W&D Weekly - June 13, 2007
Vol 2 | Num 24
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IGMA, AAMA Meet Together in California
Huntington Beach, Calif.—Globalization is moving faster than we realize, but the U.S. economy remains one of the...
Huntington Beach, Calif.—Globalization is moving faster than we realize, but the U.S. economy remains one of the most vibrant in the world, said Stuart Varney, a financial journalist with Fox News Network, speaking this week to the American Architectural Manufacturers Association and the Insulating Glass Manufacturers Alliance. The two organizations are hosting their summer meetings together here this week, with each group conducting association business on their own then coming together for joint social events and guest speakers.
Werner Preusker reviewed the success of industry efforts to promote PVC in Europe at AAMA's meeting in California.
Bill Lingnell, IGMA's technical consultant, demonstrated how he tested various methods for closing capillary tubes.
Two other major trends businesses will have to address in the coming years, Varney suggested, were changing demographics and a shift in the U.S. political culture away from wealth creation to wealth redistribution. Discussing changing demographics, the television commentator said low fertility rates in most developing countries means populations will be aging dramatically. In some European countries, more than half the population will be older than 65. Looking at the shift in the political culture of the U.S., Varney said higher taxes and greater regulation of business is all but inevitable.
DIVERGING INTERESTS
In AAMA’s early sessions, two issues emerged that are creating diverging opinions among the organization’s residential and architectural product manufacturers. One involved input into the joint window and door standard that the association produces with the Window & Door Manufacturers Association and the Canadian Standards Association. The standard currently allows residential-class windows to be rated at high design pressures typically associated with commercial and architectural products. Those products, however, must also undergo additional testing to carry their ratings. Those on the architectural product side suggest this gives the residential window manufacturers an unfair advantage as they do not have to meet the additional requirements, but can still sell their products in many commercial applications.
When asked whether AAMA should propose any change in the standard, a straw poll showed residential and architectural product manufacturers voted “along party lines.”
That trend was evident with the issue of whether or not AAMA should back a change in International Codes allowing the use of one of its thermal performance test methods as an alternative to National Fenestration Rating Council methods. With NFRC still working on its method for rating commercial fenestration, architectural product manufacturers argued that they currently don’t have a method—accepted by the codes—to rate the thermal performance of their products, and recommended that AAMA should join the other organizations promoting AAMA’s method. Residential manufacturers, on the other hand, expressed concern that they rely on AAMA’s current relationship with NFRC, and that AAMA should be cautious in taking steps that might jeopardize that relationship.
CHANGES IN AAMA CERTIFICATION PROGRAM
AAMA has spent much of the past year or so reviewing its certification program to both enhance it and make it more cost-effective for licensees. As part of the California meeting, AAMA’s John Lewis unveiled a new proposed fee structure. The overall strategy, he explained, is to move the AAMA certification program from “label-based fees” to “service-based fees.” The new plan calls for an annual cap of $60,000 on label fees for individual licensees (manufacturers that certify products). After licensees reach the cap, fees are reduced by half, Lewis continued. He also explained changes in the cost to have product lines included in AAMA’s certified product directory.
Noting that one goal for any change in fee structure would be that it must be “revenue-neutral,” he explained that the lower fees paid by some window and door manufacturers will likely lead to higher fees for companies to have verified components listed, as well as higher fees to become an AAMA-accredited lab.
Traco’s Bill Deushle spoke about structural changes to the AAMA certification program, noting that several new levels and options are being added to the “legacy” program. One option he said would be a “premier quality control program” that would incorporate production line testing. Other options under development would meet architectural product manufacturer needs for either product line or project-specific product certification.
Other business at the AAMA meeting included a presentation from Werner Preusker of Germany, who spoke about industry efforts in Germany to promote PVC in response to environmental groups that were trying to limit or ban its use. He showed highlights from the PVCplus campaign, which he reported has led to a turnaround reducing public debate and contributed to a reversal in PVC sales. Manufacturers in North America, he suggested, should be “investing in your reputation,” promoting the benefits of PVC, delivering a continuous flow of positive messages and building trust with the public. The German experience shows it is worthwhile, translating into motivated employees, increased demand and greater profitability, he concluded.
