Please note: You will need to complete the conclusion quiz online at RonBlank.com to receive credit

ARCHITECTURAL INNOVATIONS IN STUCCO & PLASTER WALL SYSTEMS

Merlex Stucco / Vero 2911 Orange-Olive Rd. Orange, CA 92865 (714) 637-1700 www.merlex.com www.vero-rialto.com

ARCHITECTURAL INNOVATIONS IN STUCCO & PLASTER WALL SYSTEMS Credit for this course is 1 AIA HSW CE Hour Course number: MER09A © Ron Blank & Associates, Inc. 2014

AN AMERICAN INSTITUTE OF ARCHITECTS (AIA) CONTINUING EDUCATION PROGRAM Approved Promotional Statement:  Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA This program is registered with the AIA/CES for continuing 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.

AN AMERICAN INSTITUTE OF ARCHITECTS (AIA) CONTINUING EDUCATION PROGRAM 

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Course Format: This is a structured, web-based, self study course with a final exam. Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to [email protected] Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. Email confirmations will be sent to the email address you have provided in your RonBlank.com account.

COURSE DESCRIPTION In this one hour course, the design professional will learn about the aesthetic and performance benefits of plasters. It will also cover the potential issues and risks of not addressing them correctly.

The course will discuss the history and natural sustainability of plaster. It will also showcase a variety of beautiful examples of plasters on exterior and interior walls.

LEARNING OBJECTIVES By completing this course, the design professional will be able to: 1. Understand the differences between stucco and other exterior substrates 2. List the issues stucco faces and the innovative solutions to the various problems 3. Describe different stucco textures and types of exterior stucco finishes – Portland cement, acrylic, waterproof, and Venetian plaster 4. Understand engineered cement for achieving optimal base coats

LEARNING OBJECTIVES CONT. 5.

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Discuss building methods and systems and how they attribute to the Title 24 building codes improved Energy Efficiency Performance Program and the overall physical and mental well-being Discuss the building design and materials using recycled stucco and the “continuous insulation” stucco system that relates to HSW in architecture Understand the history of Italian plaster finishes Describe the Italian slaked limestone vs. resin plaster finishes List the advantages of plaster finishes

AGENDA    

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Why use stucco? Stucco hurdles Solutions for cracking, discoloration and moisture Sustainability of Stucco Italian plaster for interior and exterior walls Examples of buildings with interior and exterior plaster

HISTORICAL PERSPECTIVE      

Ancient cities used lime plasters Los Angeles and other sunbelt cities built out using stucco after WW-II Small “dingbat” homes 800 to 1200 sq. ft. Homes sold for as little as $8000 Many bought on the “GI Bill” Stucco imperfections not an issue  speed and durability more important

Los Angeles 1950

Malibu 1960

ADVANTAGES OF PLASTERS    

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Natural, plentiful raw materials Low front-end cost Low life-cycle cost Virtually maintenance free Durable and long lasting Fire- and termite-resistant Aesthetics and infinite color variations

FUNDAMENTAL CHALLENGES    

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Cracking Color variation Water intrusion Cracking Cracking Cracking

TRADITIONAL SOLUTIONS    

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Apply heavier textures to hide the imperfections and cracking Use paints to hide cracks and even out color Use elastomeric paint to bridge even wider cracks Use siding on front elevations Change to synthetic stuccos

PROBLEMS WITH THESE “SOLUTIONS” 

Heavy textures hold and show dirt making an ugly texture even less appealing over time 

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Texture not always appropriate for the architecture

Paint raises front-end cost Paint reduces life cycle and raises maintenance costs Paint (especially elastomeric) traps moisture Synthetic stucco blisters and delaminates with moisture Additional coatings cover the natural hand-troweled look of real stucco

WATER PROBLEMS ESPECIALLY SERIOUS 

Moisture Intrusion causes:  

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Degradation of framing members Water intrusion to living space, impacting the health and safety of the occupants Growing of molds and spores Invitation to hordes of hungry attorneys

STUCCO INNOVATIONS

CRACKING

Base and Mesh crack reduction system

DISCOLORATION

MOISTURE

Silane-siloxane sealer

SOLUTIONS ADDRESS THE ROOT CAUSE   

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Polymer admixtures for waterproof stucco Penetrating sealers to waterproof the stucco Acrylic basecoats and lime plasters to bridge cracks and add moisture protection Base and mesh systems to significantly reduce cracking, add strength and added water resistance

THIS OPENS UP…. 

Design opportunities that now incorporate all the smooth stucco finishes we were reluctant to use before!

