The Panel Man

Insider SIPs Tips

Hello Panelman readers! You might think I’d be tired of writing about panels by now; after all, it’s been two years since my first post! But I feel more energized than ever about the amazing advances in panel technology for both residential and commercial applications, especially when it comes to SIPs (structural insulated panels for any newbies to this blog). There are so many resources out there if you’re new to SIPS, but one of the best places to start (besides this blog, haha) is over at SIPA.

I recently had the opportunity to talk with the current owner of FischerSIPS, LLC, one of the founding members of SIPA, Damian Pataluna who shared his insider tips on why building with SIPs is a great choice! I’ve known Damian for a long time: He bought his structural adhesives from me when I was at Rohm and Haas. Today, he’s the owner of FischerSIPS, a leading SIPs manufacturer out of Louisville with dealers in 11 states and the capability to supply panels worldwide. I caught up with Damian and here’s what he had to say…

The Panelman Asks: How long have you been in business?

Damian Answers: FischerSIPS was founded 1986 by Fred Fischer. I came to work with Fred in April 1993 as a sales representative. Some of our early work was with panelized and modular homes built out of SIPs that were being constructed in the inner city of Louisville. One of the main benefits I immediately noticed was that SIPs provided housing that people could not only afford, but could afford to live in; it was really rewarding. Having that early, hands-on experience working with SIPs has been crucial in my ability to support contractors and builders today. In 2004, I became a part owner; in 2006, I became THE owner of FischerSIPs. That was around the time we started manufacturing in our new SIPs plant: everything from OSB to magnesium oxide panels, cement skin SIPs to dry wall SIPs. In fact, my current 20,000SF plant is made with 4 ½” SIP Walls and 6 ½” SIP Roofs. My energy bills here are HALF of my 10,000 SF steel building just down the street.

The Panelman: What about SIPA? How long have you been involved?

Damian: I was elected to the board of directors of SIPA in 1993 and served as President from 2003-2006. I have remained on the board as a Past President and Treasurer since then.

The Panelman: What is the Fischer niche in the SIPS market place?

Damian: Part of what I like about SIPs is that they’re truly a versatile product and offer benefits for both the builders – and the people who will be using the structure. If I had to choose a niche, I’d say we specialize in small to mid-size builders.
We are a custom-oriented shop where we will bend over backwards to work with and try new products to try and help our builders and developers. We excel at custom-fabrication. Some larger manufacturers, they don’t like to try running new panels through their lines. They just look at the immediate numbers – not the long-term potential. Yes, opportunity has its costs, but I believe it’s worth it. I’d also say that RTA (ready to assemble) is another one of our niches. We’ll actually install lumber into the panels according to the builder’s specs. When the panels come to the job site, they are ready to go which saves on labor costs and reduces errors.

The Panelman: Where do you see SIPS construction going in the next ten years?

Damian: More towards complete fabrication and installation of RTA, definitely. Every builder deals with labor and time shortages at some point. And at first they may be resistant to spending just a bit more to have a RTA solution, but then when they do the math and realize that they’ll save more time and labor on the job site – it makes sense. As for new products, I think we’ll see more interest developing in new products like magnesium oxide board – I know that’s something you’ve been following closely. Already, we’re seeing more interest from overseas.

The Panelman: What is your experience with MgO board and laminating with it?

Damian: MgO board has tremendous potential in non-load bearing applications because it’s naturally resistant to the elements that builders (and homeowners) struggle with: water, mold, mildew, insects, fire, you name it! However, there is still testing that needs to be completed for structural uses. I’ve seen success stories when MgO is used for basement paneling. MgO board laminated to EPS is a fast way to finish an interior – and really, it stands up to just about anything. You’ll also get great R values from MgOSIPs, they are a tremendous insulator.

The Panelman: So back to SIPs in general, what are the benefits of SIPs in commercial and residential construction?

Damian: I could write an entire book on this! But to summarize the top five benefits, I’d say:
1) Higher R values
2) Better IAQ (Indoor Air Quality)
3) Stronger, more durable structures
4) Faster, more efficient construction
5) Less job site waste

The Panelman: Ok, so what are the negatives?

