Behind the facade

Masonry Construction, April, 2004 by Diana Granitto

Masonry is just one component of a complex wall system. If its integrity is compromised, the performance of the masonry can be affected. Few masonry contractors are willing to assume responsibility for the entire wall system because of the many potential pitfalls; however, Masonry Arts Inc., Bessemer, Ala., is one who will.

"We furnish the whole wall system: the CMU cavity wall with dampproofing and insulation, a veneer of some type, and glass and glazing," says Roy Swindal, president of the contracting firm. "We handle air and water infiltration problems in conjunction with masonry so that we can offer a single-source package.

"The masonry end of our business has always been the staple," adds Swindal, a third-generation mason. "But over time, masonry and windows have become somewhat bound to one another. We got tired of the glass companies taking our stone and incorporating it into their systems, so we decided to do the opposite. We furnish a custom system that integrates all other aspects of a building's exterior cladding with the masonry."

Masonry Arts also performs testing on the facade, including masonry, glass and glazing, and metal panels, both prior to installation and onsite. "We make sure all the components work together as a system to meet air requirements and remain impermeable," Swindal says. "That way we know how well the waterproofing works for all the materials."

Control over the whole facade--particularly regarding the constant threat of water infiltration--was the catalyst for Swindal's move toward providing total cladding services. "If we don't do the waterproofing on the backup system, how do we guarantee its integrity?" Swindal reasons. "If the flashing for the windows was not installed properly by the glazing contractor, we could be held responsible for covering up a substrate that wasn't correctly waterproofed."

Project management

As a sole-source cladding contractor, Masonry Arts controls not only the facade, but also maintains the project schedule, manages the various trades, and coordinates equipment logistics. "The equipment can be used in a number of different ways, such as setting angle irons, caulking, setting punched windows in openings, and erecting stone," states Swindal. "We can organize the project as a whole with efficient else of scaffolding and supervision. One person makes sure all the components come together."

This strategy also enables Masonry Arts to submit a bid package for the cladding portions of a project. This approach limits bid shopping, according to Swindal, and provides the opportunity to make any adjustments needed to keep costs competitive.

"The company tries to address details that it thinks will be problematic before the job bids so the owner can avoid unexpected costs," he continues. "We help architects and engineers detail the masonry" The company often works directly for the owner.

Training

Masonry Arts committed to training its skilled masonry personnel from the company's inception in 1979. However, to support the emergence of its single-source capabilities, Masonry Arts also began cross-training its field force in other crafts. Many of its 450-600 field workers are cross-trained in masonry, glazing, and welding.

"A bricklayer can always become a glazer, but it takes tremendous dexterity to be a mason," explains Swindal. "A truly skilled bricklayer can do just about anything with his hands."

The company invests about $350,000 a year for its in-house stone and masonry apprentice programs, which are based on the Mason Contractors Association of America's three-year curriculum. Additional programs for ironworkers, glazers, carpenters, and welders are under development. Currently 23 apprentices are going through the program. Typically, about 70% of those who start the program graduate within three years, according to Swindal.

All of the apprentices--first, second, and third year--spend time each week working in the field as a supplement to their classroom instruction. The fieldwork equips them with valuable onsite experience installing materials and handling real-life situations. Apprentices are paid for their time spent in the classroom and on the jobsite. They often work on the many small projects that Masonry Arts does gratis for charities and other nonprofit organizations.

Company growth

Swindal served his apprenticeship in the mid-1960s working for his father's union firm, John Swindal Masonry (JSM). He went on to earn a degree in industrial management, and returned to JSM as foreman and estimator. In 1979, the Swindals established the open-shop Masonry Arts. John Swindal, who closed JSM in 1985 and moved full-time to Masonry Arts, retired three years ago, but remains active as a consultant and CEO.

In addition to its Bessemer headquarters, Masonry Arts has offices in Pensacola and Orlando, Fla., and Washington D.C. Most of the company's work is in the Southeast, but its portfolio also includes projects in several other regions of the United States and foreign locales, such as Puerto Rico and Russia.