MAS™ does NOT build MAS™ systems.  MAS™ certifies persons/companies and provides a per system License for each MAS™ structure built.  If you want a single MAS™ structure you have two choices:

(1) Contract with a Contractor that already has the capability/experience of building MAS™ systems, and can easily give you a quote.  A list of such companies (dealers) can be found at: http://www.modernarchstructures.com/community/dealers

(2) Find a local contractor of your choice and have them get trained by MAS™ or an independent field trainer.

Note:  Many persons desiring just a single MAS™ system will have their local contractor hire an existing experienced contractor to help them with the project and allow such local contractor to get training.  MAS experienced contractors often own one or more “Form Packages” which are a necessary to construct the MAS™ system.  Although such Form Packages can be rented by the supply division of MAS™, it is often significantly less expensive to have an Contractor provide construction expertise AND their forms to your local contractor of choice.

The discovery model floor was finished with an acid etch color finish.  This process takes just a few hours and requires no skill.  The material costs are minimal.  The acid / color is spread with a broom and then hosed off.  Because the floor is freshly pored concrete, there is no need for time consuming preparation.  Simply sweep or blow the floor clean before starting the process.  A sealant coat (optional) was applied at the completion of the interior construction.

The end result is a grained / tapered look that can resemble wood or stone depending on the colors chosen.

The MAS-570™ is 24 feet x 24 feet (7.3 meters x 7.3 meters).  The height in the center (at the peak of the arches) is 12 feet (3.65 meters).  The floor area is 570 sq. feet (53.5 sq. meters)

The MAS-1300™ is 36 feet x 36 feet (11 meters x 11 meters).  The height in the center (at the peak of the arches) is 18 feet (5.5 meters).  The floor area is 1,300 sq. feet (120.5 sq. meters)

NO.

Domes are great structures and very strong, however the MAS™ structures are NOT domes.  The MAS™ system uses bisecting dual arches that form a crown at the very top area.  The corners are square and, other than the arches, the interior walls are vertical and not curved like in a dome.

The MAS™ system is NOT a Dome Home, but sometimes is referred to as a “home with a dome” due to the “dome look” of the crown formed by the bisecting arches at the top most part of the structure.

← See basic “Dome Home” below on the left and basic “MAS™ Home” on the right →

Basic Dome Home.

This is NOT A MAS™ Home

MAS™ is NOT a Dome Home!

 

Basic MAS-1300™ Home

______________________________________________

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

MAS™ will actively pursue and prosecute, to the MAXIMUM EXTENT OF THE LAW, any violations of the MAS™ intellectual property, registrations and patents (pending and issued) throughout the world under international treaties as well as local laws, statutes, agreements, and registrations.

A ADELS Fee must be paid for each structure built.  A SINGLE License is issued for each SINGLE ADELS Fee paid to MAS™.

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

The MAS™ system uses shotcrete and due to the application in layers, shotcrete does not have cold joints.  Shotcrete creates a much stronger bond and because of the consolidation during the application process and the resulting strength, cracks are unusual.  Any cracks over time would be superficial and not structural.  MAS™ guarantees this!

Most users texture the concrete with stamping and thus the graying effect is minimized.  Also, the use of color in the final 1/4″ to 1/2″ layer is very inexpensive and will eliminate the “gray” concrete look if objectionable.  Many users also elect to stain the concrete using various colors to achieve the architectural look desired.

The MAS™ system has the potential to be used in a “retaining” wall situation where the unites are place IN a sloped embankment.  This application WOULD require waterproofing AND additional structural engineering based upon the forces of the “dirt” to be held up.  It is likely that additional concrete AND re-bar would be required.

Although MAS™ leaves the interior design up to 3rd parties, the MAS™ team has created a few sample floor plans.

MAS-570™ Sample Floor Plans

MAS-1300™ Sample Floor Plans

One of the best areas to view models with sample floor plans is in the dealer area.  High Line Enterprises offers a wide selection of models, including residential, multi-unit, duplexes, triplexes, fourplexes, and garages.

MAS™ along with others find equivalent R-value to be a useful way to summarize the energy efficiency of a MAS™ structure. Since there is wide spread confusion between a “conventional R-value” and an “equivalent R-value” it is important to understand the difference.  There are a few important cautions. First, equivalent R-value is not the same as the conventional R-value and you shouldn’t pretend it is.

A MAS™ structure can be built with 3rd party insulation products which typically use OPEN cell panel insulation in the MAS™ system corners and OPEN cell spray insulation on the arch sections.  The MAS™ structure can obtain a REAL conventional R-value of 60 but will offer an equivalent R-value of 60 for significantly less insulating material. Following are the calculations which show this.

Using 3.0″ open cell foam insulation on the corner wall and hip roof gives an approximate convention R-value of 15 in this area.  Using 3″ of  closed cell foam on the arches gives an approximate conventional R-value of 60.  See the table at the end of this discussion from the US Department of Energy, National Laboratory System, Science and Technology Information Center.

With NO 2×4’s, you get approximately 10% more insulation per square foot based upon 16″ stud spacing (1/16).  You also eliminate voids which accounts for about 1/2 inch of extra insulation.  Thus to get the conventional R-value you take 13.72 times 1.094 = 15.  This is based on 3.5 inches.  However we can subtract 1/2″ as there are no voids (missing insulation) due to imperfect fitting to 2×4 studs.

Using 1.0″ closed cell foam insulation on the arches give an approximate conventional R-value of 22 in this area.  Thus the to get the conventional R-value you take 20.09 times 1.094 = 22.

The MAS™ walls are not R-60 in the above example (but they can be). They still allow heat to conduct through like R-15 and R-22 walls because that’s what they are. It’s just that they have other, different ways, to save some energy, Equivalent R-value is a way to boil all the energy savings down and summarize them in one number, But it’s a different type of number.  MAS™ Considers this configuration to be an equivalent R-value of 60.

IS IS POSSIBLE TO ACHIEVE A CONVENTIONAL R-VALUE OF 60 by using more insulation AS FOLLOWS:

It is possible to use 1″ of open cell foam insulation on the corner walls and hip roof and cover it with  2.5″ of closed cell foam to achieve a conventional R-value of 60.  This is calculated as follows: Using 1″ instead of 3″ of open cell foam yields a conventional R-value of 15/3 = 5.  We desire an R-60 and thus need to make up and R-value of 55 (60-5) with the closed cell foam.  As shown in the calculations above, we get a conventional R-22 per 1″ of closed cell foam.  Thus 55/22 = 2.5.  Thus with 2.5″ of closed cell foam sprayed on top of the 1″ of open cell foam we get a conventional R-value of 60.   Applying 2 3/4″ of closed cell foam on the arches would achieve a conventional R-value of 60 in this area.  Thus the entire MAS™ structure can be built with a conventional R-value of 60.

In summary, the MAS™ structure can achieve a conventional R-value of 60.  However, an equivalent R-value of 60 is achieved with significantly less insulation due to the lack of voids, thermal mas and other factors that have a profound effect on the use of energy for heating and cooling.

MASKanX™ is a patent pending revolutionary solution to interior partitions. MASKanX™ allows for the use of freestanding and movable wall partitions that can take full advantage of the non impeded interior spans of the MAS™ system.  These 100% clear spans allow for non-bearing interior partitions which would not be possible with conventional construction. With the MASKanX™ solution, the home owner can reconfigure the interior to add or remove rooms, re-size rooms or other living spaces in a matter of hours.

The MASKanX™ is a SINGLE hardware device solution.  MAS™ can supply the MASKanX™ device with complete design templates for the partitions.  Thus the partitions can be constructed locally through automated CNC milling machines using the supplied bit map file or constructed on site using conventional construction techniques.

What does this have to do with MAS™? If a customer wants a green house tell them to go buy one. If your MAS Distributor wants to include green houses in their project proposal there is nothing preventing a MAS Distributor from working on a project that would include a green house.

YES

There is virtually NO limit to the variety of facades that can be created with the exterior facade forming system created by MAS™ called the MASFacFos™. 

MAS™ exterior facade form sets from the MASFacFos™ forming system line such as the “PARAPET” or “SOFFIT” can be used to construct an entirely different architectural look with little incremental cost.  In addition, foam “pop outs” can be used to form (and cover in concrete) almost any exterior 3 dimensional detail such as window/door trim features, corner blocks, etc.

To view examples of MAS structures that can be constructed using the MASFacFos™ please visit the MAS EXTERIORS area of this website and select one or more GALLERY tabs.

Concrete is inherently fire proof.  Because the concrete does not encapsulate flammable material in the MAS™ exterior structural shell system there is no de-rating of the concrete required.  The interior walls can also be built from concrete making the entire finished structure highly resistant to fire, and inherently survivable should an interior contents fire erupt.  I.e. the MAS™ concrete structure does not provide ANY fuel to facilitate the spreading of a interior content fire.  The entire MAS™ structure is NON-COMBUSTIBLE.

It is unlikely that the interior contents would contain enough combustible material (fire load) to cause damage to the MAS™ concrete shell even if it became fully engulfed in a fire.

THERE IS NO COMPARISON

Modular homes were a great solution before MAS™  for fast construction,  low cost, low end homes.  The modular industry has done a great job a increasing quality and lowering cost through engineering, quality control and assembly line production.  However, the introduction of the MAS™  solution by Southern Utah University has made the modular home obsolete over night.  Why would someone contract for a more costly, longer build time, less durable, higher maintenance home when you can have a MAS™ home that will outlive you, your kids and your kids kids with virtually NO maintenance, at far less cost, in just a week or two.  The answer:  THEY WOULD’NT.  The MAS™ home is the WORLDS housing solution and will change the way people view home quality, safety and longevity.

See the MAS™ Comparison Chart for more information.

Timber Frame Post and Beam Home is at the high end of conventional construction yet the look can be easily achieved in a MAS™ home.  A MAS™ home can achieve this same look, both inside and out, using inexpensive concrete facades that will last hundreds of years.

These facades will require additional man hours for construction, but the additional material costs will be minimal.

North Woods Joinery has many solutions that can be successfully used in a MAS™ home should the owner want more than a facade.

NO – ABSOLUTELY NOT

A MAS™ home is built entirely on site and is considered 100% site built.  The reason that it can be built so fast is the use of the MAS™ Patent Pending Forming system invented at Southern Utah University under the leadership of Professor Edwards.  Houses that are NOT 100% site built often times have restrictions from communities, insurance providers, lenders, etc.  A MAS™ home should have NONE of these restrictions.

What Do the Differences Mean to You?

Restrictive Covenants and Deed Restrictions

• Communities generally have no restrictions against traditional, site built homes. Many housing developments do set minimum size requirements and stipulate you must build a house that conforms to published standards or be approved by an architectural review committee.
• Most developments allow modular homes. Some do not, but in those cases the restrictions seem to have been imposed because of an ongoing confusion about the differences between modular homes and manufactured homes.
• Restrictive covenants and deed restrictions often exclude manufactured homes.

Investigate the deed restrictions thoroughly before purchasing land for any type of new home.

Facts About Modular, Manufactured & Site Built Homes

When you are buying a home, you might hear the terms modular homes, manufactured homes and site built homes. It’s important to understand how they all differ, no matter whether you are purchasing an existing house or plan to build on land that is subject to restrictions. The differences can affect a home’s price and its resale value, and even dictate whether or not it can be built on your land.

What Are Site Built Homes?

• They are constructed entirely at the building site.
• They conform to all state, local or regional codes where the house is located.
• Often called ‘stick-built’ houses.
• A well-built, cared for site-built home generally increases in value over time, although its location plays a key role in value.
• They generally receive the least damage during natural disasters.

 What Are Modular Homes?

• Modular homes are built in sections at a factory.
• Modular homes are built to conform to all state, local or regional building codes at their destinations.
• Sections are transported to the building site on truck beds, then joined together by local contractors.
• Local building inspectors check to make sure a modular home’s structure meets requirements and that all finish work is done properly.
• Modular homes are sometimes less expensive per square foot than site built houses.
• A well-built modular home should have the same longevity as its site-built counterpart, increasing in value over time.  However, this is NOT always the case.  Also their resistance to natural disasters can be significantly less than a site-built house depending on the founding employed during construction.

 What Are Manufactured Homes?

• Formerly referred to as mobile homes or trailers, but with many more style options than in the past.
• Manufactured houses are built in a factory.
• They conform to a Federal building code, called the HUD code, rather than to building codes at their destinations.
• Manufactured homes are built on a non-removable steel chassis.
• Sections are transported to the building site on their own wheels.
• Multi-part manufactured units are joined at their destination.
• Segments are not always placed on a permanent foundation, making them more difficult to re-finance.
• Building inspectors check the work done locally (electric hook up, etc.) but are not required to approve the structure.
• Manufactured housing is generally less expensive than site built and modular homes.
• Manufactured homes sometimes decrease in value over time.
• Manufactured homes home up very poorly in natural disasters.

NO

You can NOT replace an arch with a corner therefore you can NOT have 4 square corners on a MAS-570™.  The arches are the key structural components of the MAS™ system.

There are NO round corners on any MAS™ structure.  It may be possible to perform a faux “rounding” of the two square corners on the exterior. A interior finish crew may be able to perform a faux “rounding” of the interior of these same two square corners.

It possible that you are confusing the ARCHES with a round corner.

If you want a MAS™ system with 4 corners please consider the MAS-1300™.

There are walls to the ceiling separating the two duplex units.

There is a dividing wall between the two duplex units.  Therefore the loft of one unit is ONLY open to this same unit.  One unit can NOT see into the other unit.  The dividing wall is a two piece wall that meets in the middle and overlaps.  This allows for thermal expansion and contraction.  I.e. it is staggered.  This is a detail that is probably unimportant to you at this point, but it may be helpful to understand how such a wall does not violate the requirement that “NO interior walls can be built that extend between two opposite arches”.

All reinforced concrete design (ACI) is based on a cracked concrete section called post-dominant crack.  It is all about yielding as a crack opens, Re-bar yields by stretching and Helix yields partially by stretching and the rest by untwisting  The Helix design method follows ACI in this regard and is 3 times more than the maximum allowed under the ACI 318 design code . So Helix is as good as re-bar in a post crack or “reactive” situation.  

You can add a partial loft (not complete), however it will not double the square footage.  Due to the sloping side of the arches that make up the structure on the MAS-1300™ it is not possible to use all the floor space of a 2nd floor deck system.  A 2nd floor deck system that covers approximately 1/3 the foot print of the MAS-1300™ structure will only give a usable area of approximately 200 to 250 square feet.