Damian: You’re going to pay a small amount more up front, but you’ll start saving right away. For example, let’s say a couple is working with a builder to build their dream home. On average, I’d say building with SIPs would add about 5% more to their total construction costs. However, their energy bill will be reduced by about 40-50% – and that’s a benefit they’ll see in the first month. That couple would pay a $2,000/month mortgage and a $400/month energy bill with a conventionally built home. With a SIPs home, they’d pay $2,100/month mortgage and $200/month in utilities. So that’s a savings that they can take advantage of right away.

The Panelman: What are builder reactions to SIPs? Why are they switching?

Damian: Like I mentioned earlier, a primary benefit of building with SIPs is the time and labor savings. But many builders also like the fact that their homes are being pre-fabricated in a factory setting. So much can go wrong on a job site, even to the best builders. But in a factory-controlled setting, we can catch any mistakes before they are made. That’s because we use 3D modeling to ensure the builder’s dimensions add up before we start custom-manufacturing their SIPs. It’s like a built-in quality control measure. It’s better if we catch a mistake in the modeling, than if a builder makes a mistake on the job site. Yes, you can make on-site modifications to SIPs panels, but it’s always better to catch any errors before they reach a job site.

The Panelman: What testing has been done on SIPs?

Damian: There has been extensive testing and approval on SIPs. They’re approved for walls according to ICC codes, and approval is in process for roofs. That’s why organizations like SIPA are important: we require all member manufacturers to have a complete code report and approval and an engineered line.

The Panelman: How does a builder know where to buy SIPs from?

Damian: It really depends on the end application. There are SIPs manufacturers that specialize in commercial structures, others – like Fischer SIPs – that focus on small- to mid-size builders. Ultimately, you want to choose a manufacturer that has the technology and flexibility to work with your end use. There are dozens of manufacturers listed at SIPA.

The Panelman: Thanks for your insights, Damian! Panelman readers: check back in a few weeks because Damian will review the new 2012 Model Energy Codes from the IECC (International Energy Code Council) and suggest ways you meet the new requirements through SIPs!

The Smarter Basement Panel Solution

As regular readers of this blog know, I’m really excited about the benefits of magnesium oxide board for the construction industry. It’s been almost two years since I first wrote about it and I’m still surprised it hasn’t gone mainstream. Only a handful of businesses are manufacturing MgO panels, and even fewer have discovered how to successfully bring it to the commercial and residential market. One of these companies is Tri-State Building Specialties. Read on for my interview with founder and owner David Card…

The Panel Man Asks: How long have you been in business?
David Card Answers: I’m a third generation contractor so I grew up around roofing, home improvement – you name it. After college, I narrowed my focus to specialize in sunrooms and basements and in 1991, my brother and I founded Tri-State Building Specialties. I’ve always been intrigued by the latest building products, and how they can improve our everyday lives. For example, when it comes to basements, moisture is always an issue. That’s what led me to discover magnesium oxide board, as it’s naturally mold- and mildew-resistant. I also wanted a laminate that addressed three concerns: mold resistance, a great fire rating, and an easily paintable surface. I experimented with cement board but its weight made it cumbersome to work with, laminating it created an unsightly a double seem, and it didn’t have a paintable finish.

The Panel Man: Briefly describe your basement panel system.

David Card: Our panel has three elements: the MgO “skin,” the glue, and the polystyrene foam core (EPS) which comes in 3 5/8 or 4 1/2 thickness and 8, 9, and 10 foot heights. It delivers on the “big three” issues I just mentioned – mold/mildew resistance, fire rating, and finish. It’s amazing that a 1/4 skin on this panel has the same 0, Class A Fire Rating as 1/2 or 5/8 sheet rock! It’s also MUCH more durable than sheet rock; it can take high impacts and not crumble or crack. Like I said, cement board was so heavy to work with and it often cracks under its own weight when you start going beyond 5 or 6 foot long panels. And then when you join the panels, you have to use vinyl tape (the PVC in vinyl tape has dangerous off gasses) or divider strips. Not so with our panel. We’re able to keep the integrity of an entire wall without a seam!