IGMA GUIDE DOCUMENTS
Getting down to business quickly, IGMA kicked off its sessions looking at new glazing guidelines covering both commercial and residential applications. Discussions focused on recommended glazing clearances and setting block heights for commercial IG units.
IGMA technical consultant Bill Lingnell reviewed his preliminary research on the effectiveness of standard methods for closing capillary tubes in the field. Using a small pump and a glass of water, he demonstrated how he tested both by crimping the tubes and by applying a dollop of silicone on the end, and suggested that both methods work if done properly. The key is doing the crimping and sealing correctly, he noted, and a combination of both steps offers the highest assurance that the tube will be closed.
Another document IGMA is considering is a guideline or recommendation for avoiding thermal stress cracks in glass. Lingnell presented his initial draft, which provided an explanation about how temperature differentials across the glass create thermal stresses. He then went through the list of factors that can potentially cause different temperatures at the edge of glass than across the lite as a whole. A number of attendees suggested other potential causes, including growing trees or plants, new adjacent buildings and protective shutters developed for impact markets.
Also discussed was its study on the gas permeability of sheet materials. The group is now getting ready for the second phase, developing a method for evaluating the gas permeability of edge seal assemblies, and it reviewed a request for proposal that IGMA plans to send out to various test organizations.
Both the AAMA and IGMA meetings continue through tomorrow. Look for more coverage next week in WDweekly, and expanded coverage of commercial issues from the meeting in our sister publication, e-glass weekly. JGS
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Hurd Workers Scrap Union
Employees of Hurd Windows & Doors voted last week to deunionize the company’s Merrill, Wis., facility...
Employees of Hurd Windows & Doors voted last week to deunionize the company’s Merrill, Wis., facility. The dissolution of the United Brotherhood of Carpenters and Joiners of America union follows similar moves at the manufacturer’s Medford, Wis., facilities earlier this year. The Merrill facilities were the last in the company network to be represented by a union.
“We believe our employees made a decision that is in their best interest and that of our customers,” says Scott Albers, director of human resources. “This decision, by our employees, improves our ability to compete and grants us greater flexibility to pursue innovative processes in the future. We look to the future with great anticipation and excitement.” Dominic Truniger, Hurd’s president, adds that the vote demonstrates employees’ confidence in the direction of the company, as well as their role in its success. “This deunionization permits us to proactively make decisions and diversify production so that Hurd can address the challenges of a volatile housing market,” he says. “We are very optimistic about our future.”
Hurd, owned by parent company Monarch Holdings Inc., announced last fall the permanent cut of more than 100 jobs at the Merrill facility. The custom wood window and door manufacturer is headquartered in Medford, Wis.
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PCBC Sends Message of Performance
San Francisco—If this year’s International Builders’ Show focused on aesthetics and differentiation, its West Coast counterpart, PCBC: The Premier Building Show, took a different path. At this show, exhibitors...
San Francisco—If this year’s International Builders’ Show focused on aesthetics and differentiation, its West Coast counterpart, the PCBC: The Premier Building Show, took a different path. Exhibitors highlighted their products’ performance attributes front-and-center.
Window and door manufacturers reported catering their displays to the West Coast market by showcasing in-demand styles and relevant performance features.
West Coast builders attending the PCBC Show in San Francisco received messages of performance enhancements, including new generations of high-performance glass and re-engineered components.
The West Coast audience is arguably more performance-minded, particularly builders in California dealing with the energy efficiency guidelines outlined in Title 24. Window and door manufacturers targeted this audience with details on their latest low-E glass packages, information about water resistance and other performance numbers.
“Performance glass means something to just about everybody,” said Jeff Kibler, Peachtree Doors & Windows brand manager. “Whether it’s for ‘green’ or for energy and money savings, people want to see the best of all of the glazing technology.” Peachtree, along with other operations in the Weather Shield Manufacturing family of companies, were among numerous window and door manufacturers dedicating significant display space to their performance glass offerings.
Weather Shield, Peachtree and the new Visions Windows & Doors vinyl operation each promoted Zo-e-Shield performance glass, featuring Real Warm Edge spacer, multiple layers of low-E glass and inert gas-filled airspaces. Gone are the days when manufacturers assign a trademarked name to a glass system and pass it along as different, Kibler added.
