Michigan builders, architects and contractors may be facing more-than-difficult hardships with a slowing housing situation; seeking out building solutions with new products has given some of these professionals an edge. Case in point, Birmingham, Mich.-based general contractor Mosher, Dolan, Cataldo & Kelly Commercial is about to wrap production on a 32,000-square-foot mixed-used building. The three-story complex, faced with metal panels and masonry, will have an American Bistro on the first floor; the second floor will be office space (and Mosher, Dolan, Cataldo & Kelly’s new digs); and the third floor has 11 lofts.

What marks this project as unique is that it is the first job in North America that will feature Dow’s new THERMAX Total Wall System. This system, for commercial steel stud wall assemblies, is designed to achieve high energy efficiency and contribute to large energy savings. The system offers continuous insulation value, air-barrier protection and a flashing system all-in-one. Dow says the system, which incorporates its THERMAX exterior sheathing, STYROFOAM spray polyurethane foam and WEATHERMATE flashings, offers a green solution with ease of design and installation. This advantage reduces construction time needed to install the system, the bonus of less cost and labor.

The irony is, Mosher, Dolan, Cataldo & Kelly had not originally specified the system—it was not even aware that Dow was coming out with it.

ALTERNATIVES

The company had a meeting to discuss alternatives to the original architectural plan and it was suggested that the company contact Dow since Mosher, Dolan, Cataldo & Kelly was going to use Dow’s CAVITYMATE product on the project anyway. The call was placed to see if Dow could provide a system that was a more simple system or “a way that we could draw the envelope of the building back to where it belonged,” says Steve Marszalek, principal with Mosher, Dolan, Cataldo & Kelly.

Dow representatives had informed Mosher, Dolan, Cataldo & Kelly of a new product it offered that solved these concerns. Both companies spent three months working through those details in refining the product, the Total Wall System (not to be confused with the company of the same name).

The three-in-one package system offers many benefits. For one, it enables an energy-efficient, moisture-managed wall with less materials and installation steps. Drywall contractor Dun-Rite worked on the project and used this system. Its owner, Bruce Schihi, says the Total Wall System provides a “better” exterior shell package with improved vapor and moisture seal. “The dew point is moved to the exterior finish of the wall area, virtually eliminating condensation behind the brick line.” He says the outcome is less labor and material costs. It’s also possible to have a total wall construction done by one contractor.

This project also introduced its contractors to the concept of blowing spray foam insulation from the inside. Dow’s STYROFOAM spray polyurethane foam, part of the Total Wall System, was applied on the interior of the steel studs. In theory, this will stop air infiltration by filling the gaps and penetrations, and supply strong moisture management and elimination of air convection in the wall. Jointly, the foam serves as insulation to the wall unit.

When asked what the cost for the system was compared to buying each of the products piecemeal, Marszalek says it came out roughly the same to a conventional gypsum-based system. The cost of turning a building over sooner, along with the energy costs to heat, was substantial.

The project broke ground in April 2007 and is slated for completion this fall. When complete, the building is expected to achieve a LEED Gold rating.

“I hope the product catches on,” says Marszalek. “It’s a product that makes everybody’s lives easier—architects, builders, carpenters, etc.”


For more information, visit building.dow.com. Reader Service No. 218.

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