You can NOT add a deck that spans from wall to wall due to thermal expansion limitations.  MAS™ only recommends the use of a 2nd floor decking system for storage or situations where personnel need to be located above other works for strategic reasons.

It is more cost effective to attach a MAS-570™ to the MAS-1300™ to create additional square footage then it is to install a 2nd floor deck system.

NO.  However, the MAS-570™ and the MAS-1300™ can be connected at the corners to provide for an unlimited amount of square footage and floor plan configuration.  The two models provided by MAS™ mathematically represent the most efficient two sizes that can be produced.  Therefore, if MAS™ were to create more sizes it would cost more and provide less thus making such sizes undesirable compared to the low cost and highly efficient MAS-570™ and MAS-1300™.

NO.  The MAS™ system does NOT contain any interior walls.  The MAS-570™ has a clear span of 24 feet and the MAS-1300™ has a clear span of 36 feet.  Therefore, the interior walls can be positioned in any conceivable manner and removed or relocated without regard to structural integrity.

No.  The interior windows must go in the envelope specified by the MAS™ engineers.  The MAS™ engineers allow for a great variety of window locations all on the corner areas and NONE in the arch areas.  Although there are dormers in the arch support, no other penetrations, except those for venting, are allowed by the MAS-™ engineers in the arch sections.

Multiple windows can easily be accommodated on each side of every corner.  This allows for 8 window locations which can accommodate several windows each of various sizes at each location.  Thus the number of windows, and flexibility in placement is far greater than is possible using traditional construction techniques.

There is NO additional cost to create a window opening, other than the purchase and installation of the actual window assembly.

Although the structure cost will be significantly less than ANY other form of construction, that is a difficult question to answer as MAS™ does NOT actually build structures.

If you want to know what a turn-key system, fully finished with rooms, appliances etc. will cost it is necessary to speak with a contractor.  Although MAS™ works with a great number of 3rd party vendors that can supply interior packages, etc. MAS™ is not involved with the pricing of these options.

The cost to build the shell, before windows, doors and any interior options other than insulation is something that MAS™ is familiar with.  A contractor can look up the required material as well as material quote sheets by visiting: http://www.modernarchstructures.com/technology/material-material-list

One of the key features of MAS™ structures is the ability to have a rock/brick/stone etc. exterior finish molded (stamped) into the last shotcrete layer for no additional material costs.  This allows a very upscale, top of the line, exterior look for NO additional cost other than a VERY small amount of finish labor.  This alone, coupled with NO required roofing material can represent a 25%  or more savings on the cost of construction when building an otherwise “architecturally expensive” building.

Yes.  The MAS™ system is very strong and is likely to withstand a severe impact by a tree.  However, it is difficult to quantify the size of the tree due to the many angles that it could strike the structure.  The larger the surface area of the strike, the better the chance for the object to be deflected without structural penetration or damage.

The MAS™ consists of the exterior shell only.  However, MAS™ has worked with numerous 3rd party vendors to provide interior options.  The MAS™ system can use any standard interior configuration used typical construction.  However, the MAS™ interior is often constructed of concrete partitions to allow a virtually damage proof configuration.  MAS™ provides many interior floor plans to help guide those incorporating the MAS™ system into their projects.

No, however all the openings for such doors and windows are formed as part of the construction of the MAS™ system.  There are no “bucks”, channels, stops, etc. required.  Once the MAS™ system shell is complete it is a simple matter to install windows and doors in the formed opening.  In addition, there is no increased cost to have one or more windows as the MAS™ patented forming system allows for great flexibility in such placement within the areas so designated by MAS™ engineering.

MAS™ does NOT build MAS™ systems.  MAS™ certifies persons/companies and provides a per system License for each MAS™ structure built.  If you want a single MAS™ structure you have two choices:

(1) Contract with a Contractor that already has the capability/experience of building MAS™ systems, and can easily give you a quote.  A list of such companies (dealers) can be found at: http://www.modernarchstructures.com/community/dealers

(2) Find a local contractor of your choice and have them get trained by MAS™ or an independent field trainer.

Note:  Many persons desiring just a single MAS™ system will have their local contractor hire an existing experienced contractor to help them with the project and allow such local contractor to get training.  MAS experienced contractors often own one or more “Form Packages” which are a necessary to construct the MAS™ system.  Although such Form Packages can be rented by the supply division of MAS™, it is often significantly less expensive to have an Contractor provide construction expertise AND their forms to your local contractor of choice.

The discovery model floor was finished with an acid etch color finish.  This process takes just a few hours and requires no skill.  The material costs are minimal.  The acid / color is spread with a broom and then hosed off.  Because the floor is freshly pored concrete, there is no need for time consuming preparation.  Simply sweep or blow the floor clean before starting the process.  A sealant coat (optional) was applied at the completion of the interior construction.

The end result is a grained / tapered look that can resemble wood or stone depending on the colors chosen.

The reason the MAS™ system is so easy to build is because of three primary factors, one of which is training.

1. MAS™ provides the bulk of the engineering required using its proprietary finite element analytical models.
2. MAS™ provides a patented forming system and scaffolding system (SPiFolding)
3. MAS™ provides the training necessary to construct the MAS™ system.

THE MAS™ 12 STEP PROCESS

(At a Glance)

Obtain and pay for a license from MAS™, obtain the  appropriate local permits, excavate, install slab and set vertical steel as per common construction practices require.

1. Corner layout for arch supports
2. Set fan manifold box, fans, air form ring, and air form
3. Stage SPiFolding
4. Inflate air form and set up SPiFolding/Tenting
5. Set up corner arch supports (garage openings if applicable)
6. Mark front entry for reinforcing steel (Install common arch leg at entry)
7. Attach corner panels (and garage panels if applicable)
8. Set reinforcing steel, dormers and doorway
9. Shotcrete application (layer 1)
10. Shotcrete application (layer 2)
11. Front entry arch support and shotcret layer for front entry
12. Final shotcrete layer with desired finish

MAS™ has defined a set of whistle blows (sounds) (short, long blows on a whistle) which were adopted from the train industry.  MAS™ calls this the “Whistle Code” and it is very helpful for all workers to know this code.  When volumetric mixers, pumps, skid steers, etc. are running it is often difficult to yell and be heard.  Therefore the Whistle Code is used by all workers and supervisors who each carry small whistles on a lanyard ready for use at all times.

MAS™ “WHISTLE CODE”

When visiting a construction site deploying the MAS™ system it is common to hear the workers signalling “three short beeps” on their whistles frequently.  This is the “GOING WELL” Whistle Code and is used to signal “good job”, “all is fine”, “things are going great”, “keep up the good work”, etc.  It is used as a form of motivation between workers to signal that everyone is doing a great job as a team and to keep things going as they are.

Foreman will often use the term “all threes” such as: “If you guys give me an hour of ALL THREES we can break for lunch early and take an extra 1/2 hour.”

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

MAS™ will actively pursue and prosecute, to the MAXIMUM EXTENT OF THE LAW, any violations of the MAS™ intellectual property, registrations and patents (pending and issued) throughout the world under international treaties as well as local laws, statutes, agreements, and registrations.

A ADELS Fee must be paid for each structure built.  A SINGLE License is issued for each SINGLE ADELS Fee paid to MAS™.

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

The MAS™ system uses shotcrete and due to the application in layers, shotcrete does not have cold joints.  Shotcrete creates a much stronger bond and because of the consolidation during the application process and the resulting strength, cracks are unusual.  Any cracks over time would be superficial and not structural.  MAS™ guarantees this!

Most users texture the concrete with stamping and thus the graying effect is minimized.  Also, the use of color in the final 1/4″ to 1/2″ layer is very inexpensive and will eliminate the “gray” concrete look if objectionable.  Many users also elect to stain the concrete using various colors to achieve the architectural look desired.

The MAS™ system has the potential to be used in a “retaining” wall situation where the unites are place IN a sloped embankment.  This application WOULD require waterproofing AND additional structural engineering based upon the forces of the “dirt” to be held up.  It is likely that additional concrete AND re-bar would be required.

MAS™ has NEVER had a problem getting a local entity in charge of building code enforcement to issue the permits and/or documentation necessary to build a MAS™ system structure.  The MAS™ system is designed around standard and accepted design principals using traditional engineering meeting the United States Uniform Building Code. (UBC).  Therefore, the system as designed, will likely exceed ALL local building codes.  However, if something unusual and unforeseen comes up, the MAS™ engineering team will work with the builder for no additional cost to find a solution where possible.

YES

Producibility: A term used to describe the ability of contractors to bid on a project proposal.

Although the MAS™ system is new to many contractors, MAS™ provides a “T2” training class that is specifically designed to educate a contractor on the MAS™ system and all aspects necessary to prepare a qualified, responsive and financially viable bid.

MAS™ along with others find equivalent R-value to be a useful way to summarize the energy efficiency of a MAS™ structure. Since there is wide spread confusion between a “conventional R-value” and an “equivalent R-value” it is important to understand the difference.  There are a few important cautions. First, equivalent R-value is not the same as the conventional R-value and you shouldn’t pretend it is.

A MAS™ structure can be built with 3rd party insulation products which typically use OPEN cell panel insulation in the MAS™ system corners and OPEN cell spray insulation on the arch sections.  The MAS™ structure can obtain a REAL conventional R-value of 60 but will offer an equivalent R-value of 60 for significantly less insulating material. Following are the calculations which show this.

Using 3.0″ open cell foam insulation on the corner wall and hip roof gives an approximate convention R-value of 15 in this area.  Using 3″ of  closed cell foam on the arches gives an approximate conventional R-value of 60.  See the table at the end of this discussion from the US Department of Energy, National Laboratory System, Science and Technology Information Center.

With NO 2×4’s, you get approximately 10% more insulation per square foot based upon 16″ stud spacing (1/16).  You also eliminate voids which accounts for about 1/2 inch of extra insulation.  Thus to get the conventional R-value you take 13.72 times 1.094 = 15.  This is based on 3.5 inches.  However we can subtract 1/2″ as there are no voids (missing insulation) due to imperfect fitting to 2×4 studs.

Using 1.0″ closed cell foam insulation on the arches give an approximate conventional R-value of 22 in this area.  Thus the to get the conventional R-value you take 20.09 times 1.094 = 22.

The MAS™ walls are not R-60 in the above example (but they can be). They still allow heat to conduct through like R-15 and R-22 walls because that’s what they are. It’s just that they have other, different ways, to save some energy, Equivalent R-value is a way to boil all the energy savings down and summarize them in one number, But it’s a different type of number.  MAS™ Considers this configuration to be an equivalent R-value of 60.

IS IS POSSIBLE TO ACHIEVE A CONVENTIONAL R-VALUE OF 60 by using more insulation AS FOLLOWS:

It is possible to use 1″ of open cell foam insulation on the corner walls and hip roof and cover it with  2.5″ of closed cell foam to achieve a conventional R-value of 60.  This is calculated as follows: Using 1″ instead of 3″ of open cell foam yields a conventional R-value of 15/3 = 5.  We desire an R-60 and thus need to make up and R-value of 55 (60-5) with the closed cell foam.  As shown in the calculations above, we get a conventional R-22 per 1″ of closed cell foam.  Thus 55/22 = 2.5.  Thus with 2.5″ of closed cell foam sprayed on top of the 1″ of open cell foam we get a conventional R-value of 60.   Applying 2 3/4″ of closed cell foam on the arches would achieve a conventional R-value of 60 in this area.  Thus the entire MAS™ structure can be built with a conventional R-value of 60.

In summary, the MAS™ structure can achieve a conventional R-value of 60.  However, an equivalent R-value of 60 is achieved with significantly less insulation due to the lack of voids, thermal mas and other factors that have a profound effect on the use of energy for heating and cooling.

MASKanX™ is a patent pending revolutionary solution to interior partitions. MASKanX™ allows for the use of freestanding and movable wall partitions that can take full advantage of the non impeded interior spans of the MAS™ system.  These 100% clear spans allow for non-bearing interior partitions which would not be possible with conventional construction. With the MASKanX™ solution, the home owner can reconfigure the interior to add or remove rooms, re-size rooms or other living spaces in a matter of hours.

The MASKanX™ is a SINGLE hardware device solution.  MAS™ can supply the MASKanX™ device with complete design templates for the partitions.  Thus the partitions can be constructed locally through automated CNC milling machines using the supplied bit map file or constructed on site using conventional construction techniques.

YES

There is virtually NO limit to the variety of facades that can be created with the exterior facade forming system created by MAS™ called the MASFacFos™. 

MAS™ exterior facade form sets from the MASFacFos™ forming system line such as the “PARAPET” or “SOFFIT” can be used to construct an entirely different architectural look with little incremental cost.  In addition, foam “pop outs” can be used to form (and cover in concrete) almost any exterior 3 dimensional detail such as window/door trim features, corner blocks, etc.

To view examples of MAS structures that can be constructed using the MASFacFos™ please visit the MAS EXTERIORS area of this website and select one or more GALLERY tabs.

The MAS™ system uses a conduit system that is embedded in the foundation.  The MAS-1300™ has a total of 5 duplex boxes per side, of which 2 of these home run to the electrical panel area.  Thus you end up with 20 duplex boxes, and 8 home runs.  This allows great flexibility for line voltage or low voltage applications.  The final interior wiring connects to such boxes.  If spray foam is going to be used, then Romex can be be “hot glued” to the walls when installing additional duplex outlets, and then covered by the foam.  The The MAS-570™ works in a similar manner however, it has only 3 duplex boxes and 1 home per side (total of 12 duplex boxes and 4 home runs).

Note:  The conduit system is very inexpensive as it is used to create a void in the concrete.  The concrete is what is actually protecting the final wiring and thus this inexpensive conduit does not require any type of rating.

 This is NOT a modular system.  All construction material is purchased locally giving you 100% local content.  MAS does provide (at cost) the forming systems.

Once constructed the MAS-1300™ weighs approximately 350,000 pounds thus making it unmovable!

Basic plumbing is provided either through a Plumbing Trough, that allows for plumbing to be brought in later, or basic “Stub Ups” for sewer, etc.  (or both).

Plumbing Trough: A 12″ wide plumbing trough is put about 2 inches under the top of the slab.  This allows room for a gray water sewer, black water sewer and fresh water to be “fished” in at any time.  Then it is run through the interior partitions as in standard construction.

