ProGUARD Insulated Sheathing

Where Did The Concept of Backer Board Start?

In a collaboration with a lather/plasterer, Ted Clear,the two men produced the first concrete backer board by hand, in molds.

In 1964, a tile setter by the name of Paul Dinkelhad a good idea, for faster easier construction:

Concrete Backer Board

The first concrete backer was named “WonderBoard©” by the cousin of Paul Dinkel, Howard Mees, Mees Distributors , Cincinnati.

Development of Backer Board

The first exterior jobs of backer were attemptedwith great success. Farrell’s Ice Cream was the first commercial exterior use of concrete backerboard. No longer in existence, it was located inSpringdale, OH. It was surfaced with ceramic tile.

The first exterior direct applied stucco applicationwas Queen of Peace Church, Millville, OH. It was finished with a direct applied stucco and embedded marble chip finish.


Queen of Peace ChurchMillville, OH


Soon after, knowledge of the new material, and the time savings began to generate greatinterest. Demand began to outpace hand production.

Ted Clear invented the automatic process to manufacture concrete backer.

Fin Pan, Inc. was begun to manufacture “WonderBoard”. Modulars, Inc. went into salesand marketing. The year was 1974.

Evolving Backer BoardBacker Board was beginning to catch on outsideout the Cincinnati Tri-State Area although it wasa few more years before other boards began.

Backer Board was produced in various sizes to fitspecific applications:3’ x 5’ was produced for a tub surrounds 3’ x 64” was produced order to be used for standard stud spacing.3’ x 4’ was produced for use on floors –

8’ was not available originally and extremely heavy

3’ x 5’ is still the most popular size for residential construction. Fin Pan still manufactures the various sizes for ease of installation and less waste on thejobsite.

Evolving Backer BoardUSG began producing Durock in 1987. Originally USG only produced 3’ x 5’. It was not long before Fin Pan and USG both developed an 8’ backer. USG developed the 4’ wide formatand Fin Pan developed the 3’ wide.

During this time, the “WonderBoard” name was sold by Modulars Inc. and rights given to Custom Building Products to produce.

Fin Pan, Inc. named its board “Util-A-Crete”. It is produced to the same quality standards as the original “WonderBoard”.

Evolving Backer BoardThe focus for most of the board manufacturers was lighter weight. Experimentation with the core of concrete backer boards lead USG and Custom to introduce other materials into their cores in the attempt to lighten and reduce raw material cost.

Bottom (Fly) Ash from coal fired electric plants and crushed slag from steel factories were introduced into some board, evidenced by the “coffee staining effect” or ferrous (rust) leach.Fly Ash (top ash) also were introduced into some board. A cleaner and uncontaminated material fly ash bonds well with Type 1 Portland Cement and does not produce rust staining.

Some manufacturers reduced the glass mesh count to reducecost. The result is less flexural strength.

Evolving Backer Board

Gypsum (Synthetic Gypsum) was also used in the attempt to lighten board weights.

The next change came from a company based inCanada, Unifix. Unifix introduce polystyrene beadto its core. A lightweight and easily cutable material, gained popularity and the attention of National Gypsum Company. National Gypsum acquired Unifix US and PermaBase was launched.

Type III Cements requiring high temperature curing (oven) also is used in some boards as well as entrained air to make them lighter.

Evolving Backer Board

Not to be forgotten, gypsum cored boards with fiber glass wrapped skins began to emerge with the success of DensGlass Gold for exteriors.

Fiber cement boards were next in the development path. Originally, not recommended for exterior, some fiber cement boards are still not recommendedfor exterior applications. James Hardie does not warrant nor recommend HardieBacker for exteriors

The DifferencesThe changes in the evolution of backer board are evidenced in the materials composition of each different type of backer and the effect on board properties. (Published Values*)

Backer Board Manufacturer Compressive Strength

Flexural Strength

Util-A-CreteProTEC

Fin Pan, Inc.Fin Pan, Inc.

>2600 psi>2600 psi

>1500 psi>1260 psi

DurockFiberRock

USG 2300 psi 750 psi

PermaBase Nat’l Gypsum 2250 psi 750 psi

WonderBoard Custom Bldg.Products

1250 psi >750 psi

The DifferencesWhat does Compressive Strength and Density mean to external uses of Backer Board?

The higher the compressive strength, the higher the density.

The higher the density, the slower the absorption rate.

The slower the absorption rate, the better the performance in

freeze thaw conditions.

