Blank

Documents

Transcript of Innovative Column Options for the 21st Century - Ron Blank