Cracking the Code: Understanding Fire Ratings, Codes and More

 We’ve all heard about fire ratings, but all the codes, language and rules around them can be confusing. At Ceco, we believe it’s crucially important to understand why we have them, what they really mean, how they’re created and how to use them. It will make all of us – and our buildings – safer. When installed correctly, fire-rated materials and assemblies can slow or even stop the spread of a fire. This provides precious time to get people out of the building before it is engulfed in flames or the structure collapses. 

Visualizing Principles 

If you’ve built or watched a campfire, you have some understanding of the burning characteristics of different materials. You’ve seen light, dry material catch fire and burn quickly, spreading the flames around. You’ve probably also noticed that wet, green or thicker chunks of wood take much longer to burn. And, if you’ve ever tossed an aluminum can in, you’ve noticed that it simply doesn’t burn.  

Fire ratings and tests formalize all these principles and more so that we, as builders, can ensure our buildings can resist, stop or contain fires when they start.

Understanding Terms 

While there are fireproof materials, no structure – not even complete metal construction – is fireproof. Fire resistance is the characteristic of certain materials to withstand heat and fire without catching fire themselves. Fire ratings, on the other hand, are the results of tests in which materials and assemblies (some of which are fire-resistant) were tested against fire. These tests include different construction elements, like beams, floors, columns, walls and roofs. These ratings give us an idea of how long and how well these materials and systems stand up to fire while retaining their structural integrity are usually given a rating of between one and four hours. 

Alphabet Soup 

The language and abbreviations in the world of fire ratings can be confusing because of all the different organizations that create ratings, tests and standards: 

Testing & Code Creation Agencies 

• Underwriters Laboratories (UL)  
• American Society for Testing and Materials (ASTM) 
• International Building Code (IBC) 

UL and ASTM rigorously test materials and assemblies in all kinds of environments to determine their fire resistance rating. The results inform the creation of codes by the IBC as well as local building codes. 

Regulations and Recommendation Organizations 

• International Code Council (ICC)  
• Metal Building Manufacturer’s Association (MBMA) 

To assist builders, designers, architects and engineers in understanding and following the codes created by ASTM and UL, the ICC and MBMA provide regulations and recommendations.  

Multiple Lines of Defense 

Adequately avoiding, controlling or containing fires relies on several different systems. First, fire detection systems like smoke and fire alarms help building occupants and first responders react quickly to a fire. Second, compartmentalization systems contain the fire, stopping it from quickly spreading throughout the building. These could include fire doors, fire-resistant walls and assemblies. Third, suppression systems like sprinklers, hose systems, and non-water-based fire suppression/extinguishing systems attempt to put the fire out or slow its spread until firefighting crews arrive. The term “fire-protected” takes all the above into account. 

Requirements for systems like these, as well as fire-rated building materials and assemblies, depend on several factors. What type of occupancy is the building intended for? Fire resistance demands on a warehouse will be far less stringent than those for an office building or apartment complex, where occupancy is higher. Height is another important factor, as well as the distance between the building and adjacent structures or property lines. Building material is another critical consideration. 

Steel Advantage  

Just like in the campfire we talked about earlier, fires that erupt in wooden structures – where the structure itself is flammable – face little barrier to spreading quickly. Metal buildings, on the other hand, have a simple advantage. Cold-formed steel, unlike other building materials, does not burn. It does not ignite, feed the flames, or cause them to spread. Therefore, steel framing is recognized by the IBC as a noncombustible material. In a structural fire, it easily outlasts wood framing, light-gauge steel framing, and other building systems. 

Building with steel and metal components can vastly simplify your adherence to fire codes. In building categories such as retail, office and education, the code allows for a much larger unprotected or non-fire rated area than in wood buildings – often 50% or more. Sprinkler systems are optional for a typical single-story metal building, and most metal buildings don’t require fire protection to be installed on the structural framing. Another benefit is that most insurance carriers offer substantial discounts for steel buildings. 

Fire Escape 

However, this doesn’t mean metal buildings are fireproof. High temperatures can weaken steel until it fails – but this requires temperatures in excess of 1,500°F. To protect occupants against this eventual collapse, metal buildings still may need fire rating on specific walls that separate occupancies, are close to adjacent properties or are needed for lifesaving exit corridors. 

Slow Burn 

Apart from constructing with noncombustible materials, there are other options for increasing the fire protection in your structures. Fire-resistant protection comes in many forms, such as coatings, gypsum board, spray-applied fire-resistant materials (SFRMs) and metal track with intumescent tape.  

But with products such as these, as well as with any fire rating system, following the application or installation requirements is absolutely critical. They were tested in very specific conditions. If you change any of these – say by leaving a bit of a gap in an assembly, not thoroughly cleaning a surface before adhering a fire-resistant product, using materials that weren’t part of the tested system – you are creating a failure point that could cost lives. Please be sure to understand and follow these requirements to the letter – and double-check your work. 