Smooth Santa Barbara Finish 16/20 Float Finish

20/30 Float Finish

30/30 Float Finish

WATERPROOF STUCCO 

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A chemically modified stucco that provides a water-resistant finish Designed to protect the wall cavity from water intrusion Available in full range of stucco colors and textures (i.e. 16/20, 20/30, Santa Barbara smooth finish)

BLOCKADE FINISHER

Before the waterproof stucco

After using waterproof stucco

PENETRATING SEALERS 

A silane-siloxane sealer that penetrates stucco and gives excellent water-shedding ability 

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10 year guarantee

Tintable sealer: for use over lime plasters  

Sealing and color in one step Allows for darker colors

COLOR CONSISTENCY & WATER PENETRATION ACRYLIC FINISHES 

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Acrylic-based finish used over brown coat, concrete, or masonry Provides consistent color and water- repellency Different aggregates offered for specified finishes:   

Medium Fine Super Fine

ACRYLIC FINISH TEXTURES

Medium

Fine

Super Fine

SUPER FINE ACRYLIC FINISH

Super Fine Acrylic Finish

ENGINEERED CEMENT FOR BASE COATS 

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Acceptable alternative to plastic cement and meets or exceeds ASTM C-926 standards for field-applied Portland cement plaster Better pumping than plastic cement and cement-lime mixes Sag-resistant copolymer allows for efficient application and good production rates Mix design allows for increased sand loads compared to plastic cement mixes Use of fibers can reduce cracking Available with recycled aggregate

MATRIX ENGINEERED CEMENT FOR ACHIEVING OPTIMAL PLASTER BASE COATS

Tract housing – home on left has applied scratch coat and home on right has applied brown coat

PRODUCTS ADDRESSING CRACKING BASE AND MESH 

Polymer- and fiber-modified cement coating for embedding fiberglass, alkaline-resistant mesh  

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Spread over brown coat as extra base coat 4 ounce mesh is embedded with trowel in base over entire wall surface Base coat gives improved flexural strength to keep cracks from transferring to finish coat Able to bridge cracks up to 0.04 inches Finish coat is acrylic-modified to ensure good bond to denser base coat

Consistently achieves up to 90% reduction in cracking

BASE AND MESH 

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Scratch, then moist cure once a day for 2 days Brown on the 3rd day after scratch, then moist cure once a day for 2 days Base and mesh crack reduction system plus undulations on the 3rd day after brown, no moist cure needed Finish on the next day after base and mesh crack reduction system Total process 8 work days

APPLICATION OF BASE AND MESH SYSTEM

Custom home – La Quinta, CA Application of Base and Mesh System Applying 4oz. mesh directly over brown coat

APPLICATION OF BASE AND MESH SYSTEM

Soka University – Aliso Viejo, CA Application of Base and Mesh System

COLOR COAT STUCCO FINISH APPLIED

A portion of project with color coat stucco finish applied

SOKA UNIVERSITY COMPLETED PROJECT

Soka University completed project

FINISH OVER BASE & MESH WITH MINIMAL CRACKING

Santa Barbara finish over base & mesh with minimal cracking Soka University of America – Aliso Viejo, CA

BASE AND MESH APPLICATION VIDEO

INTERIOR SMOOTH PLASTER  

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May be applied to gypsum or metal lath bases Retrofit application over drywall for interior plaster appearance Creates a smooth sheen just like plaster Apply up to a ½” thick Will be fully dry in 60 minutes and ready for finish or paint in approximately 6 hours

SMOOTH PLASTERS 

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Innovations make these finishes feasible with greatly reduced cracking Now we can incorporate them in design ideas that would never have been considered before! Smooth-troweled aesthetic is desirable in high-end European & contemporary designs Choose from Santa Barbara Finish cement stucco or seasoned slaked lime smooth plasters

INTERIOR VENEER PLASTER

INTERIOR VENEER PLASTER 

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When applying as a veneer finish, material consistency mixes slightly heavier than stucco When applying over drywall, use a bonder to cover entire wall surface before applying the interior veneer plaster to ensure bond Comet trails in the finish are possible when using integral color pigments When fully dry, plaster will cast a high shine on wall

CONTINUOUS INSULATION ONE COAT SYSTEMS 

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Fiber reinforced for strength, sag resistant, Portland cement exterior plaster Water reduces for crack resistance Plasticizers for workability Achieve greater insulation R-values when used with foam board as a continuous insulation system Allow for higher energy-efficiency and California Title 24 code compliance Allow for accelerated job scheduling due to reduced wait time between plaster base coats Available One-hour Fire Rating with specified assemblies in ICC Exception Reports

CONTINUOUS INSULATION ONE COAT SYSTEMS 

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California Title 24 Driving CI which became effective July 1, 2014 Can be a concentrate or specified to add approved ASTM C897 or C-144 controlled sand! Mix One-coat stucco concentrate with 180 - 200 lb. sand per sack May be used over a variety of substrates, giving architects and builders design flexibility Finish stucco can be cement stucco or acrylic stucco Optional recycled aggregate for 33% recycled content and LEED credit