The advantages of the Plumbing Trough is the ability to add plumbing at a later date.  Many 3rd world countries are providing central bathroom and kitchen facilities and thus have no “current” need for plumbing.  However, the ability to add plumbing without the need to tunnel, or tear down walls is a tremendous value and makes the MAS™ structure easily retrofitted as future needs and requirements change.  The same is true for the basic electrical system provided in a MAS™ system.

NO

MAS™ has done NO structural testing in the form of “stress to failure” type tests.  Our engineers have designed the MAS system using Finite Element Analysis (FEA) based upon standard and accepted engineering principals, processes and materials.

Concrete is inherently fire proof.  Because the concrete does not encapsulate flammable material in the MAS™ exterior structural shell system there is no de-rating of the concrete required.  The interior walls can also be built from concrete making the entire finished structure highly resistant to fire, and inherently survivable should an interior contents fire erupt.  I.e. the MAS™ concrete structure does not provide ANY fuel to facilitate the spreading of a interior content fire.  The entire MAS™ structure is NON-COMBUSTIBLE.

It is unlikely that the interior contents would contain enough combustible material (fire load) to cause damage to the MAS™ concrete shell even if it became fully engulfed in a fire.

When attaching MAS™ structures to one another in a retro-fit scenario the door way is made by extending the 4 foot window opening to the slab.  When attaching MAS structures to one another DURING construction there may be other options.  Such options must be engineered and may include eliminating the majority of this single corner connecting wall in both units such that the connection is “seamless”.  Such engineering is provided by MAS™ at no additional cost as part of the ADELS Fee.

Unlike conventional construction, the cost to add an additional MAS™ structure is virtually the same whether it is done during initial construction or via a retrofit (remodel) at some later date.

Note:  In the retro-fit scenario the extension of the 4 foot window to the slab to create a doorway is done as follows:

• Removal of the window unit if installed
• Saw cutting the concrete to the floor following the vertical lines of the window edge opening
• Saw cutting and chiseling  between these saw cut vertical lines and the slab
• Removal of the concrete panel below the window
• Shotcreting the saw cut and chiseled edges when the new MAS™ structure is constructed so as to encapsulate and protect any re-bar exposed during the cutting process and to finish the opening to the required width/height.  (Additional re-bar and doweling may be required if more than a few inches of Shotcrete is required to make the opening narrower or shorter)

As a contractor you are familiar with building.  What you need to learn is how to fit the MAS™ system into your existing method of construction.  To start with you will need to understand how to bid the project.  This will include determining the quantity and cost of forms and the labor time and skills required.  MAS™ provides calculators to help a contractor prepare bids.  Many contractors   use these calculators initially to understand the feasibility of using the MAS™ system for their project.

Once a contractor is confident the MAS™ system is an option for their project they will usually sign up to attend a T2 training class from MAS™.  The T2 training class will teach the contractor everything needed to bid a MAS™ structure including the advanced use of the calculators on the MAS™ website.  The T2 class will quickly orient the contractor to the MAS™ system and the unique forms that are used for construction.  The construction time line as well as the labor requirements will be thoroughly covered.

Construction with the MAS™ system is not complex and is much easier and faster than conventional construction.  Limited worker skills are required and can generally be learned in just a few days.  MAS™ provides detailed procedures, training videos and check lists as part of it’s inexpensive and thorough training programs.

One option available to a new contractor is to hire a MAS certified field trainer who can provide the expertise necessaryto do the job.  The MAS Field Trainer (an independent contractor) can also certified trainers and conduct “on the job” training for the new contractors personnel during the construction phase of the MAS™ system should Proficiency Certification be desired.  Once the new contractor has his crew trained and certified he can dismiss the Field Trainer.  This can be a cost effective and quick solution for a contractor to start their involvement with the MAS™ system.

First of all, it is the shell that is built in 5 days not a completed ready to move in home as shown in the schedule you reference.  Generally, contractors like between a few days to a week to finish a simple interior with bathrooms, bedrooms and a kitchen.  Although a MAS™ structure can be built and ready to move into in a week, MAS™ recommends that your schedule allows for a full 2 weeks from start to occupancy.  Note : The forms are generally only needed for 3.5 to 4 days, and the SPifolding is only needed for a week.

Unlike building with traditional construction, adding more personnel to a MAS™ construction project DOES NOT speed up the time it takes for construction.  This is because MAS™ has designed their procedures and forms to be highly efficient and work within the window required for concrete to cure.  Thus while the concrete is curing the personnel are not needed. Having additional personnel would accomplish nothing.  It is beneficial to have additional personnel when using a non-experienced crew or when local conditions are not conducive to construction.

Note: A typical “stick” built single family resident home takes 5 to 6 months on the average to complete in the United States.  This same home can be done in 1.5 to 3 months by putting a much larger crew on the job.  However there is a loss in efficiency when you speed up such a project such that workers get in each others way and have to wait while another contractor finishes so they can start.  The faster the home is built, the efficiency generally goes down.  The MAS™ system was designed from the ground up around an efficient dual two-man crew working 8 hours per day.  Thus if this crew worked 14 days, 8 hours per day (which is well more than it should take), there would be 448 man hours expended for the MAS-1300™ construction.  Standard “stick” built construction takes several thousands of man hours to complete.

Note: A Timber Frame Post and Beam Home is at the high end of conventional construction and construction will take longer than typical “stick” built construction.  A MAS™ home can achieve this same look, both inside and out, using inexpensive concrete facades that will last hundreds of years.

NO

Prior to March 1, 2012 there use to be two form sets for the Type G models.  One for the MAS-570™ and one for the MAS-1300™.  However, MAS™ redesigned these form sets into a single form set that can be used on both the MAS-570™ and the MAS-1300™ thereby eliminating the need to purchase two different form sets.  This redesign was a part of an entire form redesign using the new MAS™ arch form supports that are also used on the corner/cage forms and entry forms.

It is no longer possible to buy just a single MAS-570™ or single MAS-1300™ Type G form set.  The new Type G form set contains all the components to work on both the MAS-570™ and MAS-1300™ structures which is a much more cost effective and robust solution.

YES,

The ADELS Fee is charged per structure.  In the case of multiple MAS™ structures connected to each other, MAS™ will have to provide engineering for each individual structure as well as the connection detail.  For example, if you build a MAS-1300™ with a MAS-570™ attached to one corner (to be used for additional bedrooms) you will have to pay for two ADELS Fees.

The same would be true if you build a MAS-1300™ with a MAS-570™ attached to one corner as a garage, you will have to pay for two ADELS Fees.

MAS™ does not charge extra for the engineering necessary to provide this connection detail.

The ADELS Fee covers the engineering, architecture, system plans, inspections, technical support, logistical support, Southern Utah University (SUU) royalty fee and warranty.

There appears to be a complete misunderstanding of how difficult it would be to copy the MAS™ system without having access to the MAS™ engineering analytical models.

MAS™ has developed a sophisticated engineering model based around its own mathematical algorithms using finite element analysis.  MAS™ has been designed using “thin shell structural” analysis and there are just a handful of engineers in the world that understand and can operate with the advanced constraints involved with thin shell structures.

Even that handful of engineers could NOT reverse engineer the MAS™ system without incredible time and effort.  And if they did they would violate the MAS™ pending patents thus making the reward for spending such time and effort problematic.  Each structure ordered from MAS™ will have a unique set of engineering plans based upon 8 distinct environmental and code requirements.  From this MAS™ computes 77 load combinations using its confidential and highly protected (secured) algorithms.  MAS™ does not keep these exposed to the outside world via internet, etc.  They are locked down and NO one person in MAS knows or has seen all these equations.

Without the solution to these 77 loading combinations you can NOT successfully build the MAS system.

You can NOT over design the MAS™ structures like you can in conventional construction.  Thin shell solutions are sensitive.  If you don’t put the rebar where MAS™ engineers tell you or layer the shotcrete like MAS™ engineers say, the results will be either a catastrophic failure, or you will get severe cracking immediately.

When you visit MAS™ and see the Discover Model built at Southern Utah University, you can see for yourself how critical this engineering really is.  MAS™ will show you cracked panels that resulted when procedures are not followed, and flawless panels that are made by following the MAS™ engineering and procedures.

The rebar solution provided by MAS™ engineering is NOT evenly spaced or systematically directed.  The thickness of the concrete varies, as does the placement of the re-bar chairs. It is a puzzle for which the solution can ONLY  be provided by MAS™ and this solution must be provided on a structure by structure basis.

Someone could try to copy the MAS system only to find out a year down the road they built 100,000 units that are cracked and must be destroyed.  It defies logic that someone would take this chance to avoid paying a ADELS Fee that includes architecture, design, engineering, technical & logistical support and a 20 year warranty.

This ADELS Fee is far less than the cost for an individual to do their own architecture, design, engineering and includes full technical and logistical support as well as a 20 year warranty!

NO, that is NOT the purpose of the MAS™ training classes.

Other than the T1 Orientation class, the MAS™ training classes are designed to educate an experienced contractor on how to apply their existing trade to the MAS™ construction process.

MAS™ suggests that you employ a local contractor who has construction experience and knows how to work with local engineers, pull permits and build in your locality.  MAS offers Proficiency Training Courses if your contractor wants to achieve an optional Proficiency Certification.  Most contractors have no problem building a MAS structure and will often employ a field trainer on their first try to shorten any learning curve.

Trying to train persons with NO construction experience is a longer process and not recommended. The logistics involved with supervising a construction project is best done by a contractor with local experience and who understands the laws and requirements unique to the territory where the MAS™ structures are being built.

NO

Other than the License and engineering, MAS™ only supplies the forms and SPiFolding as these are specialty items that are used over and over.  The raw material to build should be purchased locally.  Thus MAS™ does NOT provide material.   MAS™ can help coordinate the procurement of shotcrete pumps etc. from 3rd party vendors if they are not available locally.  The MAS™ logistics and support division will help the contractor with engineering coordination as well as material specification and material procurement from local suppliers.

MAS™ also provides training for contractor certification.

YES – ABSOLUTELY!

The entire MAS™ concept is based upon 3rd party vendors coming forward to offer solutions that are complementary to the MAS™ system.  MAS™ has patents or pending patents on the MAS™ Forming and SPiFolding™ systems which are an integral part of the MAS™ construction process.  However, MAS™ will license 3rd party vendors to manufacture such equipment for ZERO royalty or licensing fees so long as such equipment is ONLY sold to MAS™ certified users, and such equipment is only used on structures with a MAS™ Unit License.

MAS™ must be able to monitor the quality and production of all such equipment and such costs will be the responsibility of the the 3rd party doing the manufacturing.  Many large projects contemplating the use of the MAS™ system have recognized the great savings that can be had by manufacturing the MAS™ Forming and SPiFolding™ Systems locally.

MAS™ is encouraging such “local” 3rd party manufacturing and will allow such 3rd parties to be listed on the MAS™ website in order to market such equipment to other MAS™ System users.  This is clearly a WIN WIN for all parties involved.

MAS™ has sophisticated CAD drawings for all of the MAS™ Forms and SPiFolding Systems.  Please contact the the MAS™ Producibility Department for information on becoming a 3rd party vendor for the MAS™ Forming or SPiFolding™ Systems or any other complementary system(s).

There are walls to the ceiling separating the two duplex units.

There is a dividing wall between the two duplex units.  Therefore the loft of one unit is ONLY open to this same unit.  One unit can NOT see into the other unit.  The dividing wall is a two piece wall that meets in the middle and overlaps.  This allows for thermal expansion and contraction.  I.e. it is staggered.  This is a detail that is probably unimportant to you at this point, but it may be helpful to understand how such a wall does not violate the requirement that “NO interior walls can be built that extend between two opposite arches”.

The plumbing trough is designed for homes that will be built without plumbing initially.  I.e.certain regions do not typically provide electrical or plumbing connections as the bathrooms and kitchens are located outside.

However, at some point in the future, it is likely that plumbing and electrical will be required.  Thus the plumbing trough is installed to allow a bathroom, kitchen etc. to be installed at a future point in time without a major ordeal.

All MAS™ structures are built with embedded electrical raceways (formed via inexpensive and highly flexible plastic tubing) in the concrete foundation.  Thus outside and internal electrical is easily added at any time.

This is something that your local engineer will specify.  A lot of this depends on the amount of precipitation your area gets as well as the quality of your cement and aggregate.

An excellent article on water & concrete was published in 2006  by K Howes & J McDonald and is reprinted below.  Keep in mind that shotcrete has a very low slump and thus a low water to cement ratio which helps naturally waterproof concrete.

———————-

WATERPROOF CONCRETE

WHAT IS WATERPROOF CONCRETE?

Isn’t normal, good quality concrete waterproof?

In order to provide sufficient workability for proper placing & compaction and to facilitate proper mixing and transportation to site, most plant-batched concrete will contain water in excess of that required to simply hydrate the cement. As concrete hardens, this excess water leaves the concrete and creates a network of fine capillaries and internal pores. Natural capillary absorption is the predominant mechanism of water transport through concrete whether or not a head of hydrostatic pressure is present. In essence, as far as water is concerned, normal concrete behaves like a dense sponge.

One cubic metre of normal, good quality dry concrete will absorb the equivalent of roughly 60 litres of water in just 30 minutes! (Test in accordance with BS 1881, part 122). It is the speed of this absorption that is important as this will directly affect the level of dampness, say in a basement, or the onset of reinforcement corrosion due to dissolved chlorides being carried into the concrete by water, say in a sub-sea tunnel, the tidal zone of bridge supports or from melting slush after de-icing salt has been applied.

Even the highest quality concrete contains a network of pores and capillaries and, without adequate damp-proofing protection, this may result in dampness or leaks causing deterioration of internal finishes, mould formation and a health hazard, especially in heated environments where damp concrete is a haven for bacterial development. Where chlorides and oxygen are present, corrosion to the reinforcement will occur. Where sulfates are present in the surrounding soils and groundwater, serious deterioration of the cement matrix can occur, both situations causing untold damage to the structure.

What does ‘Waterproof’ mean?

British Standards set out to ensure that reinforced concrete structures provide the degree of protection, internal environment and functionality required by owners or developers.

The term ‘Waterproof’ therefore conjures up a whole range of ideas. If the structure in question is to retain water, say a water storage tank, then the designer may simply work to the design requirements of the water retaining code, BS 8007, which sets out to limit crack width. This may be achieved by utilising a good quality, ordinary concrete, close attention to joint details and providing extra crack control reinforcement; dampness being acceptable.

