3 Faces of Pigment 49

World Center for Concrete Technology,

exemplary design for architectural block

BY ROB YOUNG

As we were driving north to Alpena, I kept wondering why my destination, the World Center for Concrete Technology, would be located in Alpena, MI on the campus of Alpena Community College.  I had known the city as a vacation site featuring beaches along the shores of Thunder Bay and Lake Huron in the summer and a winter destination for skiing, snowmobiling and ice fishing.  Certainly the access to shipping on the lake would be advantageous to the cement and cement products industries but there had to be more.  Upon arrival, I did some research on the history of the city.  There was more, much more.

During the late 1800s, timber was the natural resource.  Alpena was capitalizing on the lumber boom.  Forests were harvested and lumber floated down the Alpena and Black Rivers to Lake Huron for shipment to a final destination.  But, as in all boom times, when the product dies so does the local economy.

The Besser Influence

An enterprising man named Herman Besser operated a factory that produced staves for the barrel industry.  As forests dwindled, a new resource beneath the land emerged.  Huge limestone deposits were discovered in the area between Alpena and Rogers City.  Besser, realizing an opportunity, instructed his son, Jesse, then 18 years of age, to find some viable use for limestone.  Charging the innovative Jesse with this mission could have been the most provocative decision Herman ever made.

       Jesse became a self-taught engineer and built a hand tamp blockmaking machine which would mold single concrete masonry units one at a time.  The process soon became mechanized, then automated and the rest is history!  Today, as at the turn of the last century, Besser Company is the innovator in machinery to manufacture concrete block.  The business is very specialized.  Besser produces 50-60 blockmaking machines per year and all are custom orders.

       In 1925, Herman Besser was granted a patent addressing decorative faces on concrete block.  The patent covered the process and included detail such as aggregate gradation, use of large stone chips, proper use of cement and water, and mixing and splitting information that is still followed today where quality splits are made.  Many units have evolved from this original concept.

The original Bes-Stone split block home was built in 1923 by Herman Besser.

Other architectural block including split fluted, striated, brick, slump, followed.

       Jesse and the Besser Company influenced building materials used in Alpena.  Jesse’s generosity of land, block or funds gave Alpena the Masonic Temple (now the Civic Center), First Congregational Church, Presbyterian Church, Besser School, Alpena General Hospital, Ella White School, the Holiday Inn and more.  Besser’s great nephew, Jim Park, is now Chairman and CEO of the Besser Company.

The Harris Influence

In 1903, 44 year-old William P. Harris was sent to Alpena to open and manage a quarry for Michigan Alkali Co. Limestone was being consumed in increasing quantities for the production of soda ash used in manufacturing plate glass.

       The success of the operation Harris organized left the quarry with a burgeoning amount of limestone waste – the undersized “fines” screened out of the four-or-more-inch chunks needed for the soda ash process.  Quarries of the day were commonly jeopardized by accumulation of such waste material, but in Alpena, it gave rise to an entirely new business venture.

       In what may be one of the foremost examples of turning a liability into an asset, Michigan Alkali Vice President J.B. Ford saw a new cement-making enterprise as the “fine” answer to the quarry’s limestone waste problem.  In 1906, the Huron Portland Cement Co. formed and became one of the largest enterprises of its kind in the nation.  Harris became manager of the cement mill, while remaining quarry manager.

      Three generations of the Harris family – William P., his son Clinton P. and grandson William P. II – have all made a significant contribution to the industry.  Their strong belief in education and technical training were factors in the decision of William P. Harris II to provide generous financial support to the World Center for Concrete Technology.  As a result, Harris Hall, which now houses the WCCT at Alpena Community College, will preserve the historical record of the family’s work and remain a lasting tribute.

Exemplary Design

A visit to the WCCT is well worth the trip.  The building was designed and constructed to be exemplary in its use of concrete and architectural block.

       Todd Cordill, Senior Associate and Project Manager with the architectural firm of Hobbs + Black Associates, Inc. explained their use of a blend of pigment 4D color 49 to integrally color architectural block of three different finishes and textures to create various effects.

       Split faced units have a natural stone-like texture produced by molding two units face-to-face, then mechanically splitting them apart after curing, creating a fractured surface.  Coarse aggregate is exposed in the process.  Split faces create depth and shadows.  Used on a building’s exterior, it appears differently when the sun is shining on it and when in shadow.  Its rough texture absorbs and reflects light.  It is used to imitate limestone or sandstone.  Accent bands here are natural grey concrete masonry units with natural grey mortar.

       Burnished or ground face units are polished to a smooth reflective finish, revealing natural aggregate colors.  They have an appearance of polished natural stone.  Tinted with pigment 4D 49, the appearance is a light salmon color.