The Panel Man: What are the primary benefits in residential applications?

David Card: Our mission was to make it easily adaptable to any type of installation and room configuration. We also wanted construction-savvy homeowners to be able to install the system themselves. We provide instruction manuals, and on-site guidance in some cases, but it’s largely a “do it yourself” basement panel system. Another benefit for homeowners is that installation requires just one inspection instead of three or four separate ones for insulation, electrical, and framing (it also saves on completion time). That’s because we built in wire chases for the electrical, both sides of the panel are finished, and no additional insulation is needed.

The Panel Man: What are some general comparisons to conventional building?

David Card: In my research, I’ve found that when a basement is done conventionally and to code, magnesium oxide panels for basements are about the same price. There is no need for dry lock and vapor barriers, insulation materials, and multiple inspections. An average system can be completed in a few days! We’ve even installed about 40 panels in ONE day. Homeowners will also see some significant energy savings and enjoy a more comfortable, even temperature in their basement.

The Panel Man: What is the response from homeowners?
David Card: I’m pleasantly surprised by the amount of contacts we get direct from homeowners. But I’d like to see more contractors getting into the game. Like you, I know that education is key: There really are so many benefits to magnesium oxide-based panels. I like to remind folks that everything in construction has evolved to where it is today. Even our basic tools – the hammer, the nail – they evolved over time. We can’t stop evolving, especially when it comes to building products. Our panels really are greener, safer, and healthier – it’s the next phase in construction…in my opinion!

MgO SIPs: A Contractor’s Perspective

A House Built with MagWall Panels.

Hello Panel Man readers, I hope you had a great Memorial Day Weekend! I just got back last week from a trip to Denver where I attended an open house for Rocky Mountain MagBoard. I’m more excited than ever about magnesium oxide SIPs’ potential in the U.S. market. My enthusiasm only increased after talking to Shane Vigil, of Phoenix Framing in Colorado, as he explained the advantages of MgO SIPs from a residential framer’s perspective….

The Panel Man Asks: Before discovering the benefits of MgO SIPs, what materials were you using in residential construction?

Shane Vigil: I’ve used SIPs in residential construction for years, usually an OSB exterior with a polyurethane interior. But six weeks ago, I just completed the foundation on a 2600 sq. ft. residence using MagWall SIPs from Rocky Mountain MagBoard. I can tell you, I am completely sold on the benefits, not just for framers but for the homeowner.

The Panel Man: Since this was your first time installing MagWall, did it prolong the foundation build out?

Shane Vigil: Not at all, in fact, it took less time! To construct a typical concrete foundation, it would take about a week. That 2,600 sq. ft. house? It took two days, and that was our first time doing it. I can see it taking a day and a half in the near future. As you can imagine, homeowners appreciate the time savings, too, as they’re anxious to get into their new house! Not to mention, it takes time off expensive construction loans!

The Panel Man: What are some of the key benefits of MagWall from a homeowner’s perspective?

Shane Vigil: Well, MagWall is a non-combustible material which would appeal to any homeowner. However, it’s especially important here in the Denver area as we’re prone to wild fires. MagWall is also water, mold, mildew, and insect resistant. It’s also really durable and the interior can be finished with virtually anything. You can cover it with sheet rock or treat the seams and finish it similar drywall. Or, on the exterior, you can do a direct stone veneer or stucco application. One of the primary benefits is the energy savings!

The Panel Man: What if the MagWall is just used in the foundation, will that still provide energy savings?

MagWall Panels in a Residential Basement Foundation

MagWall Panels Offer an Innovative Alternative to Cement in a Residential Basement.

Shane Vigil: In the residential foundation we just built out, we were happy to report to the homeowner that she could easily downsize her HVAC system by 30%! People forget, concrete isn’t like insulation. In fact, unfinished concrete basements steal heat from the home, which requires increased energy consumption. MagWall is a fully insulated system, with R Values ranging above 20 – it was actually R-36 for this foundation – so instead of sucking warm air, it contributes to even distribution of heat throughout the home.