If on the other hand the structure is habitable or designed to house sensitive electronic equipment or valuable archives, then simply designing to the water retaining code is not sufficient. This is especially so given that ordinary good quality concrete provides little resistance to the passage of water vapour.

There are several degrees of waterproofing to be considered, all loosely defined under 4 categories in BS 8102.

At the lowest level, Grade 1, there is ‘Water-tight’ which simply means that water will not run or flow freely through the concrete; at the upper levels, Grades 3 & 4, there is ‘Damp-proof’, which not only requires there to be no visible water ingress but also that very high levels of water-vapour resistance will be achieved. This applies whether or not hydrostatic pressures are present.

“Watertight” VS “Waterproof” concrete

BS EN 934-2:2001 specifies absorption testing according to EN 480-5:1996 for ‘Water resisting admixtures’. This requires prism shaped samples 40mm x 40mm x 160mm long to be stood up in water 3mm deep. Interestingly, ordinary concrete samples become completely saturated within a couple of hours. The photo shows the control ordinary concrete and the sample incorporating a “Waterproofing” admixture after 12 hours

We must be clear here that the influence of cement replacement materials (*1) and water reducing admixtures, though they may improve the apparent resistance to the inflow of water under pressure, may in fact create a finer capillary structure with the effect that capillary ‘suction’ is greatly increased and thus the flow of water through the concrete by capillary absorption is speeded up. “… the narrower the pores in saturated concrete, the lower its permeability. The narrower the pores, the greater the resultant capillary pressure and so the greater the influx of water …” (*2)

*1 Pozzolanas are materials containing reactive silica and/or alumina which on their own have little or no binding property but, when mixed with lime in the presence of water, will set and harden like a cement, ie on their own they don’t do anything. E.G. pfa which is a by-product of coal fired electricity stations, also known as fly ash; ground granulated blastfurnace slag, a by-product of the steel industry sometimes called GGBS or slag; silica fume, a by-product of microprocessor silica production also known as CSF, and metakaolin, a product associated with the china clay industry

*2 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

CAPILLARY ABSORPTION VS PRESSURE PERMEABILITY

Permeability is a measure of flow under an external pressure and is a property of saturated materials: the narrower the pores in saturated concrete, the lower its permeability. Conversely, the narrower the pores, the greater the resultant capillary pressure and so the greater the depth of penetration and speed of ingress of water

But how important is ‘pressure permeability’ when compared with ‘capillary absorption’ in regard to water transport through concrete?

“Calculation of the water penetration depth during wetting showed that the speed of capillary absorption is of the order of a million times faster than permeability” (*1).

Thus, in terms of damp-proof concrete, ‘pressure permeability’ is irrelevant unless the capillary absorption problem is addressed. You will appreciate, therefore, that the idea that water passes through concrete depending on water pressure is a complete myth.

*1 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

HOW CAN ‘ORDINARY’ CONCRETE BE DAMP-PROOFED?

The traditional approach has been to attempt to ‘wrap up’ the concrete with a ‘waterproof coating’ of some kind, be it a tanking system, external membrane, surface coating or built up treatment in the case of a roof. Another approach is simply to accept that the structure will inevitably leak and to provide a drained cavity system inside the structure.

Membranes, tanking and surface coatings are invariably thin section, difficult to apply and rely heavily on the skill of the applicator to ensure integrity. If and when barrier systems fail, they may be on the wrong side of the structure (in the case of basement tanking) severely limiting the options for repair. Failure may be from bad jointing, pin holing, damage during back-filling operations or simply down to poor workmanship. Water or damp ingress seen on the inside of the structure may be at an area remote from the actual point of damage to the barrier system.

With cavity drained structures there is a loss or reduction in internal useable space and a potential maintenance liability as problems can arise unexpectedly, for example, failed pump, drainage channels silt up, over-loading due to local burst water main and the effects of rising water tables in many cities. Once such a system fails, water will usually run freely into the inner structure causing untold damage.

Attempted repair of a failed barrier or cavity drained system may not only cause significant delay in handing over a project but will be a concern to the owner and the cost of repair may be disproportionate to the cost of the original damp-proofing system used.

IS THERE NOT A BETTER OPTION? POSSIBLY

If concrete could be produced which was intrinsically waterproof, damp-proof and corrosion resistant, the Industry would no longer have to rely on the risky business of applying membranes, coatings or other temporary barrier systems. This concept is not new; there have been numerous ‘so-called’ integral waterproofing systems developed over the years that purport to make concrete ‘damp-proof’. Many have been shown to be severely limited in their long-term performance due to low dosage or failure to address the mechanism of water ingress by capillary absorption.

To ensure that an effective and reliable system of integral damp proofing is adopted, it must meet the following important performance requirements:

• Water absorption less than 1% when tested under BS 1881-122
• Comply with the European mandatory requirements of BS EN 934-2:2000 as a water resisting admixture under table 9
• Be supported by independent certification by a certifying body able and willing to stand behind that certificate and stating that the system has a proven track record of at least 30 years without loss of performance, e.g. the British Board of Agrément
• If a housing project, the product must be approved by NHBC or Zurich or other insurer as a stand-alone waterproofing system
• Have a demonstrable, proven track record in the environment where it is to be used confirming its long lasting effectiveness in that situation
• Meet the water quality test requirements under BS 6920:2000 (Testing of non-metallic materials for use with drinking water)
• Come with a proven effective warranty for the waterproofing of the structure not simply a guarantee for the product, inclusive of day-joints and service penetrations
• Be systematically monitored during construction to a comprehensive quality assurance scheme
• Have specialist technical support and back up to ensure that what is proposed is ‘fit for intended use’, that the design is sympathetic to the use of an integral waterproofer and to assist the designer and contractor as required
• The supplier and manufacturer must be of appropriate financial standing to support the guarantee and the level of service required
• Dosing must be accurate and subject to the manufacturer’s quality assurance procedures

PROFESSIONAL DUTY OF CARE AND RESPONSIBILITY!

The selection of any construction product must be done with care and this is especially the case with waterproofing of concrete structures. Failure here has been the subject of numerous claims and litigation, something that no professional person wants to be the subject of.

The problem is neatly summed up in a quote by John Ruskin (1819 – 1900): “There is hardly anything in the world that some man can’t make just a little worse and sell just a little cheaper, and the people who buy on price alone are this man’s lawful prey”

To demonstrate this point, in 1985, the Building Research Establishment carried out tests on behalf of the British Standards Institution with the idea of looking at the possibility of creating a standard for integral concrete waterproofing admixtures(*3).

Suppliers of waterproofing admixtures were asked to submit their products for testing. 15 different tests were carried out on each of the nine products put forward and compared with a ‘Control’ mix. Most of the products were worse than the control in more than 8 of the tests.

Out of all the 9 so-called ‘Waterproofing’ admixtures tested, only one product out-performed the ‘Control’, and all the other products, in all 15 tests!

*3 Tests on waterproofing admixtures for concrete, 1987. B W Adderson and M H Robertson. Building Research Establishment report N159/85

SUMMARY

Waterproof = Watertight + Damp-proof. If you are not concerned about dampness or high humidity levels, then watertight is fine. If, for example, you want a truly dry basement or tunnel or corrosion resistant structure, then you need it to be waterproof.

The most important point with reinforced concrete structures is to design and build the structures properly in the first place as there is little point in having a design life stated at 100 years if repairs have to start virtually the day after construction is completed.

Premature deterioration of reinforced concrete structures all around the world is a major concern due to the vast amount of money that will have to be spent on future maintenance or re-construction.

Whether one looks at the billions of Dollars spent annually in North America on concrete repairs…

…or in the Middle East, Far East, Africa or Europe, most of the problems could have been averted.

The Öland Bridge repairs completed in 2005 after about 15 years involving renovation work to the corroded pier supports, replacement of 19 joints and restoration of the parapet walls cost:

“… twice the cost of the original bridge at current prices”.

Or as the project manager is quoted as saying:

“Buy cheap, repair expensively”

Copyright © K Howes & J McDonald 2006. All rights reserved

All reinforced concrete design (ACI) is based on a cracked concrete section called post-dominant crack.  It is all about yielding as a crack opens, Re-bar yields by stretching and Helix yields partially by stretching and the rest by untwisting  The Helix design method follows ACI in this regard and is 3 times more than the maximum allowed under the ACI 318 design code . So Helix is as good as re-bar in a post crack or “reactive” situation.  

MAS™ has a supply division that can supply Contractors with the MAS™ proprietary forms necessary to construct the MAS™ system.  This MAS™ supply division’s sole purpose is to supply such proprietary forms AT COST to assist the Contractor and NOT as a profit center.  I.e. MAS™ is producing such forms in bulk and selling at cost to allow the Contractor the least expensive method of procuring such specialty equipment.

Assuming a crew of 4 persons that work 8 hours per day and the construction site (lot) is excavated flat with proper compaction and ready to dig the foundation:

Schedule / Timeline:

Day 1: Dig foundation, form pad, install re-bar, run plumbing, run electrical.  Pre-cut re-bar & foam that will be needed on Day 3.

Day 2: Pour, & finish concrete pad and then cover with 6 mm plastic. Pre-tie re-bar cube roof panels. Construct all opening bucks (windows, dormers & doors) that will be used on Day 3.

Pad/Foundation must cure to strength required by local engineering.  This is usually 70% of its final cure strength and generally takes 7 days to obtain.

Day 3: (after cure time noted above): Remove pad/foundation forms, set up airform and corner cage forms, install foam (pre-cut) and begin re-bar (pre-cut & formed) installation.

Day 4: Complete re-bar installation and opening buck (windows, dormers & doors) installation. Final prep for shotcrete.  Prepare option Eve/Parapet Roofing System forms if being used on Day #6.

Day 5: Spray Shotcrete layer #1 (1.5 inches) on entire structure.

Day 6: Spray Shotcrete layer #2 (1.5 inches if using three structural layers, or 2.5 inches if using two structural layers).  The option Eve/Parapet Roofing System is installed on Day #6 and increase build time by 1 day unless a second 4 man crew is brought in.  The optional Eve/Parapet Roofing System requires the three structural layer process.

Day 7: Spray Shotcrete layer #3 (1.0 inches if using three structural layers), plus additional for stamping if required.  If all structural layers were completed on Day #6, then Day 7 is devoted to spraying additional stamping layers if required.  Dormers and entry areas are typically constructed on Day #7.

Note: Aggressive concrete stamps that imprint more than 1/4″ into the 4″ structural concrete layer, will require additional non-structural shotcrete layers to allow for the aggressive architectural design.  Non-aggressive concrete stamps such as “fractured slate” can be applied to the final structural layer, ONLY with an experienced crew of enough persons to keep up with the shotcrete application.  The majority of MAS units are built using a three layer process with the final 1″ layer being stamped with a non-aggressive architectural design at a rate the stamping crew can easily screed and stamp before the concrete is too hard to stamp.

Note: In most cases, the forming system can be removed during day 7 (thus in use for 5 days).  Local engineering should conduct cylinder tests to verify the strength of shotcrete layer #1 and #2 to make the form removal decision.  This allows the forming system to be used to construct SIX structures per month.  If forms are removed on Day 7, it is suggested that all structural work, being performed on day #7, be completed before initiating such form removal.

AT this point the MAS™ system shell is complete and interior work can begin on Day #8 if structural concrete cure is approved by local engineering.  Also door & window installation should begin on Day #8 so that the structure is made weather proof as soon as possible.

If using interior concrete walls, these would usually be formed on day 8 and sprayed on day 9 and day 10 prior to the optional spraying of insulating foam.

Simple interiors can be completed in just a few days.  It depends on the complexity of the interiors.  Because the plumbing and electrical conduit has been installed on Day 1, the finish electrical and plumbing can be done in less than 1 day.

Note: If using stain coloring on the concrete floor, it is recommended that this be done after all interior work is completed, including painting, but excluding baseboards.  The 6 mm plastic coating on the concrete floor is removed just before the staining process is to begin but after all interior work is complete.  After removing the 6 mm plastic slab coating, the slab should be cleaned (if necessary) and prepared consistent with the manufactures stain application instructions.  Once the stain is complete and SEALED, the pre-painted baseboard can be installed and the MAS unit is ready for occupancy if authorized by the local engineer of record.

NO!  The shotcrete process where low slump concrete is sprayed under high pressure is critical to the construction process.  Shotcrete does not create cold joints and it makes the concrete significantly stronger and with better consolidation (less voids).

Note: As shotcrete is simply a method for placing concrete, shotcrete enjoys all the sustainability advantages of concrete as a building material including use of recycled materials, SCMs, and the very broad topics related to durability, reparability, etc.  The sustainability advantages unique to shotcrete are inherent in the placement process.

Shotcrete
Shotcrete is a process where concrete is projected or “shot” under pressure using a feeder gun onto a surface to form structural shapes including walls, floors, and roofs. The surface can be any surface that concrete can be projected onto. The surface can be smoothed or stamped while the concrete is still wet.

Architects, engineers, developers, and contractors are under ever-growing pressure to use more efficient methods in construction.  Shotcrete construction has many unique characteristics that substantially increase the sustainability aspects of both new construction and repair.  Shotcrete enables key savings in labor, materials, material handling and construction time, as well as providing increased flexibility and efficiency in shapes and thicknesses.

The most popular forming and scaffolding (SPiFolding) package ordered from MAS™ can construct two each MAS-570™s concurrently or a single MAS-1300™.  This set will form a TYPE G or TYPE R.  This popular Form/SPiFolding set can be shipped in a 20′ shipping container anywhere in the world.

You can add a partial loft (not complete), however it will not double the square footage.  Due to the sloping side of the arches that make up the structure on the MAS-1300™ it is not possible to use all the floor space of a 2nd floor deck system.  A 2nd floor deck system that covers approximately 1/3 the foot print of the MAS-1300™ structure will only give a usable area of approximately 200 to 250 square feet.

You can NOT add a deck that spans from wall to wall due to thermal expansion limitations.  MAS™ only recommends the use of a 2nd floor decking system for storage or situations where personnel need to be located above other works for strategic reasons.

It is more cost effective to attach a MAS-570™ to the MAS-1300™ to create additional square footage then it is to install a 2nd floor deck system.

NO.  The MAS™ system does NOT contain any interior walls.  The MAS-570™ has a clear span of 24 feet and the MAS-1300™ has a clear span of 36 feet.  Therefore, the interior walls can be positioned in any conceivable manner and removed or relocated without regard to structural integrity.