Where There’s Smoke… 

The integration of fire-rated assemblies and products into any construction project is as complex and varied as the endlessly different buildings in existence. ASTM and UL simply cannot test for every eventuality, combination of parts or newly imagined assembly. The best method to cope with this fact is to plan early and plan well. Engineers can help ensure continuity of assemblies and joints, that increased structural loads from fire protection and sprinkler systems can be carried, and that details such as cable trays, ducts, pipes and other penetrations are prepared for with fire-resistant solutions like intumescent firestop material – which expands under the heat of a fire to fill voids and contain the flames. 

We hope this guide helps demystify and untangle some of the confusion around fire ratings. At Ceco, we believe it’s worth understanding fire codes. For more details, consult the Fire Resistance Design Guide for Metal Building Systems, published by MBMA, which is considered the complete source for fire protection information. Or, for personal help, get in touch with a Ceco representative.

Why It Pays To Make Your Building Projects Lean and Green 

As consumers in nearly every age and demographic category become more aware of and committed to environmentally conscientious practices in business as well as their personal lives, the benefits for businesses of making Leadership in Energy and Environmental Design (LEED) certification a priority cannot be ignored. For those of us in the building industry specifically, beyond the many wonderful benefits to the earth, there are also numerous advantages for your business and your bottom line. 

LEED Benefits: Reductions

Typically, the most significant financial impact builders of LEED-certified structures realize is the energy efficiency. When constructed with efficient heating and cooling that minimizes energy and indoor/outdoor water usage, buildings can average an energy consumption reduction by 30-60%. Buildings that achieve up to 30% efficiency may qualify for basic LEED certification, with LEED Platinum-level certifications requiring 50-60% efficiency. Silver and Gold certifications require 30-47% and approximately 48%, respectively. Obviously, reduced energy use means reduced energy bills – often among the largest expenses in operating a building. 

Further reducing operating costs, most LEED-certified buildings average 15-20% lower maintenance costs than traditional commercial buildings, and even those that are retrofitted to improve green status can reduce operation costs by nearly 10% in one year. 

LEED Benefits: Increases

Not all benefits are by way of reduction however; LEED certification can also lead to increases: an average of 10% or greater increase in the value of the property, increased resale value, and an increase in employee satisfaction and overall health – which means increased productivity, fewer employee sick days, greater success with recruitment and retention, and more. 

According to Mahesh Ramanujam, president and CEO of the U.S. Green Building Council (USGBC), “Employees know that green building programs like LEED help companies to develop responsible, sustainable, and specific plans for green energy, water, waste, transportation and many other factors accountable for the human experience.” Additionally, the USGBC states that LEED buildings are linked to improved productivity, and health and wellness. In a study conducted by the organization, results showed that people’s decisions were influenced by whether or not the workplace was in a LEED-certified building, and that more than 90% of employees working in a LEED-certified building report job satisfaction. 79% of respondents say they would choose a job in a LEED-certified building over a non-LEED building.  

At Ceco, we’re proud to manufacture the metal building products that can help you achieve your LEED certification and establish your company among the leaders in creating a healthier earth and future through sustainable building practices, as well as position your business for greater success. 

Metal panels and roof systems are among the most effective building materials in improving efficiency, sustainability, and longevity. When you build with metal, you can expect overall higher performance in key areas that are used to determine your building’s LEED certification ranking, especially in Sustainable Sites, Energy and Atmosphere, Materials and Resources, and Indoor Environmental Quality categories, with indirect benefits in the Heat Island Effect and Water Efficiency categories.  

General Ways Metal Building Materials Help Improve LEED Ranking

Below are some general ways metal building materials can help improve your ranking. For specific benefits of Ceco products and how they can help you achieve your desired LEED certification, talk to a Ceco representative. 

• Cool metal roofs and coatings meet designated initial and three-year aged Solar Reflectance Index values for steep and low slope roofs in the Heat Island Effect category 
•  The minimal staging areas of prefabricated metal building systems earn points in the Site Development category 
• The effective rainwater management of metal building systems contributes to ranking in the Water Efficiency category 
• Metal building systems have high insulating value and thermal performance, supporting smaller HVAC systems and reduced electrical loads – all contributing factors in theOptimize Energy Performance category 
• Metal roofs and facades support windows and skylights, as well as PV panels and solar thermal systems, all contributing indirectly to higher ranking in the Renewable Energy Production category 
• The combined optimized environmental performance as well as adaptive reuse of metal products and materials can help with higher ranking in the Materials and Resources category, with indirect benefits also possible from metal construction’s focus on Building Life Cycle Impact Reduction, Whole-Building Life-Cycle Assessment, Building Product Disclosure and Optimization, and Sourcing of Raw Materials. The significantly smaller waste of metal building systems in Construction and Demolition Waste Management can also help add points in this category. 
• Metal walls and roofs that meet Low-Emitting Materials standards can increase the number of points earned in the Indoor Environmental Quality category 

Final Notes on LEED Certification

Of course every building project is different, based on client needs, building location, intended use, budget, and a variety of other factors. But with a little creativity and commitment to the long-term outcome of building practices, we can all work together to make a difference that leads not only to better quality buildings, but a better world for everyone for generations to come. 