Milgard Windows & Doors highlighted its SunCoatMax low-E insulating glass system, pointing out to attending builders that high performance glass packages will often allow cost-saving adjustments with other aspects of the house. “Builders can reduce the size of their air conditioning units with this glass,” explained Christopher Thiede, spokesperson for the manufacturer. “A house is definitely a system and everything plays off each other.”
Atrium Cos. sang the praises of its Cardinal LoE 366 glass, a three-coat low-E offering, over its two-coat counterparts. “We’re really talking up glass performance,” said Mark Gallant, vice president of marketing. “Builders have got to run the calculations to understand that they can save about $500 on air conditioner costs with a $60 to $100 upgrade with low-E option.”
Andersen Windows showcased its Low-E4 glass, which features an exterior coating that reduces water spots and dirt build-up when activated by sunlight, and MI Windows & Doors highlighted its use of Cardinal’s LoE 366 glass.
OPEN DOOR TO PERFORMANCE
Door manufacturers at the show emphasized strong components and integrated systems. Simpson Door Co. was clear in delivering its performance message with a display that explained to attendees how engineering tweaks on its doors result in longer-term performance. The company fingerjointed a composite material on the bottom corners of its slabs, an upgrade named UltraBlock, to resist the effects of water intrusion. The manufacturer also added a water barrier to the outside of its doors, a medium density overlay that is primed and ready to paint. “We’re trying to reach the builder with our upgrades,” said Brad Loveless, marketing manager. “We have less of a focus on aesthetics at this show, and more on performance.”
Therma-Tru Doors put its TruDefense system to the test for all to see on the trade show floor with a rain simulation display, pouring 25 inches of water per hour on an 8-foot Smooth Star inswing French door. The nearby “component wall” showed attendees the individual elements that combine to make the company’s door system. Seemingly simple adjustments to traditional door systems such as a corner pad to stop the bottom of the door from absorbing water, raised weatherseals that “lock” together to form a barrier from weather intrusion, adjustable hinges and standard multi-point locking systems, can result in the elimination of big headaches for builders down the road, the company expressed.
Therma-Tru, along with several other door manufacturers, introduced between-the-glass wrought iron designs to match Southwestern décor styles. The thinner wrought iron patterns are protected inside the IG unit, giving the option of the traditional wrought iron look without susceptibility to rusting and other damage.
The folding exterior door systems many companies displayed at the Builders’ Show in February gained additional momentum at this summer show as floor shoppers sought solutions to bring the outdoors in for West Coast and Southwest homeowners. “The trend in doors is that everything is going to bi-fold or pocket systems,” said Lance Young, sales manager for Weather Shield in Southern California and Las Vegas. “People want to transfer easily from indoors to outdoors. They want to return to nature as much as possible.”
Marvin Windows & Doors displayed a bi-fold exterior door, but also highlighted its Ultimate In-Swing French door with no center stile, as another way to open up an exterior wall to the outside. The in-swing styles are popular among buyers in some Northern climates where snow pile-up in the winter may prevent a door from swinging out.
COMPONENTS GET MAKEOVERS
No-center-stile French doors, currently popular among homeowners, call for some creative screening options, since there’s nothing in the middle to which the rolling screen can attach. Mirage Screens displayed an after-market screen option for these types of door systems that pulls in like window curtains from each side and connects in the middle with strong, non-ferrous magnets. In addition to performance upgrades to its magnetic latching system, the company also offers 45 colors to match existing building products. “I think people are becoming more aware of the retractable screen field,” says Ben Hume, president of Alco, maker of Mirage Screens. “People may want air conditioning during the day but fresh air in the evenings. It’s not so much an energy savings thing, but just plain personal comfort.”
Weather Shield highlighted some upgrades in hardware performance with its 7-foot tall casement window display. As the wood window market calls for bigger and bigger windows, the company designed a casement that functions almost like a swinging door on a three-butt hinge. The window still operates with a crank but the additional weight of the large panes of glass rests on the hinges. “Wood windows are getting bigger, so we’re showing them bigger,” said Young.
Milgard showcased higher-performing hardware on its Montecito and Tuscany vinyl window lines with its SmartTouch lock, a latching device that also doubles as a slider handle.