No.  The interior windows must go in the envelope specified by the MAS™ engineers.  The MAS™ engineers allow for a great variety of window locations all on the corner areas and NONE in the arch areas.  Although there are dormers in the arch support, no other penetrations, except those for venting, are allowed by the MAS-™ engineers in the arch sections.

Multiple windows can easily be accommodated on each side of every corner.  This allows for 8 window locations which can accommodate several windows each of various sizes at each location.  Thus the number of windows, and flexibility in placement is far greater than is possible using traditional construction techniques.

There is NO additional cost to create a window opening, other than the purchase and installation of the actual window assembly.

A carpenter generally would generally be a Foreman or Specialty Worker (Sub-Contractor).  MAS™ offers several Training Courses that allow proficiency in all areas of MAS construction should it be desired.  A carpenter will generally start with MAS™ Training Course Number T.  This is a two day training course.  Additional days of Specialty Training is available in MAS™ Training Course Number T4 to allow persons/contractors to gain expertise in individual specialty areas.  Some 3rd party companies, that have already completed training, also offer field training and support to assist a carpenter with their first project which generally provides all the familiarization with the MAS system that is required.

Please visit the following link for more information on training: http://www.modernarchstructures.com/technology/mas-certification-overview/mas-training

Although the structure cost will be significantly less than ANY other form of construction, that is a difficult question to answer as MAS™ does NOT actually build structures.

If you want to know what a turn-key system, fully finished with rooms, appliances etc. will cost it is necessary to speak with a contractor.  Although MAS™ works with a great number of 3rd party vendors that can supply interior packages, etc. MAS™ is not involved with the pricing of these options.

The cost to build the shell, before windows, doors and any interior options other than insulation is something that MAS™ is familiar with.  A contractor can look up the required material as well as material quote sheets by visiting: http://www.modernarchstructures.com/technology/material-material-list

One of the key features of MAS™ structures is the ability to have a rock/brick/stone etc. exterior finish molded (stamped) into the last shotcrete layer for no additional material costs.  This allows a very upscale, top of the line, exterior look for NO additional cost other than a VERY small amount of finish labor.  This alone, coupled with NO required roofing material can represent a 25%  or more savings on the cost of construction when building an otherwise “architecturally expensive” building.

The MAS™ consists of the exterior shell only.  However, MAS™ has worked with numerous 3rd party vendors to provide interior options.  The MAS™ system can use any standard interior configuration used typical construction.  However, the MAS™ interior is often constructed of concrete partitions to allow a virtually damage proof configuration.  MAS™ provides many interior floor plans to help guide those incorporating the MAS™ system into their projects.

No, however all the openings for such doors and windows are formed as part of the construction of the MAS™ system.  There are no “bucks”, channels, stops, etc. required.  Once the MAS™ system shell is complete it is a simple matter to install windows and doors in the formed opening.  In addition, there is no increased cost to have one or more windows as the MAS™ patented forming system allows for great flexibility in such placement within the areas so designated by MAS™ engineering.

Yes.  MAS™ has designed a scaffolding system called “SPiFolding” that surrounds the entire structure and therefore eliminates any need for a mechanical lift.  The SPiFolding system allows multiple persons to work concurrently on the MAS™ structure without interference.  The SPiFolding can be ordered separately or as part of the forming package.

No, the MAS™ shell is a monolithic structure (formed and composed of concrete without joints or seams).

GWB or paneling can be attached directly to the concrete interior shell using adhesives, or to the finished and insulated interior using any standard attachment method.

Puncture is not an issue.  The pressure is very low and the material is very strong.  Although a puncture is possible, it can be repaired with tape in the field in a few minutes time without a problem.  The repair material is stronger than the original material and thus there is no negative impact or worries about making such repairs.

That is NOT correct.  There are NO metal framed walls making up the MAS™ system.  There is a patented MAS™ cage forming system that can accept sacrificial foam for insulation or re-usable polycarbonate  substrate panels.  In both cases, the metal cage form is removed and reused.

The reason the MAS™ system is so easy to build is because of three primary factors, one of which is training.

1. MAS™ provides the bulk of the engineering required using its proprietary finite element analytical models.
2. MAS™ provides a patented forming system and scaffolding system (SPiFolding)
3. MAS™ provides the training necessary to construct the MAS™ system.

The MAS-570™ is 24 feet x 24 feet (7.3 meters x 7.3 meters).  The height in the center (at the peak of the arches) is 12 feet (3.65 meters).  The floor area is 570 sq. feet (53.5 sq. meters)

The MAS-1300™ is 36 feet x 36 feet (11 meters x 11 meters).  The height in the center (at the peak of the arches) is 18 feet (5.5 meters).  The floor area is 1,300 sq. feet (120.5 sq. meters)

The MAS™ system has the potential to be used in a “retaining” wall situation where the unites are place IN a sloped embankment.  This application WOULD require waterproofing AND additional structural engineering based upon the forces of the “dirt” to be held up.  It is likely that additional concrete AND re-bar would be required.

MAS™ has NEVER had a problem getting a local entity in charge of building code enforcement to issue the permits and/or documentation necessary to build a MAS™ system structure.  The MAS™ system is designed around standard and accepted design principals using traditional engineering meeting the United States Uniform Building Code. (UBC).  Therefore, the system as designed, will likely exceed ALL local building codes.  However, if something unusual and unforeseen comes up, the MAS™ engineering team will work with the builder for no additional cost to find a solution where possible.

NO

MAS™ has done NO structural testing in the form of “stress to failure” type tests.  Our engineers have designed the MAS system using Finite Element Analysis (FEA) based upon standard and accepted engineering principals, processes and materials.

Concrete is inherently fire proof.  Because the concrete does not encapsulate flammable material in the MAS™ exterior structural shell system there is no de-rating of the concrete required.  The interior walls can also be built from concrete making the entire finished structure highly resistant to fire, and inherently survivable should an interior contents fire erupt.  I.e. the MAS™ concrete structure does not provide ANY fuel to facilitate the spreading of a interior content fire.  The entire MAS™ structure is NON-COMBUSTIBLE.

It is unlikely that the interior contents would contain enough combustible material (fire load) to cause damage to the MAS™ concrete shell even if it became fully engulfed in a fire.

When attaching MAS™ structures to one another in a retro-fit scenario the door way is made by extending the 4 foot window opening to the slab.  When attaching MAS structures to one another DURING construction there may be other options.  Such options must be engineered and may include eliminating the majority of this single corner connecting wall in both units such that the connection is “seamless”.  Such engineering is provided by MAS™ at no additional cost as part of the ADELS Fee.

Unlike conventional construction, the cost to add an additional MAS™ structure is virtually the same whether it is done during initial construction or via a retrofit (remodel) at some later date.

Note:  In the retro-fit scenario the extension of the 4 foot window to the slab to create a doorway is done as follows:

• Removal of the window unit if installed
• Saw cutting the concrete to the floor following the vertical lines of the window edge opening
• Saw cutting and chiseling  between these saw cut vertical lines and the slab
• Removal of the concrete panel below the window
• Shotcreting the saw cut and chiseled edges when the new MAS™ structure is constructed so as to encapsulate and protect any re-bar exposed during the cutting process and to finish the opening to the required width/height.  (Additional re-bar and doweling may be required if more than a few inches of Shotcrete is required to make the opening narrower or shorter)

YES,

The ADELS Fee is charged per structure.  In the case of multiple MAS™ structures connected to each other, MAS™ will have to provide engineering for each individual structure as well as the connection detail.  For example, if you build a MAS-1300™ with a MAS-570™ attached to one corner (to be used for additional bedrooms) you will have to pay for two ADELS Fees.

The same would be true if you build a MAS-1300™ with a MAS-570™ attached to one corner as a garage, you will have to pay for two ADELS Fees.

MAS™ does not charge extra for the engineering necessary to provide this connection detail.

The ADELS Fee covers the engineering, architecture, system plans, inspections, technical support, logistical support, Southern Utah University (SUU) royalty fee and warranty.

There appears to be a complete misunderstanding of how difficult it would be to copy the MAS™ system without having access to the MAS™ engineering analytical models.

MAS™ has developed a sophisticated engineering model based around its own mathematical algorithms using finite element analysis.  MAS™ has been designed using “thin shell structural” analysis and there are just a handful of engineers in the world that understand and can operate with the advanced constraints involved with thin shell structures.

Even that handful of engineers could NOT reverse engineer the MAS™ system without incredible time and effort.  And if they did they would violate the MAS™ pending patents thus making the reward for spending such time and effort problematic.  Each structure ordered from MAS™ will have a unique set of engineering plans based upon 8 distinct environmental and code requirements.  From this MAS™ computes 77 load combinations using its confidential and highly protected (secured) algorithms.  MAS™ does not keep these exposed to the outside world via internet, etc.  They are locked down and NO one person in MAS knows or has seen all these equations.

Without the solution to these 77 loading combinations you can NOT successfully build the MAS system.

You can NOT over design the MAS™ structures like you can in conventional construction.  Thin shell solutions are sensitive.  If you don’t put the rebar where MAS™ engineers tell you or layer the shotcrete like MAS™ engineers say, the results will be either a catastrophic failure, or you will get severe cracking immediately.

When you visit MAS™ and see the Discover Model built at Southern Utah University, you can see for yourself how critical this engineering really is.  MAS™ will show you cracked panels that resulted when procedures are not followed, and flawless panels that are made by following the MAS™ engineering and procedures.

The rebar solution provided by MAS™ engineering is NOT evenly spaced or systematically directed.  The thickness of the concrete varies, as does the placement of the re-bar chairs. It is a puzzle for which the solution can ONLY  be provided by MAS™ and this solution must be provided on a structure by structure basis.

Someone could try to copy the MAS system only to find out a year down the road they built 100,000 units that are cracked and must be destroyed.  It defies logic that someone would take this chance to avoid paying a ADELS Fee that includes architecture, design, engineering, technical & logistical support and a 20 year warranty.

This ADELS Fee is far less than the cost for an individual to do their own architecture, design, engineering and includes full technical and logistical support as well as a 20 year warranty!

This is something that your local engineer will specify.  A lot of this depends on the amount of precipitation your area gets as well as the quality of your cement and aggregate.

An excellent article on water & concrete was published in 2006  by K Howes & J McDonald and is reprinted below.  Keep in mind that shotcrete has a very low slump and thus a low water to cement ratio which helps naturally waterproof concrete.

———————-

WATERPROOF CONCRETE

WHAT IS WATERPROOF CONCRETE?

Isn’t normal, good quality concrete waterproof?

In order to provide sufficient workability for proper placing & compaction and to facilitate proper mixing and transportation to site, most plant-batched concrete will contain water in excess of that required to simply hydrate the cement. As concrete hardens, this excess water leaves the concrete and creates a network of fine capillaries and internal pores. Natural capillary absorption is the predominant mechanism of water transport through concrete whether or not a head of hydrostatic pressure is present. In essence, as far as water is concerned, normal concrete behaves like a dense sponge.

One cubic metre of normal, good quality dry concrete will absorb the equivalent of roughly 60 litres of water in just 30 minutes! (Test in accordance with BS 1881, part 122). It is the speed of this absorption that is important as this will directly affect the level of dampness, say in a basement, or the onset of reinforcement corrosion due to dissolved chlorides being carried into the concrete by water, say in a sub-sea tunnel, the tidal zone of bridge supports or from melting slush after de-icing salt has been applied.

Even the highest quality concrete contains a network of pores and capillaries and, without adequate damp-proofing protection, this may result in dampness or leaks causing deterioration of internal finishes, mould formation and a health hazard, especially in heated environments where damp concrete is a haven for bacterial development. Where chlorides and oxygen are present, corrosion to the reinforcement will occur. Where sulfates are present in the surrounding soils and groundwater, serious deterioration of the cement matrix can occur, both situations causing untold damage to the structure.

What does ‘Waterproof’ mean?

British Standards set out to ensure that reinforced concrete structures provide the degree of protection, internal environment and functionality required by owners or developers.

The term ‘Waterproof’ therefore conjures up a whole range of ideas. If the structure in question is to retain water, say a water storage tank, then the designer may simply work to the design requirements of the water retaining code, BS 8007, which sets out to limit crack width. This may be achieved by utilising a good quality, ordinary concrete, close attention to joint details and providing extra crack control reinforcement; dampness being acceptable.

If on the other hand the structure is habitable or designed to house sensitive electronic equipment or valuable archives, then simply designing to the water retaining code is not sufficient. This is especially so given that ordinary good quality concrete provides little resistance to the passage of water vapour.

There are several degrees of waterproofing to be considered, all loosely defined under 4 categories in BS 8102.

At the lowest level, Grade 1, there is ‘Water-tight’ which simply means that water will not run or flow freely through the concrete; at the upper levels, Grades 3 & 4, there is ‘Damp-proof’, which not only requires there to be no visible water ingress but also that very high levels of water-vapour resistance will be achieved. This applies whether or not hydrostatic pressures are present.

“Watertight” VS “Waterproof” concrete

BS EN 934-2:2001 specifies absorption testing according to EN 480-5:1996 for ‘Water resisting admixtures’. This requires prism shaped samples 40mm x 40mm x 160mm long to be stood up in water 3mm deep. Interestingly, ordinary concrete samples become completely saturated within a couple of hours. The photo shows the control ordinary concrete and the sample incorporating a “Waterproofing” admixture after 12 hours

We must be clear here that the influence of cement replacement materials (*1) and water reducing admixtures, though they may improve the apparent resistance to the inflow of water under pressure, may in fact create a finer capillary structure with the effect that capillary ‘suction’ is greatly increased and thus the flow of water through the concrete by capillary absorption is speeded up. “… the narrower the pores in saturated concrete, the lower its permeability. The narrower the pores, the greater the resultant capillary pressure and so the greater the influx of water …” (*2)

*1 Pozzolanas are materials containing reactive silica and/or alumina which on their own have little or no binding property but, when mixed with lime in the presence of water, will set and harden like a cement, ie on their own they don’t do anything. E.G. pfa which is a by-product of coal fired electricity stations, also known as fly ash; ground granulated blastfurnace slag, a by-product of the steel industry sometimes called GGBS or slag; silica fume, a by-product of microprocessor silica production also known as CSF, and metakaolin, a product associated with the china clay industry

*2 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

CAPILLARY ABSORPTION VS PRESSURE PERMEABILITY

Permeability is a measure of flow under an external pressure and is a property of saturated materials: the narrower the pores in saturated concrete, the lower its permeability. Conversely, the narrower the pores, the greater the resultant capillary pressure and so the greater the depth of penetration and speed of ingress of water

But how important is ‘pressure permeability’ when compared with ‘capillary absorption’ in regard to water transport through concrete?