       The same pigment 4D 49 in a glazed unit produces a deep rich rust color.  Glazing bonds a permanent color facing (typically porcelain or ceramic-like) to the CMU.  A glazed surface is waterproof, resistant to staining and graffiti, highly impact resistant, as well as being resistant to many chemicals and bacteria.  Special admixtures and mortars are available for use with glazed units to provide better stain, bacterial and water penetration resistance.

       Glazed units are often used for brightly colored accent bands.  The stain and moisture resistant finish reduces maintenance.  Here the rich glazed block is used on interior lobby walls as a decorative element, as well as a sturdy, maintenance free surface impervious to dings, dents and scratches.

       Mortar is also tinted with pigment 4D 49 and appears a bit lighter than the glazed unit, yet darker than the burnished units, above, while distinctively complementary to each.  Again, on the interior walls, the neutral grey mortar acts as the accent band.

       The serpentine shape of the building shows CMU can be used innovatively to create interest with curves.

Meeting the Construction Challenge

Mike Radosa, Vice President Field Operations, Boettcher Masonry, always enjoys a challenge like this.  “It takes special skill and precision to lay out the mortar joints allowing the units to follow the curve.  The architect wanted to show what could be done with block.  This is a great example!  This owner had extremely high expectations.  We were told before bidding, this would be a zero tolerance job.  It was to be flawless.

       “The challenge was BIG in every aspect of the job.  Eighty variations of block needed to be tightly specified, delivered just in time and inventoried for specific use.  Estimator Sam Kasley was right on the money for each item.

       “Most of the building was constructed during winter months with snow on the ground in Alpena lasting from November through March.  Construction began in August, so we were able to create a materials enclosure to get through the winter.”

       For Boettcher, it was business as usual.  The first ISO certified mason contractor in the country, Boettcher always performs to high quality standards in every aspect of every job.

       Radosa said they do quite a bit of radius work now.  “The larger the radius, the more you can accomplish with mortar.  1/16” more on front of the joint and 1/16” less on the back of the joint or vice versa.  For a tight radius, block may need to be trimmed.  It is easier to achieve with stacked bond.  We can construct it any way the customer wants.”

Material of Choice

Al Kuchnicki, Sales Manager, 4D, and material supplier for the WCCT, said “There were 50 molds used to meet the variety of shapes and sizes required.  Ground face units may have had only a single face burnished or multiple surfaces burnished including additional faces, ends and bullnoses.  There were 4”, 6”, 8” and 12” units used on this project, as well as half highs and scored CMUs.  The sill blocks were typical bullnose units.”  4D has a complete line of standard sizes and shapes with the additional capacity to customize shapes with the additional capacity to customize shapes with their gang saw.”

       While the building’s exterior and lobby are truly an artistic expression using architectural concrete masonry units, the entire building features the many advantages of CMUs.

       Durability of CMU block ensures that is will look the same 50 years hence and be virtually maintenance free for its duration.

       The cost effectiveness of a loadbearing masonry wall system comes in first every time – right from the design stage through engineering and construction.  Even throughout the life of the building, with low maintenance and heating and cooling efficiencies, loadbearing masonry continues to win at being cost effective.

       Fire resistance offers up to a 4-hour fire rating, allowing suitable time to safely empty an entire building filled with tenants, staff, guests or inhabitants.

       Sound absorbing qualities allow the WCCT to include a noisy blockmaking plant in the same structure as quiet classrooms and labs by using lightweight units which are more sound absorbent.

       Cordill stated the owner’s desire to make this building a living example of standards for concrete masonry.  The lobby and classroom wings are multi-wythe construction, loadbearing masonry.  Single wythe construction is used in the blockmaking plant.

       “It is very rare that we get an opportunity to be as creative in design as we were here and to design various textures into one building like this,” said Cordill.  “The design demonstrates the capabilities and dispels any limitation for CMUs.  This building shows non-rectilinear wall construction.  There are two center points of arches in the floor plan to minimize the necessity of stacked bond.  We found the best intersecting point and used that polygon within the arc for the windows.”

       “Owners are telling us more and more what they want in their buildings, but still appreciate when we offer suggestions – like colored mortars.  Typically, that is one element they really like but were not aware of.  We are using a lot more burnished block.  I almost see that as a trend now.  Its smooth, polished face is very attractive and very durable.  We use it frequently in schools, public libraries and correctional facilities.”

       So many building throughout the city of Alpena are constructed with architectural block, making this city architecturally very interesting with its variety from colors, textures, molds and patterns in laying.  The whole city is a tribute to the legacy of the Besser Company.