Most people involved in the design and construction of buildings recognize that all buildings must meet the provisions of applicable building codes. However, not everyone understands where the code provisions come from or how they are developed. In fact, the codes are the result of a very comprehensive, ongoing process that involves many organizations and people around the country. This process may produce minor code revisions, or major updates, that directly affect the design and construction of a variety of building types including metal building systems.

What code are we talking about? The International Building Code (IBC) is the most commonly used building code across the United States. The IBC is prepared by a collaborative group known as the International Code Council (ICC) who engage thousands of code officials, design professionals, construction contractors, and material suppliers in an ongoing code review and updating process based on a three-year cycle. Different committees address specific concerns, analyze and assess the issues, and prepare new code language or procedures. The committees then offer these up for review, revision, public comment, and (hopefully) ultimate approval by the full ICC for inclusion in the next code update. It is then up to local jurisdictions (typically states) to decide whether they will formally and legally adopt the latest, revised version of the IBC and other codes (i.e. Energy Code, Residential Code, etc.).

In many cases, the ICC recognizes that there are professional specialty groups who have developed very specific standards commonly used throughout the construction industry. Instead of trying to duplicate those efforts, it is routine for the IBC to reference such a standard and adopt it into the code. There is a full list of such referenced standards at the end of the IBC (and other codes) identified by their formal name and number and the group that prepares and publishes them. When such a standard is duly incorporated by reference, it is in fact part of the code as well.

By way of example, one can look at a specific code provision related to the structural design of buildings and how it impacts metal building systems. Chapter 16 of the IBC addresses Structural Design requirements for buildings and Section 1609 in particular is focused on Wind Loads. One of the first paragraphs of this section (1609.1.1) states “Wind loads on every building or structure shall be determined in accordance with Chapters 26 to 30 of ASCE 7.” This is a case where the code defers to a recognized outside source. The American Society of Civil Engineers (ASCE) publishes ASCE 7 which is titled: “Minimum Design Loads for Buildings and Other Structures”. This published standard is developed by a committee of civil/ structural engineers and others from around the United States, Canada, and elsewhere. Chapters 26 to 30 of ASCE 7 address wind loading on buildings, hence the specific reference in IBC1609.

Currently, there is a change being proposed by the ASCE 7 Wind Load Subcommittee for voting (balloting) by the full committee for inclusion in the next edition due to be published in 2022. If adopted, it would change the definition of “effective wind area” when calculating wind load on structural members in a building. By allowing a larger effective wind area, the change would lead to a decrease in the applied pressure on roof and wall components of buildings. This would be particularly relevant to metal buildings since the change would recognize that a low-rise building with long, continuous members is subjected to different wind load conditions compared to a mid-rise or high-rise building. Specifically, it would allow wind loads to be reduced in lapped purlins and girts, and in roof and wall panels by accounting for their ability to distribute the effects of localized wind gust pressures over a wide area. Such a change could mean a more efficient structural design that could save on the weight and cost of structural members. This provision of ASCE 7 has received some favorable reception by those able to vote on it so far, so it may indeed become reality in just a few years.

At the same time, another effort is also underway to streamline the process of calculating wind pressure. Currently, ASCE 7 identifies two methods to do that known as the Directional Procedure and the Envelope Procedure. Dr. Greg Kopp of Western University in Ontario is leading an effort to unify these two methods. This is an enormous task that some parties greatly desire to see finished in time for the 2022 ASCE 7 edition. However, it likely will require further development since Dr. Kopp has already discovered areas where both methods show a lack of correlation with wind tunnel data housed in a National Institute of Standards and Technology (NIST) database. He is working closely with a group of long-time wind researchers to develop an approach that appropriately addresses both methods.

It is the work of many people, including committee members who are part of the Ceco team, which allows relevant issues like these to be properly addressed, researched, vetted, and incorporated into the codes and standards that promote the health, safety, and welfare of the general public. To find out more about how codes are used to design metal buildings, contact your local Ceco representative.

Every year the U.S. Bureau of Labor Statistics reports on the number of reported injuries, illnesses and fatalities that occur in a variety of work situations, including the construction industry. According to the latest data (2018) there were three incidents reported for every 100 employees—essentially saying that three percent of the construction workforce was involved in a reportable injury, illness or fatality that year. While that rate is down from prior years, the fact remains that any such incident is a difficult and often costly issue to recover from for both employees and employers. Therefore, it is not surprising that workplace safety is seen as a primary focus among many construction workers and managers.