“Calculation of the water penetration depth during wetting showed that the speed of capillary absorption is of the order of a million times faster than permeability” (*1).

Thus, in terms of damp-proof concrete, ‘pressure permeability’ is irrelevant unless the capillary absorption problem is addressed. You will appreciate, therefore, that the idea that water passes through concrete depending on water pressure is a complete myth.

*1 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

HOW CAN ‘ORDINARY’ CONCRETE BE DAMP-PROOFED?

The traditional approach has been to attempt to ‘wrap up’ the concrete with a ‘waterproof coating’ of some kind, be it a tanking system, external membrane, surface coating or built up treatment in the case of a roof. Another approach is simply to accept that the structure will inevitably leak and to provide a drained cavity system inside the structure.

Membranes, tanking and surface coatings are invariably thin section, difficult to apply and rely heavily on the skill of the applicator to ensure integrity. If and when barrier systems fail, they may be on the wrong side of the structure (in the case of basement tanking) severely limiting the options for repair. Failure may be from bad jointing, pin holing, damage during back-filling operations or simply down to poor workmanship. Water or damp ingress seen on the inside of the structure may be at an area remote from the actual point of damage to the barrier system.

With cavity drained structures there is a loss or reduction in internal useable space and a potential maintenance liability as problems can arise unexpectedly, for example, failed pump, drainage channels silt up, over-loading due to local burst water main and the effects of rising water tables in many cities. Once such a system fails, water will usually run freely into the inner structure causing untold damage.

Attempted repair of a failed barrier or cavity drained system may not only cause significant delay in handing over a project but will be a concern to the owner and the cost of repair may be disproportionate to the cost of the original damp-proofing system used.

IS THERE NOT A BETTER OPTION? POSSIBLY

If concrete could be produced which was intrinsically waterproof, damp-proof and corrosion resistant, the Industry would no longer have to rely on the risky business of applying membranes, coatings or other temporary barrier systems. This concept is not new; there have been numerous ‘so-called’ integral waterproofing systems developed over the years that purport to make concrete ‘damp-proof’. Many have been shown to be severely limited in their long-term performance due to low dosage or failure to address the mechanism of water ingress by capillary absorption.

To ensure that an effective and reliable system of integral damp proofing is adopted, it must meet the following important performance requirements:

• Water absorption less than 1% when tested under BS 1881-122
• Comply with the European mandatory requirements of BS EN 934-2:2000 as a water resisting admixture under table 9
• Be supported by independent certification by a certifying body able and willing to stand behind that certificate and stating that the system has a proven track record of at least 30 years without loss of performance, e.g. the British Board of Agrément
• If a housing project, the product must be approved by NHBC or Zurich or other insurer as a stand-alone waterproofing system
• Have a demonstrable, proven track record in the environment where it is to be used confirming its long lasting effectiveness in that situation
• Meet the water quality test requirements under BS 6920:2000 (Testing of non-metallic materials for use with drinking water)
• Come with a proven effective warranty for the waterproofing of the structure not simply a guarantee for the product, inclusive of day-joints and service penetrations
• Be systematically monitored during construction to a comprehensive quality assurance scheme
• Have specialist technical support and back up to ensure that what is proposed is ‘fit for intended use’, that the design is sympathetic to the use of an integral waterproofer and to assist the designer and contractor as required
• The supplier and manufacturer must be of appropriate financial standing to support the guarantee and the level of service required
• Dosing must be accurate and subject to the manufacturer’s quality assurance procedures

PROFESSIONAL DUTY OF CARE AND RESPONSIBILITY!

The selection of any construction product must be done with care and this is especially the case with waterproofing of concrete structures. Failure here has been the subject of numerous claims and litigation, something that no professional person wants to be the subject of.

The problem is neatly summed up in a quote by John Ruskin (1819 – 1900): “There is hardly anything in the world that some man can’t make just a little worse and sell just a little cheaper, and the people who buy on price alone are this man’s lawful prey”

To demonstrate this point, in 1985, the Building Research Establishment carried out tests on behalf of the British Standards Institution with the idea of looking at the possibility of creating a standard for integral concrete waterproofing admixtures(*3).

Suppliers of waterproofing admixtures were asked to submit their products for testing. 15 different tests were carried out on each of the nine products put forward and compared with a ‘Control’ mix. Most of the products were worse than the control in more than 8 of the tests.

Out of all the 9 so-called ‘Waterproofing’ admixtures tested, only one product out-performed the ‘Control’, and all the other products, in all 15 tests!

*3 Tests on waterproofing admixtures for concrete, 1987. B W Adderson and M H Robertson. Building Research Establishment report N159/85

SUMMARY

Waterproof = Watertight + Damp-proof. If you are not concerned about dampness or high humidity levels, then watertight is fine. If, for example, you want a truly dry basement or tunnel or corrosion resistant structure, then you need it to be waterproof.

The most important point with reinforced concrete structures is to design and build the structures properly in the first place as there is little point in having a design life stated at 100 years if repairs have to start virtually the day after construction is completed.

Premature deterioration of reinforced concrete structures all around the world is a major concern due to the vast amount of money that will have to be spent on future maintenance or re-construction.

Whether one looks at the billions of Dollars spent annually in North America on concrete repairs…

…or in the Middle East, Far East, Africa or Europe, most of the problems could have been averted.

The Öland Bridge repairs completed in 2005 after about 15 years involving renovation work to the corroded pier supports, replacement of 19 joints and restoration of the parapet walls cost:

“… twice the cost of the original bridge at current prices”.

Or as the project manager is quoted as saying:

“Buy cheap, repair expensively”

Copyright © K Howes & J McDonald 2006. All rights reserved

All reinforced concrete design (ACI) is based on a cracked concrete section called post-dominant crack.  It is all about yielding as a crack opens, Re-bar yields by stretching and Helix yields partially by stretching and the rest by untwisting  The Helix design method follows ACI in this regard and is 3 times more than the maximum allowed under the ACI 318 design code . So Helix is as good as re-bar in a post crack or “reactive” situation.  

NO!  The shotcrete process where low slump concrete is sprayed under high pressure is critical to the construction process.  Shotcrete does not create cold joints and it makes the concrete significantly stronger and with better consolidation (less voids).

Note: As shotcrete is simply a method for placing concrete, shotcrete enjoys all the sustainability advantages of concrete as a building material including use of recycled materials, SCMs, and the very broad topics related to durability, reparability, etc.  The sustainability advantages unique to shotcrete are inherent in the placement process.

No.  The interior windows must go in the envelope specified by the MAS™ engineers.  The MAS™ engineers allow for a great variety of window locations all on the corner areas and NONE in the arch areas.  Although there are dormers in the arch support, no other penetrations, except those for venting, are allowed by the MAS-™ engineers in the arch sections.

Multiple windows can easily be accommodated on each side of every corner.  This allows for 8 window locations which can accommodate several windows each of various sizes at each location.  Thus the number of windows, and flexibility in placement is far greater than is possible using traditional construction techniques.

There is NO additional cost to create a window opening, other than the purchase and installation of the actual window assembly.

The MAS-1300 arches are built with a thickness of  8″ of concrete to the height of approximately 14.5 feet above the ground.  The remaining portion of the arches and structure are built with thickness of 4″.

The MAS™ engineers generally specify 4,000 PSI concrete.  However, please consult with MAS™ engineering for your specific project.

No, the MAS™ shell is a monolithic structure (formed and composed of concrete without joints or seams).

The reason the MAS™ system is so easy to build is because of three primary factors, one of which is training.

1. MAS™ provides the bulk of the engineering required using its proprietary finite element analytical models.
2. MAS™ provides a patented forming system and scaffolding system (SPiFolding)
3. MAS™ provides the training necessary to construct the MAS™ system.

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

MAS™ will actively pursue and prosecute, to the MAXIMUM EXTENT OF THE LAW, any violations of the MAS™ intellectual property, registrations and patents (pending and issued) throughout the world under international treaties as well as local laws, statutes, agreements, and registrations.

A ADELS Fee must be paid for each structure built.  A SINGLE License is issued for each SINGLE ADELS Fee paid to MAS™.

YES

Producibility: A term used to describe the ability of contractors to bid on a project proposal.

Although the MAS™ system is new to many contractors, MAS™ provides a “T2” training class that is specifically designed to educate a contractor on the MAS™ system and all aspects necessary to prepare a qualified, responsive and financially viable bid.

As a contractor you are familiar with building.  What you need to learn is how to fit the MAS™ system into your existing method of construction.  To start with you will need to understand how to bid the project.  This will include determining the quantity and cost of forms and the labor time and skills required.  MAS™ provides calculators to help a contractor prepare bids.  Many contractors   use these calculators initially to understand the feasibility of using the MAS™ system for their project.

Once a contractor is confident the MAS™ system is an option for their project they will usually sign up to attend a T2 training class from MAS™.  The T2 training class will teach the contractor everything needed to bid a MAS™ structure including the advanced use of the calculators on the MAS™ website.  The T2 class will quickly orient the contractor to the MAS™ system and the unique forms that are used for construction.  The construction time line as well as the labor requirements will be thoroughly covered.

Construction with the MAS™ system is not complex and is much easier and faster than conventional construction.  Limited worker skills are required and can generally be learned in just a few days.  MAS™ provides detailed procedures, training videos and check lists as part of it’s inexpensive and thorough training programs.

One option available to a new contractor is to hire a MAS certified field trainer who can provide the expertise necessaryto do the job.  The MAS Field Trainer (an independent contractor) can also certified trainers and conduct “on the job” training for the new contractors personnel during the construction phase of the MAS™ system should Proficiency Certification be desired.  Once the new contractor has his crew trained and certified he can dismiss the Field Trainer.  This can be a cost effective and quick solution for a contractor to start their involvement with the MAS™ system.

There appears to be a complete misunderstanding of how difficult it would be to copy the MAS™ system without having access to the MAS™ engineering analytical models.

MAS™ has developed a sophisticated engineering model based around its own mathematical algorithms using finite element analysis.  MAS™ has been designed using “thin shell structural” analysis and there are just a handful of engineers in the world that understand and can operate with the advanced constraints involved with thin shell structures.

Even that handful of engineers could NOT reverse engineer the MAS™ system without incredible time and effort.  And if they did they would violate the MAS™ pending patents thus making the reward for spending such time and effort problematic.  Each structure ordered from MAS™ will have a unique set of engineering plans based upon 8 distinct environmental and code requirements.  From this MAS™ computes 77 load combinations using its confidential and highly protected (secured) algorithms.  MAS™ does not keep these exposed to the outside world via internet, etc.  They are locked down and NO one person in MAS knows or has seen all these equations.

Without the solution to these 77 loading combinations you can NOT successfully build the MAS system.

You can NOT over design the MAS™ structures like you can in conventional construction.  Thin shell solutions are sensitive.  If you don’t put the rebar where MAS™ engineers tell you or layer the shotcrete like MAS™ engineers say, the results will be either a catastrophic failure, or you will get severe cracking immediately.

When you visit MAS™ and see the Discover Model built at Southern Utah University, you can see for yourself how critical this engineering really is.  MAS™ will show you cracked panels that resulted when procedures are not followed, and flawless panels that are made by following the MAS™ engineering and procedures.

The rebar solution provided by MAS™ engineering is NOT evenly spaced or systematically directed.  The thickness of the concrete varies, as does the placement of the re-bar chairs. It is a puzzle for which the solution can ONLY  be provided by MAS™ and this solution must be provided on a structure by structure basis.

Someone could try to copy the MAS system only to find out a year down the road they built 100,000 units that are cracked and must be destroyed.  It defies logic that someone would take this chance to avoid paying a ADELS Fee that includes architecture, design, engineering, technical & logistical support and a 20 year warranty.

This ADELS Fee is far less than the cost for an individual to do their own architecture, design, engineering and includes full technical and logistical support as well as a 20 year warranty!

• DEVELOPER
• CONTRACTOR
• FOREMAN
• SPECIALTY WORKER (Sub-Contractors) (such as Concrete Finisher, Excavator, etc.)

A simple way to look at it: A DEVELOPER hires a CONTRACTOR who employs one or more FOREMEN who oversee and inspect the work done by the SPECIALTY WORKERS (Sub-Contractors).

There is NO exclusivity, however a MAS Distributor can receive a geographical region and no other MAS Distributor can operate in that region without permission from the MAS Distributor that has been given that area. In essence, this is exclusivity while allowing MAS™ to accept others if a MAS Distributor cannot provide the level of service being demanded in such area.

A “geographical area” is just one of four arenas that a MAS Distributor can receive an authorization for.  MAS™ calls this a “FAD” designation.

• A specific Project (example: “ABC City low income housing bid #340-16-C”) or;
• A specific Field (example: “Military Bunkers, for ammunition storage”) or;
• A specific Area (example: The Southern Portion of Mexico) or;
• A specific Department (example: US Federal Emergency Management Agency)

This depends on the PFAD designation being requested.  The PFAD designations are listed below.  To receive an “A”rea, “F”ield, or “D”epartment MAS Distributor designation requires significantly more work than receiving a “P”roject MAS Distributor designation.  MAS Distributor “P”roject designations are routinely given by MAS™ to Contractors so they can incorporate the MAS™ system into their project.  It is rare for MAS™ to grant an MAS Distributor “P”roject designation to someone other than a Contractor.  MAS often refers to Contractors who also function as a MAS Distributor on their own projects as “Super Contractors”.

MAS Distributor (Certified Project Coordinator):  When a company is certified at MAS Distributor, it can be for:

• A specific Project (example: “ABC City low income housing bid #340-16-C”) or;
• A specific Field (example: “Military Bunkers, for ammunition storage”) or;
• A specific Area (example: The Southern Portion of Mexico) or;
• A specific Department (example: US Federal Emergency Management Agency).

For more information please select the MAS Distributor tab at: http://www.modernarchstructures.com/technology/mas-certification-overview/mas-certification-levels

MAS™ does NOT grant exclusive territories, however  MAS™ does allow the MAS Distributor to decide whether to allow one or more MAS Distributors to operate in an area if they are the holder of an MAS Distributor “A”rea certification.  So in essence this is exclusivity, but such exclusivity is granted by the MAS Distributors in the area.