Windsor Windows & Doors’ show representatives said builders are increasingly aware that different products deliver different levels of performance, and they aren’t shy about grilling sales personnel on the details. “People are really conscious these days about performance,” says Scott Renke, western division sales manager of Windsor. “They’re asking about what types of wood we’re using and where it comes from. They’re specifying alder, for example, to match cabinets, trim and interior doors, and they want to know it will perform as an exterior door.”
As PCBC is a staple event for many West Coast builders, Windsor and many other exhibitors tailored booths to reflect Western tastes in style and preferences in performance. “This is the first year we’re showing products specific to the West,” Renke says. “We’ve tailored our performance and aesthetic message to high-end custom home builders and architects serving this market.”
PCBC organizers expected a crowd of about 30,000 attendees this year to visit more than 700 exhibitors. Next year’s event will be June 25-27 at the Mascone Center in San Francisco. For more information, visit http://www.pcbc.com. CL
Jim Kehoe, one of the owners of Portland Millwork, accepts from Window & Door senior editor Christina Lewellen the 2006 Dealers of the Year Award for Excellence Serving Professionals. Accepting with him is Tom Stumpfig (left), territory manager for Weather Shield Manufacturing.
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CMI Completes Texas Plant
CraftMaster Manufacturing Inc. has wrapped up construction of its new interior door production facility in Garland, Texas...
CraftMaster Manufacturing Inc. has wrapped up construction of its new interior door production facility in Garland, Texas, located just northeast of Dallas. The facility measures 253,000 square feet and will be the company’s third door manufacturing facility. CMI announced the expansion last November and had expected the plant to be online in the second quarter of this year. The company reports it began shipping its CraftMaster doors May 30.
The new Texas plant will help CMI meet door production requirements in more areas of the U.S.
“Opening a production facility in the Dallas/Fort Worth Metroplex will immediately help us meet customer demands in the Southern and Mid-central United States for all of our raised panel interior doors,” says Bob Merrill, CMI president and CEO. CMI chose the Garland location for its strategic shipping access throughout Texas, as well as to Oklahoma, Kansas, Louisiana and Arkansas, he adds.
Based in Chicago, CMI produces building products for the residential, commercial and industrial markets at its Towanda, Penn., facility. The company adds the Garland site to its other door manufacturing facilities in Christiansburg, Va., and Ozark, Ala.
To read past WDweekly articles about CMI, click here.
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Conference Focuses on Expanding Color Options for Vinyl Windows and Other Building Products
Charlotte, N.C.—Technology is improving to meet growing market demand for color in plastic building materials...
Charlotte, N.C.—Technology is improving to meet growing market demand for color in plastic building materials, according to speakers at Profiles 2007, held here last week. Coming to North America for the first time, the two-day event was organized by Applied Market Information Ltd., a UK-based market research company that has hosted previous editions in Europe.
Color was not only the focus of talks, but also of many tabletop displays at Profiles 2007.
In its inaugural year, Profiles 2007 proved to be a successful forum for the exchange of ideas and information between those involved in the industry.
Jeff Miller of Comfort Line predicted that new manufacturing technologies would accelerate the growth of fiberglass windows and doors in the coming years.
Cincinatti Extrusion's Hans Matthesius discussed advances in co-extrusion technology in Europe.
Profiles 2007 attracted approximately 150 people, including window and numerous other building product manufacturers, extruders, resin and additive suppliers, extruders. In addition to the numerous presentations, the two-day event also featured a tabletop exhibition. Among the products being showcased were laminates and paints for window and other profiles, new devices for quality control measurement of profiles, a new color inspecting device and equipment for applying texture to profiles.
John Swanson, Window & Door editor/associate publisher, led off the program, reviewing recent trends in the window and door industry. Noting vinyl’s high level of market penetration, he predicted that “more manufacturers will begin exploring color options as well as alternative materials to differentiate themselves.”
ADDING COLOR
Offering an overview of inorganic and organic pigments, as well as dyes, James Rediske, a color specialist with Lanxess Corp., emphasized that manufacturers have many issues to address when adding color. The ability of a basic polymer matrix to hold up structurally, its resistance to weathering exposure and various processing issues can all be challenges. Still, he emphasized, given the range of pigments and materials available, color “is a value added feature that doesn’t have to add significant cost if properly accomplished.”