When a specialty subcontractor, such as a metal building erector/installer, is preparing to work on a job site that is managed by a general contractor or construction manager, one of the first points of discussion is usually safety. In addition to general safety policies and procedures for a specific project’s job site, there are also regulations provided by the Occupational Safety and Health Administration (OSHA) that usually need to be taken into account. There may also be local safety requirements related to construction. In addition, with all of these there is the potential for random inspections and significant fines imposed for non-compliance. It therefore becomes incumbent on all parties to communicate and document some important items, including those that follow:

Job Site Safety Plan

A site Safety and Health Plan is usually the starting point for not only general contractors, but also for subcontractors as well. These plans describe the potential hazards of the work site, along with all company policies, controls and work practices adopted to minimize those hazards. Commonly, a general contractor will request a Safety Plan from subcontractors before they are allowed to step foot on the site and begin work. The subcontractor plan needs to be reviewed and coordinated with the general contractor’s plans for consistency and commonality on issues such as accident prevention, equipment, reporting incidents, etc. Technically, OSHA does not require a formal written comprehensive Safety and Health Plan, although it is highly advised and in fact required by some states. There are a number of free templates and fee-based computer software computer programs that are routinely used in the creation of such comprehensive plans.

Site Conditions

Not all sites are the same, and each one can provide different conditions that impact what defines a safe work environment as compared to another site. Things like open excavations, raised areas, wet areas, and more all need to be addressed in terms of how people move about these locations and what protective measures are in place (guard rails, gates, etc.). Equally as important is the identification of who controls the site and regulates which workers can safely work where.

Fall Protection

Falls from a raised elevation are the leading cause of fatalities on construction sites, accounting for over a third of job site deaths according to the BLS (366 of 971 fatalities in 2017). It is likely that all of these were preventable by following some very simple safety practices. For installers/erectors of metal buildings in particular, the best preventive measure is the proper use of safety harnesses by all workers who are carrying out any duties above the next lowest level. Note that it is not enough for an employer to simply provide the harnesses. Rather, all employees must be trained in how to use them, what to do if something is not functioning properly, and how to react in case of a fall while wearing one. The harnesses themselves must be inspected every day (not just weekly or monthly) for any wear, loose items, or damage. It’s also advisable to ensure harnesses are certified for compliance with the current requirements as of a particular date. If the requirements change, which they often do, then the equipment can become out of date and is no longer certified. In that case, enhancements or replacements may be required.

Moving Objects

Equipment (i.e. a crane, lift, boom, etc.) is routinely used on a job site to move materials of all types, particularly steel components. When those materials are hoisted and moved into place, there is a risk to people who may be working nearby or adjacent to the equipment. It is in the interest of jobsite safety that clear communication or warnings are understood by all workers whenever moving objects are involved in construction. Given the relatively heavy weight of some of the materials, even a brief lapse in attention to oncoming objects can cause significant harm or a fatal encounter.

Equipment

All equipment used on a job site is subject to mandatory inspections. If the equipment is leased (which is the most common situation) then the leasing company usually has detailed records of maintenance history, safety compliance, etc. These records should be requested and presented for inspection to demonstrate the safety of the equipment. If the equipment is owned by a contractor, then the same type of records need to be available and presented showing that all pieces of equipment are checked and inspected in a timely manner.

Personal Protection Equipment (PPE)

Construction safety standards have long been diligent on the use of masks, shields, hard hats, gloves, boots, and other devices to protect workers heads, hands, feet, and lungs where appropriate. The recent coronavirus has pointed out the importance of similar items in terms of public health as well. In all cases, these items need to be made readily available by employers or clear indications must be given as to what the proper safety attire is in order to be allowed to work on any job site.

Overall, safety is everyone’s concern and the only way to achieve and maintain safe work sites is for everyone to communicate and work together on common safety goals. To find out more about how to achieve this on your current or next project, contact your local Ceco representative.

Designing and constructing an exterior wall assembly means that four performance barriers need to be addressed and included. Specifically, there needs to be a Weather Resistive Barrier (WRB), an air barrier, insulation as a thermal barrier, and a structural support method to hold these barriers in place. In conventional construction incorporating each of these four components often means that four different trades install four different products. This takes coordination effort, a variable amount of time, and a variable amount of cost.  

 For those who have ever wondered if there is a better way to build a wall the answer is yes! A single solution is now available that integrates all  of these components into a 4 in 1 product addressing air, water, vapor, and thermal barriers. Known as insulated composite backup panels (ICBP) they are manufactured to create a better wall solution that designers and contractors can readily incorporate into their building projects. Some of their benefits include the following: 

 ICBP “All-in-One” Make-up: The ICBP panels are essentially “sandwich” panels fabricated with continuous inner and outer metal faces and a central foam core. The outer metal is referred to as the face skin, while the inner metal is called the liner skin. They each come in various thicknesses ranging from a standard 29 gauge, down to a heavier 20 gauge. The face and liner skins provide protection from environmental elements with a non-curing butyl as the liner side seal, which creates the weather-tight barrier. The foam core between the two skins is commonly a highly efficient polyisocyanurate or polyurethane foam.. The closed cell foam provides the thermal barrier required, and can also help with water resistance. The foam and metal then work together to provide structural integrity for the panel. Typically the panels allows for a choice of exterior rainscreen finishes. With everything related to the performance of the wall provided in one product, it truly is an “all-in-one” construction solution.  