There are many positive business reasons that would benefit multiple MAS Distributors to operate co-jointly in an area.  MAS™ leaves this decision up to the individual MAS Distributors.

The same is true with respect to the “F”ield and “Department” certifications.  If MAS™ receives an application for a MAS Distributor that would conflict with an existing MAS Distributor, the existing MAS Distributor would have to authorize MAS™ to proceed before MAS™ would issue such an MAS Distributor certification.

The reason the MAS™ system is so easy to build is because of three primary factors, one of which is training.

1. MAS™ provides the bulk of the engineering required using its proprietary finite element analytical models.
2. MAS™ provides a patented forming system and scaffolding system (SPiFolding)
3. MAS™ provides the training necessary to construct the MAS™ system.

MAS™ has defined a set of whistle blows (sounds) (short, long blows on a whistle) which were adopted from the train industry.  MAS™ calls this the “Whistle Code” and it is very helpful for all workers to know this code.  When volumetric mixers, pumps, skid steers, etc. are running it is often difficult to yell and be heard.  Therefore the Whistle Code is used by all workers and supervisors who each carry small whistles on a lanyard ready for use at all times.

MAS™ “WHISTLE CODE”

When visiting a construction site deploying the MAS™ system it is common to hear the workers signalling “three short beeps” on their whistles frequently.  This is the “GOING WELL” Whistle Code and is used to signal “good job”, “all is fine”, “things are going great”, “keep up the good work”, etc.  It is used as a form of motivation between workers to signal that everyone is doing a great job as a team and to keep things going as they are.

Foreman will often use the term “all threes” such as: “If you guys give me an hour of ALL THREES we can break for lunch early and take an extra 1/2 hour.”

As a contractor you are familiar with building.  What you need to learn is how to fit the MAS™ system into your existing method of construction.  To start with you will need to understand how to bid the project.  This will include determining the quantity and cost of forms and the labor time and skills required.  MAS™ provides calculators to help a contractor prepare bids.  Many contractors   use these calculators initially to understand the feasibility of using the MAS™ system for their project.

Once a contractor is confident the MAS™ system is an option for their project they will usually sign up to attend a T2 training class from MAS™.  The T2 training class will teach the contractor everything needed to bid a MAS™ structure including the advanced use of the calculators on the MAS™ website.  The T2 class will quickly orient the contractor to the MAS™ system and the unique forms that are used for construction.  The construction time line as well as the labor requirements will be thoroughly covered.

Construction with the MAS™ system is not complex and is much easier and faster than conventional construction.  Limited worker skills are required and can generally be learned in just a few days.  MAS™ provides detailed procedures, training videos and check lists as part of it’s inexpensive and thorough training programs.

One option available to a new contractor is to hire a MAS certified field trainer who can provide the expertise necessaryto do the job.  The MAS Field Trainer (an independent contractor) can also certified trainers and conduct “on the job” training for the new contractors personnel during the construction phase of the MAS™ system should Proficiency Certification be desired.  Once the new contractor has his crew trained and certified he can dismiss the Field Trainer.  This can be a cost effective and quick solution for a contractor to start their involvement with the MAS™ system.

NO, that is NOT the purpose of the MAS™ training classes.

Other than the T1 Orientation class, the MAS™ training classes are designed to educate an experienced contractor on how to apply their existing trade to the MAS™ construction process.

MAS™ suggests that you employ a local contractor who has construction experience and knows how to work with local engineers, pull permits and build in your locality.  MAS offers Proficiency Training Courses if your contractor wants to achieve an optional Proficiency Certification.  Most contractors have no problem building a MAS structure and will often employ a field trainer on their first try to shorten any learning curve.

Trying to train persons with NO construction experience is a longer process and not recommended. The logistics involved with supervising a construction project is best done by a contractor with local experience and who understands the laws and requirements unique to the territory where the MAS™ structures are being built.

• DEVELOPER
• CONTRACTOR
• FOREMAN
• SPECIALTY WORKER (Sub-Contractors) (such as Concrete Finisher, Excavator, etc.)

A simple way to look at it: A DEVELOPER hires a CONTRACTOR who employs one or more FOREMEN who oversee and inspect the work done by the SPECIALTY WORKERS (Sub-Contractors).

A carpenter generally would generally be a Foreman or Specialty Worker (Sub-Contractor).  MAS™ offers several Training Courses that allow proficiency in all areas of MAS construction should it be desired.  A carpenter will generally start with MAS™ Training Course Number T.  This is a two day training course.  Additional days of Specialty Training is available in MAS™ Training Course Number T4 to allow persons/contractors to gain expertise in individual specialty areas.  Some 3rd party companies, that have already completed training, also offer field training and support to assist a carpenter with their first project which generally provides all the familiarization with the MAS system that is required.

Please visit the following link for more information on training: http://www.modernarchstructures.com/technology/mas-certification-overview/mas-training

MAS™ does NOT build MAS™ systems.  MAS™ certifies persons/companies and provides a per system License for each MAS™ structure built.  If you want a single MAS™ structure you have two choices:

(1) Contract with a Contractor that already has the capability/experience of building MAS™ systems, and can easily give you a quote.  A list of such companies (dealers) can be found at: http://www.modernarchstructures.com/community/dealers

(2) Find a local contractor of your choice and have them get trained by MAS™ or an independent field trainer.

Note:  Many persons desiring just a single MAS™ system will have their local contractor hire an existing experienced contractor to help them with the project and allow such local contractor to get training.  MAS experienced contractors often own one or more “Form Packages” which are a necessary to construct the MAS™ system.  Although such Form Packages can be rented by the supply division of MAS™, it is often significantly less expensive to have an Contractor provide construction expertise AND their forms to your local contractor of choice.

The discovery model floor was finished with an acid etch color finish.  This process takes just a few hours and requires no skill.  The material costs are minimal.  The acid / color is spread with a broom and then hosed off.  Because the floor is freshly pored concrete, there is no need for time consuming preparation.  Simply sweep or blow the floor clean before starting the process.  A sealant coat (optional) was applied at the completion of the interior construction.

The end result is a grained / tapered look that can resemble wood or stone depending on the colors chosen.

The reason the MAS™ system is so easy to build is because of three primary factors, one of which is training.

1. MAS™ provides the bulk of the engineering required using its proprietary finite element analytical models.
2. MAS™ provides a patented forming system and scaffolding system (SPiFolding)
3. MAS™ provides the training necessary to construct the MAS™ system.

THE MAS™ 12 STEP PROCESS

(At a Glance)

Obtain and pay for a license from MAS™, obtain the  appropriate local permits, excavate, install slab and set vertical steel as per common construction practices require.

1. Corner layout for arch supports
2. Set fan manifold box, fans, air form ring, and air form
3. Stage SPiFolding
4. Inflate air form and set up SPiFolding/Tenting
5. Set up corner arch supports (garage openings if applicable)
6. Mark front entry for reinforcing steel (Install common arch leg at entry)
7. Attach corner panels (and garage panels if applicable)
8. Set reinforcing steel, dormers and doorway
9. Shotcrete application (layer 1)
10. Shotcrete application (layer 2)
11. Front entry arch support and shotcret layer for front entry
12. Final shotcrete layer with desired finish

MAS™ has defined a set of whistle blows (sounds) (short, long blows on a whistle) which were adopted from the train industry.  MAS™ calls this the “Whistle Code” and it is very helpful for all workers to know this code.  When volumetric mixers, pumps, skid steers, etc. are running it is often difficult to yell and be heard.  Therefore the Whistle Code is used by all workers and supervisors who each carry small whistles on a lanyard ready for use at all times.

MAS™ “WHISTLE CODE”

When visiting a construction site deploying the MAS™ system it is common to hear the workers signalling “three short beeps” on their whistles frequently.  This is the “GOING WELL” Whistle Code and is used to signal “good job”, “all is fine”, “things are going great”, “keep up the good work”, etc.  It is used as a form of motivation between workers to signal that everyone is doing a great job as a team and to keep things going as they are.

Foreman will often use the term “all threes” such as: “If you guys give me an hour of ALL THREES we can break for lunch early and take an extra 1/2 hour.”

The MAS-570™ is 24 feet x 24 feet (7.3 meters x 7.3 meters).  The height in the center (at the peak of the arches) is 12 feet (3.65 meters).  The floor area is 570 sq. feet (53.5 sq. meters)

The MAS-1300™ is 36 feet x 36 feet (11 meters x 11 meters).  The height in the center (at the peak of the arches) is 18 feet (5.5 meters).  The floor area is 1,300 sq. feet (120.5 sq. meters)

NO.

Domes are great structures and very strong, however the MAS™ structures are NOT domes.  The MAS™ system uses bisecting dual arches that form a crown at the very top area.  The corners are square and, other than the arches, the interior walls are vertical and not curved like in a dome.

The MAS™ system is NOT a Dome Home, but sometimes is referred to as a “home with a dome” due to the “dome look” of the crown formed by the bisecting arches at the top most part of the structure.

← See basic “Dome Home” below on the left and basic “MAS™ Home” on the right →

Basic Dome Home.

This is NOT A MAS™ Home

MAS™ is NOT a Dome Home!

 

Basic MAS-1300™ Home

______________________________________________

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

MAS™ will actively pursue and prosecute, to the MAXIMUM EXTENT OF THE LAW, any violations of the MAS™ intellectual property, registrations and patents (pending and issued) throughout the world under international treaties as well as local laws, statutes, agreements, and registrations.

A ADELS Fee must be paid for each structure built.  A SINGLE License is issued for each SINGLE ADELS Fee paid to MAS™.

MAS™ EMPLOYS A SOPHISTICATED ELECTRONIC LICENSE VERIFICATION SYSTEM TO PREVENT THE THEFT OF THE MAS™ INTELLECTUAL PROPERTY, REGISTRATIONS, AND PATENTS (PENDING AND ISSUED).

See the following area of the MAS™ website area for more information on the MASTronic™: http://www.modernarchstructures.com/technology/mas-licensing/mastronics-embedded-rfid-license-tracking-device

The MAS™ system uses shotcrete and due to the application in layers, shotcrete does not have cold joints.  Shotcrete creates a much stronger bond and because of the consolidation during the application process and the resulting strength, cracks are unusual.  Any cracks over time would be superficial and not structural.  MAS™ guarantees this!

Most users texture the concrete with stamping and thus the graying effect is minimized.  Also, the use of color in the final 1/4″ to 1/2″ layer is very inexpensive and will eliminate the “gray” concrete look if objectionable.  Many users also elect to stain the concrete using various colors to achieve the architectural look desired.

The MAS™ system has the potential to be used in a “retaining” wall situation where the unites are place IN a sloped embankment.  This application WOULD require waterproofing AND additional structural engineering based upon the forces of the “dirt” to be held up.  It is likely that additional concrete AND re-bar would be required.

MAS™ has NEVER had a problem getting a local entity in charge of building code enforcement to issue the permits and/or documentation necessary to build a MAS™ system structure.  The MAS™ system is designed around standard and accepted design principals using traditional engineering meeting the United States Uniform Building Code. (UBC).  Therefore, the system as designed, will likely exceed ALL local building codes.  However, if something unusual and unforeseen comes up, the MAS™ engineering team will work with the builder for no additional cost to find a solution where possible.

YES

Producibility: A term used to describe the ability of contractors to bid on a project proposal.

Although the MAS™ system is new to many contractors, MAS™ provides a “T2” training class that is specifically designed to educate a contractor on the MAS™ system and all aspects necessary to prepare a qualified, responsive and financially viable bid.

Although MAS™ leaves the interior design up to 3rd parties, the MAS™ team has created a few sample floor plans.

MAS-570™ Sample Floor Plans

MAS-1300™ Sample Floor Plans

One of the best areas to view models with sample floor plans is in the dealer area.  High Line Enterprises offers a wide selection of models, including residential, multi-unit, duplexes, triplexes, fourplexes, and garages.

MAS™ along with others find equivalent R-value to be a useful way to summarize the energy efficiency of a MAS™ structure. Since there is wide spread confusion between a “conventional R-value” and an “equivalent R-value” it is important to understand the difference.  There are a few important cautions. First, equivalent R-value is not the same as the conventional R-value and you shouldn’t pretend it is.

A MAS™ structure can be built with 3rd party insulation products which typically use OPEN cell panel insulation in the MAS™ system corners and OPEN cell spray insulation on the arch sections.  The MAS™ structure can obtain a REAL conventional R-value of 60 but will offer an equivalent R-value of 60 for significantly less insulating material. Following are the calculations which show this.

Using 3.0″ open cell foam insulation on the corner wall and hip roof gives an approximate convention R-value of 15 in this area.  Using 3″ of  closed cell foam on the arches gives an approximate conventional R-value of 60.  See the table at the end of this discussion from the US Department of Energy, National Laboratory System, Science and Technology Information Center.

With NO 2×4’s, you get approximately 10% more insulation per square foot based upon 16″ stud spacing (1/16).  You also eliminate voids which accounts for about 1/2 inch of extra insulation.  Thus to get the conventional R-value you take 13.72 times 1.094 = 15.  This is based on 3.5 inches.  However we can subtract 1/2″ as there are no voids (missing insulation) due to imperfect fitting to 2×4 studs.

Using 1.0″ closed cell foam insulation on the arches give an approximate conventional R-value of 22 in this area.  Thus the to get the conventional R-value you take 20.09 times 1.094 = 22.

The MAS™ walls are not R-60 in the above example (but they can be). They still allow heat to conduct through like R-15 and R-22 walls because that’s what they are. It’s just that they have other, different ways, to save some energy, Equivalent R-value is a way to boil all the energy savings down and summarize them in one number, But it’s a different type of number.  MAS™ Considers this configuration to be an equivalent R-value of 60.

IS IS POSSIBLE TO ACHIEVE A CONVENTIONAL R-VALUE OF 60 by using more insulation AS FOLLOWS:

It is possible to use 1″ of open cell foam insulation on the corner walls and hip roof and cover it with  2.5″ of closed cell foam to achieve a conventional R-value of 60.  This is calculated as follows: Using 1″ instead of 3″ of open cell foam yields a conventional R-value of 15/3 = 5.  We desire an R-60 and thus need to make up and R-value of 55 (60-5) with the closed cell foam.  As shown in the calculations above, we get a conventional R-22 per 1″ of closed cell foam.  Thus 55/22 = 2.5.  Thus with 2.5″ of closed cell foam sprayed on top of the 1″ of open cell foam we get a conventional R-value of 60.   Applying 2 3/4″ of closed cell foam on the arches would achieve a conventional R-value of 60 in this area.  Thus the entire MAS™ structure can be built with a conventional R-value of 60.