NEW RESIDENTIAL ENERGY CODE BY CALIFORNIA ENERGY COMMISSION (CEC) All homes must perform at or above the following Standard:  Continuous Insulation (CI) Standard  

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When using 2x4 wood studs and R-13 batts, then R-5 CI When using 2x4 wood studs and R-15 batts, then R-4 CI

Also compliant: 2x6 wood studs, 24”o.c., with R-21 batts

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1.5” x 17 gauge stucco netting (recommended)

Sheathing Water Resistive Barrier Tongue & Groove Foam Insulation Board Woven Wire Continuous Insulation One Coat Stucco System Applied to a Minimum Thickness of 3/8”

Integrally Colored Finish Coat at 1/8” thickness

CONTINUOUS INSULATION ONE COAT STUCCO SYSTEM FOR INCREASED JOB SCHEDULING 

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Based on the ICC Report, fibered cement reduces cure times and increases production Scratch, then moist cure once a day for 2 days Brown on the 3rd day after scratch, then moist cure once a day for 2 days Spray/trowel on min 3/8” nominal thickness Color coat 5 days instead of 10 based on the CA Building Code (UBC)

APPLICATION OF CONTINUOUS INSULATION ONE COAT SYSTEM

Application of Continuous Insulation One Coat System

APPLICATION OF CONTINUOUS INSULATION ONE COAT SYSTEM

Application of Continuous Insulation One Coat System

APPLICATION OF CONTINUOUS INSULATION ONE COAT SYSTEM

Application of Continuous Insulation One Coat System

COMPLETION OF APPLICATION OF CONTINUOUS INSULATION ONE COAT SYSTEM

Completion of Application of Continuous Insulation One Coat System

COMPLETION OF APPLICATION OF CONTINUOUS INSULATION ONE COAT SYSTEM WITH COLOR COAT FINISH

Completion of Application of Continuous Insulation One Coat System with Color Coat Finish

MAKING STUCCO SUSTAINABLE 

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Stucco has always been made from plentiful natural materials Energy code is prompting innovation in energy efficiency through continuous insulation systems (CI) Recycled content available in plasters Reduced carbon options for the green consumer Many rating systems (LEED, Build it Green) favor recycled content Flyash/slag are smart ways to divert landfill tonnage & reduce cement content Others use glass spheres from post-consumer glass waste

33% RECYCLED EXTERIOR STUCCO   

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Graded aggregates that function like silica sand Available in 16/20 and 20/30 textures Enhances the beauty of sand finish projects due its higher content of large aggregate Graded aggregates that have been crushed, washed, and sized for any stucco texture This can fulfill USGBC criteria for sustainable projects Actual crushed concrete from demolished building, roads, bridges, etc.

33% RECYCLED STUCCO

Ball & Euclid Plaza - Anaheim, CA 33% Recycled Stucco

33% RECYCLED STUCCO

HISTORY OF ITALIAN PLASTER 

Romans used lime widely for construction, and many buildings are standing today  

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Cooked dolomitic lime is aged 2 years for workability, durability 

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They knew nothing of the chemistry, only how it worked and looked Today we know the cycle and the best lime formulations to use

Dolomitic: Calcium & Magnesium Oxides as occurs in Dolomites Mountains in NE Italy and provides added durability vs Calcium alone

Marble aggregate enriches the colors and gives the traditional warmth and softness to the finish 

Comes from the Carrara, Italy marble quarries

WHY LIME PLASTER? 

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Creates exceptional color mottling and movement for oldworld looks Plaster allows for texture and color effects, whereas painted effects are limited to color and appear artificial Reduced cracking and richer color movement relative to traditional cement smooth plasters (no cement shrinkage) Natural Italian materials with great design flexibility & nonflammable Does not flake or peel Resistant to alkali corrosion, UV rays Can be applied to brown coat, drywall, plaster and brick Competitive applied cost compared to faux paint

MANUFACTURING PROCESS

Raw material, calcium carbonate and magnesium

KILN

Original and current kiln where stones are cooked Fourth generation manufacturing plant

NATURAL SAWDUST

Natural sawdust made using recycled wood from local Italian furniture stores to heat the kiln

COOKED STONES

Cooked stones which have turned into calcium and magnesium oxide

SELECTED CALCIUM OXIDE

Selected calcium oxide Only the whitest stones are chosen. The darker ones are used for creating Italian sculptures and statues

SLAKING THE LIME

Slaking the lime

MATURATION

Grassello matures from three to 24 months in lime beds 3 month slaked lime is used for mortars in restoring historical buildings and 24 month lime is used in creating Venetian limestone plasters

GRASSELLO DI CALCE

GRASSELLO DI CALCE “Lime putty ” is what the seasoned limestone turns into after a 24 month slaking process

FROM STONE TO STONE

1. stones

2. kiln firing

8. application

7. production

3. cooked limestone

6. seasoning

4. slaking 5. lime milk

LIME PLASTERS  

Address cracking, discoloration, & moisture control Discoloration? What discoloration? 