 Choices in the Types of ICBPs: There are two fundamental types of ICBPs. The standard version is lighter gauge, installs horizontally, and is intended to be attached to the structural support system for the building, such as a metal stud wall or metal girts not more than 24” o.c.. The long-span version installs vertically, needs to be attached on supports greater than 24” o.c. and is suitable for interior metal surfaces. These different panel type options allow for applicable accommodations in the way that the panels are incorporated into a building design.  

 Design Flexibility: The use of ICBPs allows any type of exterior finished appearance to be used on the walls. For the exterior various materials can be used. With traditional ICBPs, an integral rail system is available that fits into the joints of the face skins for installation of rain screen systems. Those rails can then support any common type of finish material such as metal panels,  masonry, terra cotta, stucco on a substrate, etc. On the inside, the liner panels may be left exposed (as is the case in some utilitarian metal buildings) or covered with gypsum board, wood, paneling, tile, or any other interior treatment.  Note that this full design flexibility makes ICBPs different from insulated metal panels (IMPs) which allow only finished metal on the exterior and interior of the building. Regardless of the final design though, exterior walls that use foam insulation need to meet specific code requirements including air, water, structural, thermal and fire testing.  Manufacturers of ICBPs typically have conducted this testing on a wide range of design and assembly types, with documentation available to prove their code compliance.  

 Customized Thermal Performance: Different climate zones require different levels of insulation. ICBPs meet this challenge because it’s possible to specify the thicknesses of insulation required for different project locations—thicker insulation means higher total R–values. Furthermore, manufacturers of ICBPs provide complete materials, and instructions on how to properly seal the edges of the panels, in order to create barriers that are continuous and highly energy conserving. When properly tied into other building systems and components (i.e. windows, doors, roof assemblies, floor assemblies, etc.) the result should be excellent energy performance customized to suit the building. Of course, designers and contractors need to pay close attention to those details for the best outcomes. 

 Time and Cost Savings: Using one trade instead of multiple subcontractors to install air, water, and thermal barriers clearly makes construction easier. That means that a building can be enclosed quicker so that interior work can start sooner, leading to a possible reduction in the overall total construction time. Less labor and less time also means more cost savings, offering an economical, efficient, and appealing alternative to traditional construction.   

 Broad Usage: With all of these well-established benefits, it is easy to see that the possibilities are virtually endless for their use in any type of project. In fact, they have been used quite successfully on many different commercial building types including schools, hospitals, retail, offices, metal buildings, hospitality buildings, higher education buildings, and others. The use of ICBPs should definitely be considered by anyone looking to improve performance, retain design flexibility, and control time and cost.  

 To find out more about how these innovative panels can help with your current or next project contact your local Ceco representative.   

In our prior blog post, we pointed out different ways to overcome confusion related to different aspects of the energy code. In this post, we will look at some of the ways that metal buildings address specific insulation provisions to successfully meet or exceed them.

The International Energy Conservation Code (IECC) identifies minimum levels of thermal insulation that are required throughout the building envelope (i.e. roofs, walls, floors, etc.). Specifically, Table C402.1.3 is a handy reference to see what the code is based on. It breaks down the different insulation requirements categorized by the portion of the thermal envelope being addressed and then by different construction techniques. Minimum R-values are then listed for the insulation only (based on assumptions about the rest of the construction) that are specific to each climate zone. Let’s look at how this applies to roofs and walls in the 2018 version of the IECC.

Roof Insulation:

Table C402.1.3 recognizes three common types of commercial building roof construction and lists minimum R-values for the insulation for each of the 8 climate zones as follows:

• Insulation entirely above the roof deck: This is common practice for low slope roofs that use rigid continuous insulation (ci) across the entire roof deck. The continuous insulation is an important distinction since it is based on no interruptions in the insulation from the ceiling structure, framing, etc. which reduce the effective R-value considerably. In these cases, the minimum insulation level ranges from R-20ci in climate zone 1 up to R-35ci in climate zones 7 and 8.
• Insulated attic system: Metal framing that uses trusses or other structural members to create an open attic commonly use insulation batts or blown-in insulation on the floor of the attic to thermally isolate it from the occupied space below. In these cases, the table requires R-38 insulation in Climate Zones 1-5 and R-49 in Climate Zones 4 (multifamily residential buildings)-8.
• Metal building roofing system: While a metal building can be constructed using either of the techniques listed above, the IECC recognizes that metal buildings have developed their own unique form of roof insulation too. That form involves an exposed liner system which the IECC defines in Chapter 2 as follows:

Liner System (LS): A system that includes the following: 1) A continuous vapor barrier liner membrane that is installed below the purlins and that is uninterrupted by framing members. 2) Uncompressed, unfaced insulation resting on top of the liner membrane and located between the purlins.

Back in Table C402.1.3, there are then 2 R-values listed for this type of construction. The first value ranges from R-19 to R-30 depending on climate zone and is for  the “unfaced insulation” which is presumed to be “draped over purlins and then compressed when the metal roof panels are attached.” The second value is the minimum R-value for the insulation installed in the liner system, which must be at least R-11 LS in all climate zones. Thermal spacer blocks are presumed in this type of construction to maintain the acceptable R-values. All metal building manufacturers are well aware of the latest requirements for Liner Systems and have the means to address accommodating them as part of the roof structural framing. Communication between the manufacturer and the designer are important, however, to be sure that the proper detailing is achieved.