The Panel Man: In comparison to working with other materials, how does MagWall measure up?

Shane Vigil: As I mentioned earlier, unlike OSB or stick frame sheathing, you can apply virtually any finish directly to the MagWall. For example, in a typical concrete foundation basement finish, you have to built out the wall about a total of 5 inches, then add in insulation, vapor barrier and cover with drywall which takes away interior space from the basement. With MagWall, you don’t lose any space. Or, let’s say a homeowner wants a stucco finish on the exterior of the home. With conventional framing, you’d need to apply tar paper, then lathe and then apply the stucco. In a MagWall frame, the lathing process is eliminated so you’re saving time, labor and an inspection, which means, you’re saving money. Also, with OSB, you need a house wrap and usually a vapor barrier depending on the climate. MagWall doesn’t require ether. Again, this results in saving time, labor, and money. By eradicating these extra layers, you’re also reducing opportunities for problems to occur. MagWall just makes it a streamlined, simplified process.

Rocky Mountain MagBoard Provides On-Site Support.

The Panel Man:

How did the manufacturer, Rocky Mountain MagBoard, assist with your first MagWall installation?

Shane Vigil: The owners of Rocky Mountain MagBoard are builders themselves. Not only do they have a deep understanding of the MagWall product, but they have the expertise to ensure its proper application. In addition to the comprehensive installation manuals and instruction they provided, they were on site with me and my team the entire time. They wanted to ensure I was really educated on how to work with MagWall, explaining everything from installation of the trusses to connection details.

The Panel Man: Any final thoughts you want to share as a framer?

Shane Vigil: Just as you are, I’m excited about MagBoard and MagWall. It gives me a new product to offer customers and as you can tell from my experience using it for the first time, it really benefits both the framer and the homeowner.

In the Denver Area?

Don’t miss a chance to check out magnesium oxide SIPs in person – tomorrow! Contact me if you’d like more info…

Meet the MagBoard Company

Happy New Year, Panelman readers! To start off 2011, I’d like to share exciting news about magnesium oxide board (MgO) in a structural insulated panel (SIP) application. I think this year, MgO SIPs may gain serious ground as a mainstream building material. If you’d like to learn more about MgO SIPs, check out my earlier post, here.

I talked with MagBoard and MagWall founder and owner, Gordon Ritchie, to learn more about his company and how his panel systems are the result of his search for a superior building product. In my next blog post (look for it next week), I talk with Roger Goodhue who will be manufacturing and distributing MagBoard-based SIPS out of his Colorado facility. Let’s get started…

The Panelman Asks: What is the story of the MagBoard company?

Gordon Answers: I’ve been in the advanced building materials industry for over 20 years, with much of that time spent focusing on SIPs through the start up of several manufacturing plants. Like anyone involved in building materials science, I was constantly looking for improved products. Magnesium oxide board caught my attention in a structural sheathing application because it’s naturally resistant to hazards – moisture, mold, insects, and fire – and MgO is extremely strong. Magnesium oxide seemed an answer to the weaknesses that plague other building materials. OSB and plywood are no match for fire and moisture. Cement products are brittle and unhealthy, and “exotic” fiberglass and composite materials aren’t cost-effective. So, for about two years I investigated MgO boards for use in SIPS , and eventually invested in it by starting my own company and manufacturing MagBoard. We have gone on to produce MagWall SIPS using MagBoard with great results.

The MagBoard Factory, QC Certified by Intertek.

The Panelman Asks: Why did you start your own company when there are other magnesium oxide SIPs manufacturers?

Gordon Answers: In one word: Quality. During my early years in investigating MgO, I was disappointed by the performance of many of the products we tested. MgO itself is an outstanding material, but the manner in which it is made into building materials varies greatly. We tested over 34 boards in house and with third parties and none met the requirements for the North American market. They were either too brittle and broke, or they did not have the structural strength to meet the building codes in the US and Canada. In the end, we decided to invest the time and money to develop our own formulations, processes and equipment to get a product we can stand behind.