World Class Center for World Class Programs

Jim Hayford, Executive Director of the WCCT, is a graduate of Michigan State University and also holds a Masters Degree in Construction Management from the University of Florida.  He worked as a building contractor in the State of Florida for more than 20 years specializing in masonry structures.  Recognizing the need to expand and further evolve, the WCCT hired Hayford in May of 2000 as Executive Director.  His zeal for masonry is a major asset to the WCCT.  His enthusiasm and ardor for masonry permeate the school.  He is excited with this opportunity to build world-class programs for this one-of-a-kind educational and research facility.  Much has been accomplished in his two years with the WCCT but plans for the future are only beginning.  Premary objectives are to provide hands on training, testing and research designed for the entire concrete products industry – manufacturers, suppliers, architect, builders, etc.  As Hayford says, “Meeting current and future challenges of the concrete related industries is the sole purpose of the WCCT.  Having a resource completely dedicated to this pursuit is an exciting competitive edge for the entire global industry.”

       The WCCT is a partnership of the concrete and concrete products industries, the State of Michigan, U.S. Department of Commerce EDA, U.S. Department of Agriculture and Alpena Community College.  It consists of four major components:  

·     Academic degree programs

·     Workforce training, development and certification programs

·     Confidential research

·     Certified facilities

       Alpena Community College has offered a Concrete Technology degree program for more than 30 years and a workforce training program, Blockmakers Workshops®, for more than 40 years.  Next fall will celebrate 50 years of blockmaking education offered through Alpena Community College in conjunction with the Besser Company.

Educational Process

The core of the educational process is hands on training.  This results in applied, not theoretical, education.  Classrooms are state of the art containing the most up to date audio, visual and telecommunication equipment.  Blockmakers Workshops® classroom even provides a translation suite for foreign speaking students.

       Five separate laboratories are contained within Harris Hall:  computer lab, mason training lab, production and manufacturing research lab, student instruction lab and a testing lab.  The production and manufacturing research lab is available for lease to companies, organizations and associations.  This facility may be used for confidential projects or specific topics may be thoroughly researched by degree program students who will analyze results and assemble a detailed report.  “Six research projects are being conducted this summer,” states Hayford.  “Five are related to recycling.”

       The academic degree program is a two-year curriculum leading to anAssociate in Applied Science Degree in Concrete Technology.  Graduates of this program may also continue on to complete a Bachelor of Science in Business Administration Degree offered at the campus through Lake Superior State University.  Graduates of the academic degree program have enjoyed tremendous success in job placement.  The most recent graduating class experienced 100% placement.  Two hundred and fifty job opportunities were available to the twenty-four graduates.  Salaries offered were in the $35,000 to $38,000 range and most included benefits and a company vehicle.

       The WCCT offers workshops and seminars to all in the industry.  The Executive Session, designed for management personnel, affords an overview of materials and the process of manufacturing concrete products.  It is a valuable tool for personnel in areas such as administration, finance, accounting, communications and marketing.  The Blockmakers Workshops® series has been expanded to meet the growing need for workforce development.  Examples of elements now included in this program are concrete masonry technology, specialty products and preventative maintenance.  Coming in May is a new management program, which will include courses on first line supervision, plant management and financial management for the concrete products industry.

       The WCCT with the Masonry Institute of Michigan hosts workshops for architects to instill an awareness of the myriad of uses and advantages of using concrete masonry untis and architectural block.  Participants are instructed on the manufacturing of split face concrete blocks and watch an actual splitting operation on the Besser equipment in the WCCT’s lab.  Versatility of design utilizing shapes, textures and colors of architectural block, a demonstration of the proper sampling techniques for mortar, grout and concrete, a presentation on loadbearing masonry, fire rating and testing of different panel assemblies are presented.  Four to five hundred Blockmakers are trained every year; 1—15% of those are from outside the U.S.

Goal of the WCCT

The mission of the World Center For Concrete Technology is “to provide leadership, advancement and mastery of concrete technology through education, training, research, testing, information management and communications.  This will be accomplished by securing shared participation, cooperation assistance and support of all those interested in concrete technology worldwide.”

       To assist in attaining this objective as well as to meet specific needs of the concrete and concrete products industries, an advisory group, The Partners Council, has been formed.  Representatives from the Council consist of Alpena Community College, Besser Company, W.R. Grace & Company, Lafarge North America Michigan Limestone Operations, CSR Rinker Materials Corp., Oldcastle APG and Master Builders.

       After leaving Jim Hayford and the WCCT, I noticed a new structure, the Thunder Bay Recreation Center at the edge of campus.  Another structure made exclusively of block.  Over a dozen variations of block to be exact.  The use of attractive acoustic block in the multi-purpose room allows it to be used as a comfortable facility for wedding receptions as well as basketball, volleyball and floor hockey.  This variety brought to mind one of Hayford’s classic remarks quoting Jesse Besser.  “The only element restricting the many uses of architectural block is one’s imagination.”