Wall Insulation:

Table C402.1.3 continues with a category for “Walls, above grade” and lists two construction types that are relevant to our discussion.

• • Metal framing: The common practice of using metal framing to create an exterior wall means that insulation is interrupted every 16 or 24 inches on center by a metal stud that breaches the insulating capability of that wall. Hence, continuous insulation is required here, too, in addition to the insulation in the stud cavities. Therefore, the table identifies R-13 as the minimum insulation level between studs in all climate zones plus the addition of continuous insulation ranging from R-5ci to R-17.5ci depending on climate zone.
  • Metal Buildings: Metal buildings can, of course, use metal framing as the exterior wall/ building enclosure but there is also a more unique method that the code recognizes using horizontal purlins and girts between vertical or bent columns. In this case, the assumed construction anticipates that the metal components will interrupt a little bit more of the insulation than metal stud framing. Accordingly, the minimum insulation levels are the same R-13 between framing in all climate zones, but just a little bit higher for the continuous insulation ranging from R-6.5ci to R-19.5ci depending on climate zone.

Note that Table C402.1.3 that we have been referencing is based on following a purely “prescriptive” approach, which is the simplest way to show code compliance. The IECC does allow other ways to show compliance, but they are based on demonstrating a comparable level of insulation across the building. Using insulated metal panels, (IMPs) for example, would require using one of those other methods to show compliance.

If there are questions about what level of insulation is required, consult the IECC and an architect or engineer who can review the specific conditions of your metal building project. You can find out more information about metal buildings and energy code compliance at http://www.mbma.com or http:www.cecobuildings.com.

All new and renovated buildings are subject to following not only general building codes, but also an Energy Code – the most common of which is the International Energy Conservation Code (IECC). There are a number of misperceptions about this code that can cause confusion when a metal building is being designed and constructed. Here are a few things to keep in mind to overcome that confusion.

Understand the Intent of the IECC:

(Section C101.3) This code does not regulate energy use (i.e. you don’t get fined if your energy bill is too high) rather, it regulates “design and construction” just like other codes do. The focus of the IECC is not structure or fire safety, but rather “effective energy use and conservation.” The energy use part has to do with things like mechanical and electrical equipment that needs to be energy efficient (i.e. controlling the amount of energy needed as input to get a desired output such as light or heat). The energy conservation part (i.e. reduce the need for energy in the building in the first place) is all about the building enclosure including things like thermal insulation levels, windows, doors and control of air infiltration (i.e. drafts). These measures need to be effective long term “over the useful life of the building” just like any other code provision.

Acknowledge the 3 Year Updates to the IECC:

The International Code Council (ICC) is the organization responsible for developing and updating most of the commonly used codes across the United States, including the IECC. They are a very democratically run organization with representation and input from literally thousands of professionals in the design, construction and code enforcement arena. They follow a process whereby changes or updates can be proposed, vetted, debated, aired publicly, voted on and adopted (or not) following a process that takes 3 years. Hence the IECC has been revised and re-issued every three years since it’s first publication in the year 2001. During that time, the provisions that affect commercial buildings, in particular, have become more stringent particularly in terms of insulation levels and the way that air infiltration is addressed.

Know the Locally Adopted Version:

All codes are enforced by a local authority having jurisdiction (AHJ), which is typically a city or town code enforcement officer. However, they are often required to follow the version of the codes that have been adopted at the state level since it is typically the state legislatures that vote the codes into law across a state. One thing to keep in mind is that different states can, and do, adopt different versions of the codes, particularly the IECC. That means a building in one location could be required to follow the latest, 2018, version of the IECC while a building in another state might be subject to the 2012 or the 2015 version of the IECC. This can cause confusion unless those involved check with the AHJ and are clear about which version of the code is placed and what needs to be followed. Of course, a default approach taken by many is simply to design to the latest version of the code, which is typically the most stringent, and therefore meet the requirements of all prior versions as well.

Know Your Climate Zone:

The IECC recognizes that different locations will have different impacts on a building’s energy use based on the type of climate it is located in. Therefore, the IECC identifies 8 different climate zones (#1 in southern Florida progressing up to #8 in Alaska) and assigns a climate zone number to each county within the United States. It is important to look up which of these 8 climate zones a building is being constructed in because the energy code requirements do vary according to the climate zones. Not understanding this point has lead to confusion when someone thinks they need to be following certain criteria that are different than what they thought because they were not looking at the correct climate zone.