The Panelman Asks: How does MagBoard differ from other MgO companies?

Gordon Answers: First and foremost, we are a manufacturer – not a broker. This empowers us to ensure quality and product integrity from initial fabrication of raw materials through final testing and distribution. We have invested in the latest manufacturing equipment and designed a production process that allows for consistency and repeatability. Our MagBoard factory participates in third-party QC certification programs through Intertek, and we’re audited by them every 90 days. The other thing is the depth of testing we have done. MagBoard is a listed product with Intertek and we have done extensive product and assembly testing using MagBoard for wood and steel framing. We have taken this same approach for SIPs where we have full testing with NTA for our MagWall panels and have developed our own specialized manufacturing equipment for MagWall to control quality and consistency.

The Panelman Asks: For someone new to MgO SIPs, what would be the most similar material out there today, and why switch to MgO?

Gordon Answers: Everyone in the SIP business pretty well understands the pluses and minuses of OSB. MagBoard’s resistance to fire, water, insects and mold allows our customers to apply finishes directly to magnesium oxide panels and eliminates the need for expensive EFIS systems or drywall that only add costs for builders who use OSB SIPs. Fire codes are also driving force, so there is an advantage for a rated noncombustible material as the sheathing. Many people, including us, have looked at cement board SIPs but it just doesn’t work well. We have all the testing and have been making and selling MgO SIPs for the last four years. We are seeing rapid growth because our customers have a better product with a lower installed cost.

The Panelman Asks: What about the cost of MgO SIPs, is it comparable to other products like OSB panels?

Gordon Answers: There are really two parts to the question. MagWall SIPs sell for about the same price as traditional OSB SIPs. Of course, each process that goes into protecting the OSB from rot or fire adds another layer of cost, not to mention another inspection from the building department. So our panels’ lower finishing costs can save customers a lot of time and money in the end. Then there is the issue of lifetime costs. Because MgO panels are water, mold, termite resistant the long term life cycle costs are lower that for conventional OSB SIPs.

Another MagWall Installation Project.

The Panelman Says: Thanks Gordon, for sharing the exciting developments in MgO panel technology! Panelman readers, stay tuned, next week I speak with Roger Goodhue. With over 32 years in the building industry, Roger is fully embracing MgO structural panels and he talks about their applications in everything from a residences in Colorados to the construction of his own manufacturing facility.

The Panel Man in Print

I’m excited to share with my panel of Panelman readers, that Walls and Ceilings magazine published an article I wrote in its October issue. Read it here!

As you know, I’m trying to ignite dialogue about new and innovative panel and lamination materials. In the article, I talk about the challenges of getting a new product – like magnesium oxide board – to be accepted in the building and construction industry. I’d love to hear your feedback on the article, and on the topics I brought up!

Envisioning Change (SIPs) in Indian Construction

Post 4 in a Series of 4

Q&A Session with Anuj Dayama, who lives in Jaipur, India. Anuj works in the natural stone industry in India and is exploring advanced, “greener” building products and technology in hopes that he can introduce safer, cost-effective, and energy-efficient solutions to the Indian building community.

The Panelman Asks: What would you like to see happen in the construction industry in India?

Anuj Answers: I would like to see India continue to embrace lighter, more energy-efficient structures that are sustainable and green. Building with SIPs would allow us to complete construction projects faster, with less waste, and at reduced energy and labor rates. The SIPs technology can also be used to manufacture wood-free, moisture-resistant and fire-rated doors very cost effectively. This will prevent a lot of trees from being chopped down for compressed wood-base doors which are used presently. These green building techniques would provide our citizens with safe (earthquake-resistant!), sustainable, comfortable structures. Our affordable housing sector could really benefit from SIPs building technology.