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Lime plasters give authentic color movement that is a feature not a defect

Acrylic primer gives added water-resistance and crackresistance Lime finishes do not shrink when they cure

ANTIQUA I FINISH

Resort at Pelican Hill– Newport Coast, CA “#1 Resort in the United States” ranking by the readers of leading luxury travel magazine, Condé Nast Traveler and earned the Forbes Five-Star rating for the second year in a row

ANTIQUA I FINISH

Resort at Pelican Hill guest suites– Newport Coast, CA

ANTIQUA I FINISH

Resort at Pelican Hill Upper Villas– Newport Coast, CA

BACK IN YOUR DESIGN TOOLBOX 

Smooth-troweled finishes  

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Imperfect “Mission style” finishes  

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Smooth matte lime finishes with the look of the old world Smooth glossy resin finishes for contemporary designs Cat face Hump and bump

Lime paint – old world looks on a budget

ANTIQUA LIME PLASTER

Custom Home – Crystal Cove, CA

HUMP AND BUMP FINISH

The Resort at Pelican Hill – Newport Coast, CA

PALATIAL HOME THEATER

Custom Home, Huntington Beach, CA

BRINGING NATURE FROM OUTSIDE IN

Custom Home, Chino Hills, CA

BEACHFRONT LIVING

Custom Home, The Strand, CA

BRINGING THE BEACH INSIDE

Custom Home, Huntington Beach, CA

CONTEMPORARY RETAIL VERSACE

Versace, South Coast Plaza, Costa Mesa, CA

HOSPITALITY AT ITS FINEST NATIONAL AND INTERNATIONAL

The Cheesecake Factory – Houston, TX

EVOLUTION RESIN FINISH

The Cheesecake Factory – Houston, TX

ANTIQUA I WITH EPOCA SPATOLATO LIME FINISHES

The Cheesecake Factory – San Mateo, CA

ANTIQUA I

Crystals at City Center, Las Vegas, NV

SOHO LOFT

New York City, New York

SMOOTH, POLISHED PLASTERS INTERIOR/EXTERIOR

Orsini Apartments – Los Angeles, CA

Private Residence– Maui, HI

OPULENT CEILINGS

Custom home, Pelican Crest, CA

TRENDY LOUNGES

VIP Lounge, Dodger Stadium, CA

URBAN LIVING

Central Park West at Astoria, Irvine, CA 81

RECOLORING WITH MOVEMENT: STUDENT CENTER AT CLAREMONT-MCKENNA

BEFORE

AFTER: Lime Paint applied over stained stucco

DIFFERENCES AMONG PLASTERS 

SEASONED SLAKED LIME 

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BAGGED (HYDRATED) LIME 

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Shrinkage from curing, mottling from troweling

ACRYLIC/RESIN 

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Some workability, possible pops and pits

CEMENT 

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Superior workability, depth of color, hydration

Flatter look, typically interior only, mottling by layering

CLAY 

Lowest CO2 emissions, but does not set (softer)

COURSE SUMMARY Now the design professional will be able to: 1. Understand the differences between stucco and other exterior substrates 2. List the issues stucco faces and the innovative solutions to the various problems 3. Describe different stucco textures and types of exterior stucco finishes – Portland cement, acrylic, waterproof, and Venetian plaster 4. Understand engineered cement for achieving optimal base coats

COURSE SUMMARY CONT. 5.

6.

7. 8.

9.

Discuss building methods and systems and how they attribute to the Title 24 building codes improved Energy Efficiency Performance Program and the overall physical and mental well-being Discuss the building design and materials using recycled stucco and the “continuous insulation” stucco system that relates to HSW in architecture Understand the history of Italian plaster finishes Describe the Italian slaked limestone vs. resin plaster finishes List the advantages of plaster finishes

ARCHITECTURAL INNOVATIONS IN STUCCO & PLASTER WALL SYSTEMS

Merlex Stucco / Vero 2911 Orange-Olive Rd. Orange, CA 92865 (714) 637-1700 www.merlex.com www.vero-rialto.com

ARCHITECTURAL INNOVATIONS IN STUCCO & PLASTER WALL SYSTEMS Credit for this course is 1 AIA HSW CE Hour Course number: MER09A © Ron Blank & Associates, Inc. 2014

CONTACT  

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www.merlex.com or mobile web, http://merlex.com/mobi/ www.vero-rialto.com or mobile web, http://www.verorialto.com/mobi/ Read our blogs Everything Stucco and Spread The Plaster Follow us on