Recognize the Difference Between Insulation and Infiltration:

The IECC is based on good, fundamental science and principles related to controlling the flow of energy, particularly in walls, floors and roofs. That’s why it establishes minimum levels of thermal insulation in those areas – to reduce the amount of unwanted heat loss in cold climates or heat gain in warm climates and thus reduce the amount of energy needed to keep the building comfortable. A common misperception, however, is that insulation will also control unwanted air infiltration. In fact, that is usually not the case. Fiberglass, for example, is used as an air filter in furnaces because it allows air to flow very nicely through it. Instead, the IECC has progressively implemented a series of mandatory (i.e. they simply must be done) provisions focused on eliminating drafts and sealing the entire building enclosure. (Section C402.5) These provisions involve the use of air barriers in walls and roofs, air leakage controlled in windows and doors and addressing some special details. In many cases, it may also require testing the building with a “blower door fan” to measure, under a standard prescribed air pressure difference, how much air is leaking into the building. If the building doesn’t meet the code minimum numbers, then it must be further sealed and tested until it does.

Some of these things may sound a bit daunting at first which may be why some of the confusion has developed. In fact, they have been looked at and addressed with some good solutions developed that have become fairly well-understood and commonplace to use. In our next blog post, we will take a look at some of those solutions as used quite effectively in metal buildings to not only meet the code requirements but even exceed them.

In the meantime, you can find out more information about metal buildings and energy use at http://www.mbma.com or http:www.cecobuildings.com .

It’s hurricane season – and for anyone who has experienced what that can mean for a building, there is reason to take notice. The time to pay attention is during design and construction to create a building that can resist the effects of high winds, torrential rain and other storm effects. In particular, engineered metal buildings have been shown to be particularly resilient in this regard. Steel structures, metal roofing and metal siding are all routinely designed, tested and rated to withstand different levels of severe weather, with most achieving excellent results. Beyond laboratory testing, the 2017 hurricane season provided some real world, dramatic examples demonstrating the strength and resiliency of metal buildings.

Harvey Threatens Ingleside ISD’s New Metal Building Facilities

On August 25, 2017, Hurricane Harvey, a category 4 storm, hit the coast of Texas near Corpus Christi with 130 mph winds and left 250,000 people without power. According to the National Hurricane Center, it ultimately caused $125 billion in damage – more than any other natural disaster in U.S. history except Hurricane Katrina in 2005. Hurricane Harvey affected 13 million people from Texas through Louisiana, Mississippi, Tennessee, and Kentucky with at least 88 people losing their life as a result of the storm.

Just 12 days before Harvey hit, on August 14, 2017, a metal building project was completed, which was unknowingly in the direct path where the hurricane came ashore the following week. The Ingleside Independent School District (ISD), on the northern side of Corpus Christi Bay, chose to use Ceco Builder Weaver & Jacobs Constructors, Inc. to provide metal buildings for their new High School Sports Complex and Maintenance Building. The project included a 40,000 square foot indoor football practice facility, a 15,000 square foot maintenance facility, and a 20,000 square foot bus barn all comprised of the SuperLok® standing seam roof system and PBR wall panels.

Fortunately for most Texas building owners on the Gulf Coast, the Texas Department of Insurance has some appropriate requirements for wind resistance in buildings in order to be eligible for property insurance at favorable rates. In the case of the Ingleside ISD, the design criteria was for a T-1 designation able to withstand 140 mile per hour winds. When Hurricane Harvey tore through the area, the engineering, design, fabrication, and construction were all put to the ultimate test with sustained winds approaching that design limit.

How did the project do? The school district personnel and the contractor went and assessed the property after the storm. To their great relief and delight, all of the buildings were fully intact. No fasteners came out, no roof or siding panels were damaged, and no breaches to the building enclosure were found. The only damage determined was to a single downspout on one of the buildings which was quite easily repairable. The outcome of this project is a testament to the truly durable nature of metal buildings.

To find out more about the best practices and ways to protect your metal building, especially during hurricanes, contact your local Ceco representative.

Metal building packages, like most other manufactured or fabricated products in America, are typically transported as freight by commercial trucking lines. Historically, there have been plenty of trucking companies with plenty of drivers who would happily take on the job of transporting a metal building to a construction site. However, times have changed.

The Issue: A Shrinking Workforce of Truckers

An April 3rd, 2018 article in Wall Street Journal Today points out some nationwide trends that affect virtually every industry in the United States. Notably, the current trucking workforce is aging, just like the rest of the population, with an average age of 49 years old for a long-haul trucker in 2014 compared to an average of 42 years old in 2002. Normally the aging out of truckers would be replaced by younger ones entering the workforce, but that isn’t happening. The article notes that a commercial trucking license requires the licensee to be 21 years of age. Recruiters for schools that train new truckers are noting that many young people are opting for other work in construction, manufacturing, or energy related jobs rather than waiting until they are old enough to train for their trucking license. And they have a good chance at better pay and better working conditions in those other fields too.

The Effects: Higher Transportation Costs

The observable dilemma here is that enrollment in commercial driving courses is at record lows while demand for drivers is at a record high due to a strong economy producing surging freight volumes. Basic economics indicates that when supply is low and demand is high, prices can be expected to increase, and that is what is happening.