I also see potential in modular construction and high-rise steel building (check out www.livingsteel.org). SIPs are so versatile and can be used for home extensions, prefabricated construction, and high-rise steel buildings where there is a strict requirement of fire safety. For example, magnesium oxide (MgO) panels are naturally fire-resistant. I would like to see a SIPs manufacturing plant or an onsite assembly system right here in India, and would like to connect with anyone out there who’s interested in making that a reality.

MgO SIPs would save on time, labor costs, and energy.

Pictured here is a new construction site in India. Building with SIPs would save on time, energy, and labor costs.

Anuj is interested in connecting with U.S. construction companies who want to be a part of the fast-growing alternative building movement in India. Contact me (Fred, aka the Panelman) and I will get you in touch with Anuj! fmiller@totalpanelsource.com

How Building Codes in India Impact Construction

Post 3 in a Series of 4

The Panelman Asks: What are the building code requirements for MgO SIPs and how do they compare with ICC codes?

Anuj Answers: Presently, most of the building codes in India are based on conventional construction techniques. Like aerated concrete, the new SIPs technology will have to find a place in the building codes eventually. But for that to happen, we need more local test reports. The international test reports, like ASTM and UL are also accepted in India.

I believe SIPs building – especially magnesium oxide board (MgO board) will really take off once basic testing certificates are also acquired from reputed local testing labs like CBRI Roorkee (http://www.cbri.res.in/). Their reports are well respected in our country and their costs are quite reasonable. Also, the SIPs technology can be used right away within the existing building codes for non-load-bearing applications and partitions which are a major part of new construction and remodeling. SIPs (and MgO board) technology could replace problem-prone gypsum board and fiberglass wool insulation that is currently being used. An awareness initiative and solid technical support from a SIPs company could help the Indian building community understand and use this already fully developed building technology in their projects.

A Third Floor Addition Using Conventional Construction in India.

Anuj Says: “This picture I took demonstrates a great potential of SIPs use over existing flat concrete roof slabs. Where a third level is being added, the builders are using 9″ brick walls and a rebar roof. It is very cumbersome and time-consuming to build another level at this height with conventional heavy materials. You can see the shuttering work in progress. As for the roof, without SIPs use, this is going to be a very heavy structure which is going to absorb a lot of heat from all sides. A lighter, more energy-efficient building technology would help both the builder and the building owner.”

Anuj is interested in connecting with U.S. construction companies who want to be a part of the fast-growing alternative building movement in India. Contact me (Fred, aka the Panelman and I will get you in touch with Anuj! fmiller@totalpanelsource.com

Overcoming Construction Challenges in India with MgO SIPs

Post 2 in a Series of 4: Ideas for Overcoming Challenges in Conventional Indian Building

The Panelman Asks: What do you believe are some of the solutions to overcoming the challenges that conventional building methods present in India?

Anuj Answers: The green building movement is really gaining momentum here in India. (Check out the list of upcoming tradeshows below for an idea of just how much industry buzz is going on!). Many of us in the construction industry are exploring lightweight materials that can still hold strong in an earthquake, are resistant to corrosion and water damage, and that require less labor and energy to implement.

I attended the Metal & Steel Building Systems Expo this past June here in India, and was amazed at all of the new building concepts coming to market that address our challenges. Magnesium Oxide (MgO) board in a SIPs application are most compatible with steel structures due to their low weight and very high fire resistance. A good approach for developing the market for MgO boards and SIPs construction technology here can be through derivation of initial cost difference compared to other building systems, energy savings, and affordability in this highly cost-sensitive market. Good sourcing of raw materials, a cost effective marketing approach and maximum near site assembly of panels to save on transportation can result in lower labor and manufacturing costs. A huge potential still remains looking at the small number & variety of alternate building products currently available compared to India’s market size, growing needs and our great appetite for better, greener building products and technology.

Typical residential highrise in Mumbai, India

Pictured is a typical high-rise residential structure in Mumbai. High-rise building has fueled India's interest in greener, altnernative techniques like MgO SIPs.