The Differences

All Concrete Backer Boards absorb some water. The absorption of moisture is slowed in boards that have denser cores. The introduction of dissimilar materials, like polystyrene can leavepathways to transmit water.

A more homogenous core will allow materials to bond more thoroughly, become dense and resist the absorption of water. The perceived drawback is that the board is heavy and more difficult to cut. A moisture barrier is needed withall concrete based backer boards

The Differences

Some of the backer boards that are recommendedfor exterior use have gone to a glass mat wrappedexterior.

Advantages:Protects hygroscopic coreProtects against core damageResists Freeze ThawDisadvantages:Screw Penetration may cause moisture migration and core degradationCan not direct apply finishes

Glass Mesh count also plays a large role in flexural strength and values.

Woven fiberglass embedded has the highest flexural strengths. They provide the best tension and compression assembly translating to flat backer board.

Some manufacturers have an 8 x 8 count weave, some 8 x10, 8 x 12 and some 10 x 16. Flexural strength numbers directly correlate to weave counts.

The Differences

The Differences

Backer Board Manufacturer Compressive Strength

Flexural Strength

Util-A-CreteProTEC

Fin Pan, Inc.Fin Pan, Inc.

>2600 psi>2600 psi

>1500 psi>1260 psi

DurockFiberRock

USG 2300 psi 750 psi

PermaBase Nat’l Gypsum 2250 psi 750 psi

WonderBoard Custom Bldg.Products

1250 psi >750 psi

Current Accepted Exterior Assemblies

These two assemblies are similar in their details.

One has a polystyrene insulation board in the assembly

In the assembly:Gypsum Board (Int.)Stud Framing & CavityCavity InsulationStructural SheathingMoisture BarrierConcrete Backer BoardMesh Joint TapeLow Density Polystyrene InsulationMesh ReinforcementBase CoatTextured Finish

Advantages and Disadvantages of Current Assemblies

Advantages:Quick AssemblyBudget Friendly MaterialsDurable Disadvantages:Studs Are Un-insulated Allowing Heat/Cold TransferCan Increase HVAC Loads on the Building Envelope- Energy InefficiencyLow Density Polystyrene May Not Resist Damage Compromising Exterior FinishCavity Insulation May Become SaturatedMany Layers of Labor To Install

Thermal Bridging-Disadvantage

“These ties should be connected to the steel studs with screws. About two threads hold this screw in the 16-gauge outside flange of the metal stud. Thermal bridging at the stud could cause condensation to form at the inside face of this outside flange in the cold weather months.A rust or a galvanic cell reaction could develop at the juncture between the screw and the stud. The connection between the two could eventually deteriorate and become loose, which means that the masonry tie and the brick veneer also could become loose, causing cracks in the horizontal (bed) joints of the brick veneer.Cracks lead to water penetration through a brick veneer and provide an avenue for moisture to get inside the building, All associated problems could then be blamed on the masonry contractor who installed the brick veneer and masonry ties. However, it is actually a design problem.”

Masonry Construction , Jan, 2003 by Michael Gurevich

Only In Cold Climates – Right?

The purpose of insulation is to

separate one environment from

the other.

Warm Climates Need Insulation Too!

Emerging Sustainable & Energy Efficient Design

Insulation Needs to Be Applied on the Exterior of Stud or Frame Wall

What about EIF’s?

EIF’s – Right Concept – Wrong Assembly


Why Did It Experience Failures?

Surface could be “Spongy” and Damage ProneLeading to Water Intrusion and Gypsum Degradation.

Too many site applied layers to be reliable


The Solution Is to :

Insulate the Exterior of the Frame Wall

Provide Wind and Moisture Barrier

Provide a Durable Damage Resistant Surface That Will Accept Direct Applied Elastomeric, Faux Stone, Exterior Rated Ceramic Tile or Brick Veneer

Remove Hygroscopic Materials From the Assembly

Move the Dew Point Outside the Wall Cavity


Concrete Backer Board is a Perfect Solution

This is a new& emerging technologyProvides in a pre-assembled panel…InsulationVapor and Wind Barrier

Durable Surface

Sustainable Energy Efficient Design – The Time is Now!

Since the energy crisis of the 1970’s, the U.S. has flirted with energy efficient materials.

When times are flush, energy efficient designgets forgotten – immediate cost rules!

The use of Concrete Backer Board has developed over the course of the last 40 years to be a material of choice in sustainable design.

Emerging technologies and materials will continue to contribute to not only sustainable but energy efficient design.

ProGUARD Insulated Sheathing

Design

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