Trucking by flat bed truck, the manner in which metal building components and packages are shipped, is particularly affected by this national trend. Drivers of flat bed trucks are responsible for the physically demanding and time consuming work of securing their load with straps, tarps, and other means to protect it from the elements. And they need to be out in the weather doing that work all year long. Compare that to driving a standard 53-foot cargo van type of truck or a refrigerated truck where the driver is only responsible for driving, and the difference is notable. Scott VanOstrand, Director of Transportation at NCI has reported that “On average across the US, each flatbed truck/driver has over 100 loads to choose from.” With that much choice, drivers could easily pass on the less appealing shipments and only choose the ones they like”. Scott goes on to point out, “The DAT Truck to Load ratio is a measurement of supply/demand in the flatbed market and it has never been as high as it is right now. As our economy strengthens and the truck driver shortage continues on, this ratio becomes further and further imbalanced.”

The Response: Plan for Managing Transportation Costs

The metal building industry is finding itself caught in this circumstance, just like all other industries. Typically, the cost of shipping a metal building package is quoted by an independent trucking company based on weight, distance to ship, and other relevant variables. Now, it is also being based on the increasing costs of flatbed truck drivers happening all across the country. Estimates across the board indicate that transportation costs could be 25 – 35 percent higher in 2018 compared to last year. That means every $1,000 of previously budgeted shipping cost could now be around $1,300 and needs to be planned for.

In order to manage these outside cost increases, customers who place multiple orders should consider consolidating orders to create full truck loads where possible or where that isn’t already the case with full building packages. Working with manufacturers early on in the design and fabrication process should also allow for transportation price quotes that anticipate and reflect the reality of increased shipping costs. Forecasts after 2018 aren’t available yet, but with no relief in sight over the growing demand and shrinking supply for truck drivers, costs are likely to continue to rise.

To find out more about the best ways to anticipate and control costs and construction budgets during this changing transportation market, contact your local Ceco representative.

Winter brings snow to many places, and sometimes a lot of it. While skiers and school children may rejoice, those tasked with maintaining metal-roofed buildings may wonder what is the best action to take. Fortunately, the Metal Building Manufacturers Association (MBMA) offers some advice in the Metal Building Systems Manual.

How much is too much?

When a metal roof undergoes a structural engineering design, it necessarily takes into account the code-required levels of snow accumulation for the building location. At the low end, that might be on the order of 10-20 pounds per square foot (psf). However, on the high end it could be over 40 pounds per square foot. How does that translate into inches of snow? This does not translate easily as snow can vary wildly in density from being light and fluffy to wet and heavy. The MBMA suggests that something less than 5 pounds per square foot per inch of depth for very wet or heavy snow is a conservative estimate. Of course, that means if the roof is designed for a snow load of 20 psf, then any buildup over 4-5 inches might start to be a structural concern. Consultation with a structural engineer on the carrying capacity of the building and a reasonable range of snow density and weight can provide insights for a specific building.

High Slope versus Low Slope

Roof pitch makes a notable difference in all aspects of snow buildup on a roof. A high slope roof (i.e., more than 4:12) can experience conditions where some or all of the snow slides off of the roof. This can happen particularly when the sun is out or if heat loss from the building creates a water layer under the snow. By contrast, a low slope roof (i.e., less than 4:12) will not typically see the same sort of snow sliding, meaning it is more likely to build up and accumulate over time, typically getting icier and denser as it does so. This is a concern across the surface of the general roofing area, but it is a particular concern anywhere there is a change in height or where a vertical surface is encountered, such as a parapet wall, chimney, equipment, etc. In these locations, windblown snowdrifts can become trapped, so instead of blowing off of the roof, they accumulate in these areas, creating concentrations of heavier than planned dead weight. The accumulated snow can also find its way above flashings, and its thawing and freezing can eventually cause water leaks into the building.

Clearing Snow while Avoiding Roof Damage

The MBMA makes it clear that if excessive snow builds up on a metal roof, the best thing to do is remove some of the snow in order to ensure the loads are at safer levels. Also to ensure product quality, the MBMA stresses that removing snow carelessly or with any form of metal or sharp tools is not the recommended approach. Such an approach may cause serious roof damage to occur. Instead, they recommend a systematic approach that focuses on removing the excess snow only, leaving an acceptable, thinner layer on the roof to melt and disperse on its own. They also emphasize the importance of removing it uniformly from the entire surface of the roof, starting in the areas of accumulated snowdrifts, and then moving evenly across the roof from there. The MBMA also makes a point to note that piling snow from one place on the roof to another, even in small areas, is clearly counterproductive and can cause structural problems.

Keeping People Safe

Anyone going up onto a roof even in the best conditions needs to follow proper safety procedures, and this is certainly magnified when the roof is covered with snow and/or ice. Safe access from inside or outside the building needs to be assured, along with the use of a safety harness or similar precautions. Certain areas of the roof deserve obvious attention, such as the roof edges and near any snow-covered skylights or hatches. All of this is easier to accomplish when the snow is fresh and likely more easily handled. This makes timing of the removal important to worker safety as well, since it can mean the difference between smooth removal and extra exertion.

To find out more about the best practices and ways to protect your metal building, especially in winter, get some more insights by contacting your local Ceco representative.