Like Fred, I believe that MgO SIPs are an ideal solution to the challenges I have outlined. MgO SIPs could deliver the same load bearing and security that our standard 9” thick exterior brick/ concrete envelope walls provide for compatible roof systems – with much less material. In a modular application, MgO SIPs would reduce labor costs as pre-fabricated components could be assembled on site. The water damage issue would also be solved as magnesium oxide is naturally resistant to corrosion and mold/mildew growth. I believe that MgO boards could replace gypsum, fiber cement, calcium silicate, plywood, and other problem-prone building materials here in India. Just like in the U.S., we need to work together to promote these advantages to the public – and the entire building community.

Green Building Organizations and Websites to Reference

www.igbc.in An organization established by USGBC in India

www.grihaindia.org This organization also certifies green buildings, like IGBC

www.bee-india.nic.in Bureau oF Energy Efficiency that rates buildings according to energy use

Fall 2010 Green Building Events in India

Green Building Congress 2010, October 6-9 2010 at Chennai Trade Centre, Chennai
ZAK: Innovative, Lightweight, Faster, & Sustainable Building Construction Technology Expo Sep 30. Oct. 3, Bandra Kurla Complex, Mumbai
ET ACETECH Chennai Trade Centre, November 26-18

A Global Perspective: New Construction in India

One of the benefits of blogging is connecting with a community of other folks interested in the latest innovations in structural panels. We’re engaging in conversation, sharing ideas, and creating new partnerships – and that engagement is happening on a global scale.

Through this blog, I’ve met Anuj Dayama in India, who’s just as excited about MgO panel applications as I am (good to know I’m not the only one in the world all worked up about magnesium oxide!). Through our conversations, Anuj has shed light on the current construction situation in India – and how the latest panel and building technology could solve some of their challenges. Over the next two weeks, I’ll share Anuj’s answers to questions I asked. He’s also taken some great photos, which I’ll post. So without further adieu, here’s question #1…

Post 1 in a Series of 4: Challenges in Indian Construction

The Panelman Man Asks: We have our fair share of new construction challenges here in America, what sorts of challenges does India face in new construction?

Anuj Answers: Most of our commercial and residential new construction utilizes full density concrete-rebar for structural work and concrete blocks or red clay brick masonry with Portland plaster for walls. These materials require a lot of curing at various stages. Now, one of the main problems we face in India is a steadily growing potable water shortage in a lot of areas. This makes the curing process very difficult, expensive, and not very energy efficient. Curing results in pollution and wastage of our precious potable water, which is at dangerously low levels or already depleted in some regions. The increasing salt levels in our decreasing underground water table deteriorate concrete and plaster mixes while accelerating rebar rust.

Another challenge we face in conventional new construction is that concrete and brick yield little or no insulation, so we are forced to increase energy use to stay cool in summer. We have rising annual temperatures, which makes this an urgent issue. It is a challenge to stay cool in un-electrified rural areas as well as urban centers, where frequent power cuts reduce access to air conditioning.

concrete rebar flat roofs in India, SIPs would work better

Pictured are flat rebar-concrete roofs in India. These roofs account for maximum solar gains and very hot top-floor temperatures. A 4" SIPs roof structure would work much better...

To make matters worse, conventional construction creates the “heat island effect” by absorbing heat all day and then releasing it at night. Remember, in India we have nearly six months of extreme heat, and three peak months with average peak temperatures between 105 and 120 Fahrenheit. New construction is also very time consuming. Unfortunately that time is often wasted when an earthquake occurs as most conventional structures are not very earthquake resistant. We can never forget the 2001 Gujarat earthquake that took thousands of lives of people who were living in such structures.

One of the greatest challenges is the weight of concrete building; it requires so much energy to work with Portland concrete – both in transportation and labor. Until a decade ago, the other challenge was getting the building community to open up to new materials, and invest in testing (I know that Fred faces this issue, too.) Lately, thanks to government encouragement of alternative building methods, this has changed considerably. New materials like aerated concrete blocks, steel framing with boards, SIPs panels, and PU sandwich metal skin structures are steadily gaining popularity. Tomorrow, I’ll answer Fred’s question about ways we might overcome our challenges…