Building product manufacturers are seeing steadily increasing demand for colors, reported Kathryn Brannon of the Shepherd Color Co. Not only are more colors wanted, but darker colors are more in demand too. Pointing to the siding industry in particular, she said there’s also a steady trend away from coloring the entire profile to just using color on the exterior. Manufacturers in general are going to thinner and thinner capstocks and films.
Focusing on inorganic pigments, she explained that there are new heat-reflective products that can control the heat, but also warned manufacturers to use a great deal of care in choosing them. Noting the trend to exterior surface applications, she pointed out that visual opacity does not predict infrared opacity and this is one of many issues a plastics profile manufacturer needs to consider when developing color products. Due to exposure to the sun, UV, temperature extremes, moisture and pollutants, she said, there are many interactions “that may not be obvious, but we have to deal with them.”
Roman Hawrylko of PolyOne Corp., reported that new products from his company could expand the color palette offered by window manufacturers, based on testing done in Arizona, Florida and Ohio. Among existing products, he noted, weathering performance varies, with dark browns working best. Although hot desert and tropical climates are typically seen as being the toughest for vinyl colors, he reported that Northern industrial climates have proved even more difficult for many products.
Reviewing test results for new PVC alloys formulated for color profiles, Hawrylko said that dark colors are not only retained, but actually tend to darken when exposed to sunlight. The new formulations, which can be used for solid profiles or in capstock applications, also offer significant processing improvements over previous color materials, he said.
Siding manufacturers are using ASA, AES and ABS polymers to provide homeowners with more color options, reported Greg Gemeinhardt of Lustran Colors, part of Lanxess. He reviewed different options in ASA formulas for adding dark and medium colors over PVC siding. His company has also developed a new low-gloss product for use over PVC in profile applications.
PROFILE WRAPPING
One of the most widely used technologies for providing more finish options on vinyl windows is profile wrapping. Teaming up to present the latest technologies in equipment, adhesives and laminates were Siegfried Becker of Delle Vedove, Michael Ermel of Jowat Adhesives and David Harris of American Renolit. Becker discussed advances in machinery, pointing out that for glue application, suppliers are moving away from rollers to slot coaters. Slot coaters are more precise and transfer minimal heat to the wrapping material to prevent stretching, he explained. Ermel discussed the advantages of polyurethane hot melt adhesives.
Laminates have a long history of use with PVC window profiles in Europe, reported Harris. He estimates that 30 percent to 40 percent of windows sold there feature a laminated exterior. The lamination process is well established in the U.S. market too, he noted, as many window makers use it to provide woodgrain interiors. New products that should open the U.S. market further to exterior laminates feature an acrylic base layer (in place of PVC), combined with a transparent layer of PVDF, making the product extremely weather resistant, he said.
FIBERGLASS WINDOWS
While much of the talk focused on plastics and polymers, Jeff Miller of Comfort Line reviewed the advantages he sees in fiberglass windows and doors, including high strength, low expansion and construction and the ability to be finished in multiple colors.
“It’s the right material for the Sunbelt—from Florida to California,” he said, because it can be used to meet impact requirements and handle the dark colors often preferred in these markets.
Pultruded fiberglass products have been around for some time, and are in a similar position that vinyl was in the mid ’80s in the U.S. market, he continued. Extrusion outputs needed to be increased before vinyl could take off in the market, and pultruders need to increase the line speeds of their equipment to grow today. That, he reported, is beginning to happen, and he pointed to technology his firm developed for a sunroom product as a big step forward. He also said his company was planning to introduce a new round-top fiberglass product, as it had overcome another previous limitation associated with pultruded windows and doors.
TITANIUM DIOXIDE
A key ingredient in vinyl window profiles used to prevent degradation by UV and provide a consistent white color is titanium dioxide. The conference featured three speakers on the subject, including Andrew Feng of DuPont Titanium Technologies, who reported on a recent weather study performed by his firm. Like PolyOne’s Hawrylko, he noted that Northern industrial climates—near Shanghai in his company’s tests—also proved to be one of the most challenging for vinyl appearance.
Tom Rachal of Tronox emphasized that not all TiO2 products are the same, even those billed as “equivalents.” The use of one product in place of another may not be disastrous, but it’s certainly not optimum and he reviewed the impact of different TiO2 products on the color of various vinyls.
Marty Paisner of Millennium Chemicals reported on new, ultra-fine TiO2 products that should help in the development of dark color profiles. He cautioned, however, that they could offer some processing challenges.
Paisner also looked at how different segments of the building products industry have defined “color hold” to date, reviewing ASTM standards and how they are used in certification programs created b y the Vinyl Siding Institute and the American Architectural Manufacturers Association, and the Plastic Lumber Trade Association.
MANUFACTURING TECHNOLOGIES
Not all the discussion in Charlotte focused on materials, with a number of speakers looking at new developments in profile equipment. Hans Matthesius of Cincinnati Extrusion reviewed co-extrusion technology, focusing on its history in Europe. He said co-extrusion is used to produce profiles for different colors, however much of his discussion focused on how window producers are using profiles combining a core made of recycled materials and co-extruded with a visible layer of virgin material. This approach, he explained, emerged following the rise of the anti-PVC movement in Europe, which spurred the industry, in turn, to make a concerted effort to use more recycled content.
This type of co-extrusion is demanding from a capital investment perspective, requiring high-end tooling. It also makes die tuning in production more challenging he commented. Matthesius said this type of co-extrusion would be suitable for the U.S. market if pressures from the environmental movement grow. He also noted that there are advantages, including potentially lower material costs.
Peter Zut of Krauss-Maffei focused on a new extruder screw design that allows water to cool the screw internally. The screw barrel is longer, he noted, and provides a larger processing window, delivering higher output, enhancing flexibility and improving quality.
Robert Perrault of Pallmann Machinenfabrik, reviewed new lines for taking in-plant vinyl scrap and reducing it to powder so it can be used again in profiles. Handling waste vinyl can be manpower intensive, he said, and previous equipment options for recycling content have required workers to manually feed scrap pieces or have been too large for a typical window manufacturing plant. New recycling lines, sized for window manufacturers, now allow loading of scrap from bins, enabling one person to load and operate the entire recycling operation, he reported.
Geared toward producers of all types of building products, the program also included discussions of materials for flexible profiles and wood/plastic composites used in decking and other applications. Gorell Windows’ Tyson Schwartz was also on the agenda, offering a look at how vinyl products are finding growing demand in regions with impact-resistance requirements.
At the end of the event, John Nash, a director with Applied Market Information, noted that with the strong turnout for the first-time North American event, the company is planning to host a similar event next year in the U.S. JGS
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- Nearly 100,000 Green Homes Certified Through Market-Driven Green Building Nationwide, Says NAHB
from National Association of Home Builders - For Many Retirees, Home's Too Sweet to Leave
from USATODAY.com - Foreclosures Up 6 Percent in May 2007 According to Bargain Network
from BusinessWire.com
...
Nearly 100,000 Green Homes Certified Through Market-Driven Green Building Nationwide, Says NAHB
from National Association of Home Builders
A new survey of local home building associations reveals that more than 97,000 homes have been built and certified by voluntary, builder-supported green building programs around the country since the mid-1990s, according to the National Association of Home Builders. That’s more than a 50 percent increase from the last survey of green homes: In 2004, the National Association of Home Builders Research Center counted 61,000 green homes in the United States... read more
For Many Retirees, Home's Too Sweet to Leave
from USATODAY.com
Bill and Rosemary Knapp had begun to envision retirement together. But where? During last year's Fourth of July holiday, they made their decision: They would retire close to home. After 29 happy years in the same colonial house in the town of Brick, N.J., the Knapps had decided to move. Bill, 60, who'd retired in 2002, and Rosemary, 59, with plans to retire in the next year, felt their neighborhood had changed... read more
Foreclosures Up 6 Percent in May 2007 According to Bargain Network
One New Foreclosure Filing for Every 772 U.S. Households
from BusinessWire.com
Bargain Network (bargain.com), a leading online provider of real estate foreclosures, pre-foreclosures and for-sale-by-owner property listings and information reported today that the number of properties entering some stage of the foreclosure process in May 2007 climbed approximately 6 percent to 149,000 listings compared to April 2007. This also marks a 38 percent increase in foreclosure listing activity compared to November 2006 when properties in some stage of foreclosure totaled 108,000... read more