In summary, the MAS™ structure can achieve a conventional R-value of 60.  However, an equivalent R-value of 60 is achieved with significantly less insulation due to the lack of voids, thermal mas and other factors that have a profound effect on the use of energy for heating and cooling.

MASKanX™ is a patent pending revolutionary solution to interior partitions. MASKanX™ allows for the use of freestanding and movable wall partitions that can take full advantage of the non impeded interior spans of the MAS™ system.  These 100% clear spans allow for non-bearing interior partitions which would not be possible with conventional construction. With the MASKanX™ solution, the home owner can reconfigure the interior to add or remove rooms, re-size rooms or other living spaces in a matter of hours.

The MASKanX™ is a SINGLE hardware device solution.  MAS™ can supply the MASKanX™ device with complete design templates for the partitions.  Thus the partitions can be constructed locally through automated CNC milling machines using the supplied bit map file or constructed on site using conventional construction techniques.

What does this have to do with MAS™? If a customer wants a green house tell them to go buy one. If your MAS Distributor wants to include green houses in their project proposal there is nothing preventing a MAS Distributor from working on a project that would include a green house.

YES

There is virtually NO limit to the variety of facades that can be created with the exterior facade forming system created by MAS™ called the MASFacFos™. 

MAS™ exterior facade form sets from the MASFacFos™ forming system line such as the “PARAPET” or “SOFFIT” can be used to construct an entirely different architectural look with little incremental cost.  In addition, foam “pop outs” can be used to form (and cover in concrete) almost any exterior 3 dimensional detail such as window/door trim features, corner blocks, etc.

To view examples of MAS structures that can be constructed using the MASFacFos™ please visit the MAS EXTERIORS area of this website and select one or more GALLERY tabs.

The MAS™ system uses a conduit system that is embedded in the foundation.  The MAS-1300™ has a total of 5 duplex boxes per side, of which 2 of these home run to the electrical panel area.  Thus you end up with 20 duplex boxes, and 8 home runs.  This allows great flexibility for line voltage or low voltage applications.  The final interior wiring connects to such boxes.  If spray foam is going to be used, then Romex can be be “hot glued” to the walls when installing additional duplex outlets, and then covered by the foam.  The The MAS-570™ works in a similar manner however, it has only 3 duplex boxes and 1 home per side (total of 12 duplex boxes and 4 home runs).

Note:  The conduit system is very inexpensive as it is used to create a void in the concrete.  The concrete is what is actually protecting the final wiring and thus this inexpensive conduit does not require any type of rating.

 This is NOT a modular system.  All construction material is purchased locally giving you 100% local content.  MAS does provide (at cost) the forming systems.

Once constructed the MAS-1300™ weighs approximately 350,000 pounds thus making it unmovable!

Basic plumbing is provided either through a Plumbing Trough, that allows for plumbing to be brought in later, or basic “Stub Ups” for sewer, etc.  (or both).

Plumbing Trough: A 12″ wide plumbing trough is put about 2 inches under the top of the slab.  This allows room for a gray water sewer, black water sewer and fresh water to be “fished” in at any time.  Then it is run through the interior partitions as in standard construction.

The advantages of the Plumbing Trough is the ability to add plumbing at a later date.  Many 3rd world countries are providing central bathroom and kitchen facilities and thus have no “current” need for plumbing.  However, the ability to add plumbing without the need to tunnel, or tear down walls is a tremendous value and makes the MAS™ structure easily retrofitted as future needs and requirements change.  The same is true for the basic electrical system provided in a MAS™ system.

NO

MAS™ has done NO structural testing in the form of “stress to failure” type tests.  Our engineers have designed the MAS system using Finite Element Analysis (FEA) based upon standard and accepted engineering principals, processes and materials.

Concrete is inherently fire proof.  Because the concrete does not encapsulate flammable material in the MAS™ exterior structural shell system there is no de-rating of the concrete required.  The interior walls can also be built from concrete making the entire finished structure highly resistant to fire, and inherently survivable should an interior contents fire erupt.  I.e. the MAS™ concrete structure does not provide ANY fuel to facilitate the spreading of a interior content fire.  The entire MAS™ structure is NON-COMBUSTIBLE.

It is unlikely that the interior contents would contain enough combustible material (fire load) to cause damage to the MAS™ concrete shell even if it became fully engulfed in a fire.

When attaching MAS™ structures to one another in a retro-fit scenario the door way is made by extending the 4 foot window opening to the slab.  When attaching MAS structures to one another DURING construction there may be other options.  Such options must be engineered and may include eliminating the majority of this single corner connecting wall in both units such that the connection is “seamless”.  Such engineering is provided by MAS™ at no additional cost as part of the ADELS Fee.

Unlike conventional construction, the cost to add an additional MAS™ structure is virtually the same whether it is done during initial construction or via a retrofit (remodel) at some later date.

Note:  In the retro-fit scenario the extension of the 4 foot window to the slab to create a doorway is done as follows:

• Removal of the window unit if installed
• Saw cutting the concrete to the floor following the vertical lines of the window edge opening
• Saw cutting and chiseling  between these saw cut vertical lines and the slab
• Removal of the concrete panel below the window
• Shotcreting the saw cut and chiseled edges when the new MAS™ structure is constructed so as to encapsulate and protect any re-bar exposed during the cutting process and to finish the opening to the required width/height.  (Additional re-bar and doweling may be required if more than a few inches of Shotcrete is required to make the opening narrower or shorter)

As a contractor you are familiar with building.  What you need to learn is how to fit the MAS™ system into your existing method of construction.  To start with you will need to understand how to bid the project.  This will include determining the quantity and cost of forms and the labor time and skills required.  MAS™ provides calculators to help a contractor prepare bids.  Many contractors   use these calculators initially to understand the feasibility of using the MAS™ system for their project.

Once a contractor is confident the MAS™ system is an option for their project they will usually sign up to attend a T2 training class from MAS™.  The T2 training class will teach the contractor everything needed to bid a MAS™ structure including the advanced use of the calculators on the MAS™ website.  The T2 class will quickly orient the contractor to the MAS™ system and the unique forms that are used for construction.  The construction time line as well as the labor requirements will be thoroughly covered.

Construction with the MAS™ system is not complex and is much easier and faster than conventional construction.  Limited worker skills are required and can generally be learned in just a few days.  MAS™ provides detailed procedures, training videos and check lists as part of it’s inexpensive and thorough training programs.

One option available to a new contractor is to hire a MAS certified field trainer who can provide the expertise necessaryto do the job.  The MAS Field Trainer (an independent contractor) can also certified trainers and conduct “on the job” training for the new contractors personnel during the construction phase of the MAS™ system should Proficiency Certification be desired.  Once the new contractor has his crew trained and certified he can dismiss the Field Trainer.  This can be a cost effective and quick solution for a contractor to start their involvement with the MAS™ system.

THERE IS NO COMPARISON

Modular homes were a great solution before MAS™  for fast construction,  low cost, low end homes.  The modular industry has done a great job a increasing quality and lowering cost through engineering, quality control and assembly line production.  However, the introduction of the MAS™  solution by Southern Utah University has made the modular home obsolete over night.  Why would someone contract for a more costly, longer build time, less durable, higher maintenance home when you can have a MAS™ home that will outlive you, your kids and your kids kids with virtually NO maintenance, at far less cost, in just a week or two.  The answer:  THEY WOULD’NT.  The MAS™ home is the WORLDS housing solution and will change the way people view home quality, safety and longevity.

See the MAS™ Comparison Chart for more information.

First of all, it is the shell that is built in 5 days not a completed ready to move in home as shown in the schedule you reference.  Generally, contractors like between a few days to a week to finish a simple interior with bathrooms, bedrooms and a kitchen.  Although a MAS™ structure can be built and ready to move into in a week, MAS™ recommends that your schedule allows for a full 2 weeks from start to occupancy.  Note : The forms are generally only needed for 3.5 to 4 days, and the SPifolding is only needed for a week.

Unlike building with traditional construction, adding more personnel to a MAS™ construction project DOES NOT speed up the time it takes for construction.  This is because MAS™ has designed their procedures and forms to be highly efficient and work within the window required for concrete to cure.  Thus while the concrete is curing the personnel are not needed. Having additional personnel would accomplish nothing.  It is beneficial to have additional personnel when using a non-experienced crew or when local conditions are not conducive to construction.

Note: A typical “stick” built single family resident home takes 5 to 6 months on the average to complete in the United States.  This same home can be done in 1.5 to 3 months by putting a much larger crew on the job.  However there is a loss in efficiency when you speed up such a project such that workers get in each others way and have to wait while another contractor finishes so they can start.  The faster the home is built, the efficiency generally goes down.  The MAS™ system was designed from the ground up around an efficient dual two-man crew working 8 hours per day.  Thus if this crew worked 14 days, 8 hours per day (which is well more than it should take), there would be 448 man hours expended for the MAS-1300™ construction.  Standard “stick” built construction takes several thousands of man hours to complete.

Note: A Timber Frame Post and Beam Home is at the high end of conventional construction and construction will take longer than typical “stick” built construction.  A MAS™ home can achieve this same look, both inside and out, using inexpensive concrete facades that will last hundreds of years.

Timber Frame Post and Beam Home is at the high end of conventional construction yet the look can be easily achieved in a MAS™ home.  A MAS™ home can achieve this same look, both inside and out, using inexpensive concrete facades that will last hundreds of years.

These facades will require additional man hours for construction, but the additional material costs will be minimal.

North Woods Joinery has many solutions that can be successfully used in a MAS™ home should the owner want more than a facade.

NO – ABSOLUTELY NOT

A MAS™ home is built entirely on site and is considered 100% site built.  The reason that it can be built so fast is the use of the MAS™ Patent Pending Forming system invented at Southern Utah University under the leadership of Professor Edwards.  Houses that are NOT 100% site built often times have restrictions from communities, insurance providers, lenders, etc.  A MAS™ home should have NONE of these restrictions.

What Do the Differences Mean to You?

Restrictive Covenants and Deed Restrictions

• Communities generally have no restrictions against traditional, site built homes. Many housing developments do set minimum size requirements and stipulate you must build a house that conforms to published standards or be approved by an architectural review committee.
• Most developments allow modular homes. Some do not, but in those cases the restrictions seem to have been imposed because of an ongoing confusion about the differences between modular homes and manufactured homes.
• Restrictive covenants and deed restrictions often exclude manufactured homes.

Investigate the deed restrictions thoroughly before purchasing land for any type of new home.

Facts About Modular, Manufactured & Site Built Homes

When you are buying a home, you might hear the terms modular homes, manufactured homes and site built homes. It’s important to understand how they all differ, no matter whether you are purchasing an existing house or plan to build on land that is subject to restrictions. The differences can affect a home’s price and its resale value, and even dictate whether or not it can be built on your land.

What Are Site Built Homes?

• They are constructed entirely at the building site.
• They conform to all state, local or regional codes where the house is located.
• Often called ‘stick-built’ houses.
• A well-built, cared for site-built home generally increases in value over time, although its location plays a key role in value.
• They generally receive the least damage during natural disasters.

 What Are Modular Homes?

• Modular homes are built in sections at a factory.
• Modular homes are built to conform to all state, local or regional building codes at their destinations.
• Sections are transported to the building site on truck beds, then joined together by local contractors.
• Local building inspectors check to make sure a modular home’s structure meets requirements and that all finish work is done properly.
• Modular homes are sometimes less expensive per square foot than site built houses.
• A well-built modular home should have the same longevity as its site-built counterpart, increasing in value over time.  However, this is NOT always the case.  Also their resistance to natural disasters can be significantly less than a site-built house depending on the founding employed during construction.

 What Are Manufactured Homes?

• Formerly referred to as mobile homes or trailers, but with many more style options than in the past.
• Manufactured houses are built in a factory.
• They conform to a Federal building code, called the HUD code, rather than to building codes at their destinations.
• Manufactured homes are built on a non-removable steel chassis.
• Sections are transported to the building site on their own wheels.
• Multi-part manufactured units are joined at their destination.
• Segments are not always placed on a permanent foundation, making them more difficult to re-finance.
• Building inspectors check the work done locally (electric hook up, etc.) but are not required to approve the structure.
• Manufactured housing is generally less expensive than site built and modular homes.
• Manufactured homes sometimes decrease in value over time.
• Manufactured homes home up very poorly in natural disasters.

NO

Prior to March 1, 2012 there use to be two form sets for the Type G models.  One for the MAS-570™ and one for the MAS-1300™.  However, MAS™ redesigned these form sets into a single form set that can be used on both the MAS-570™ and the MAS-1300™ thereby eliminating the need to purchase two different form sets.  This redesign was a part of an entire form redesign using the new MAS™ arch form supports that are also used on the corner/cage forms and entry forms.

It is no longer possible to buy just a single MAS-570™ or single MAS-1300™ Type G form set.  The new Type G form set contains all the components to work on both the MAS-570™ and MAS-1300™ structures which is a much more cost effective and robust solution.

YES,

The ADELS Fee is charged per structure.  In the case of multiple MAS™ structures connected to each other, MAS™ will have to provide engineering for each individual structure as well as the connection detail.  For example, if you build a MAS-1300™ with a MAS-570™ attached to one corner (to be used for additional bedrooms) you will have to pay for two ADELS Fees.

The same would be true if you build a MAS-1300™ with a MAS-570™ attached to one corner as a garage, you will have to pay for two ADELS Fees.

MAS™ does not charge extra for the engineering necessary to provide this connection detail.

The ADELS Fee covers the engineering, architecture, system plans, inspections, technical support, logistical support, Southern Utah University (SUU) royalty fee and warranty.

There appears to be a complete misunderstanding of how difficult it would be to copy the MAS™ system without having access to the MAS™ engineering analytical models.

MAS™ has developed a sophisticated engineering model based around its own mathematical algorithms using finite element analysis.  MAS™ has been designed using “thin shell structural” analysis and there are just a handful of engineers in the world that understand and can operate with the advanced constraints involved with thin shell structures.

Even that handful of engineers could NOT reverse engineer the MAS™ system without incredible time and effort.  And if they did they would violate the MAS™ pending patents thus making the reward for spending such time and effort problematic.  Each structure ordered from MAS™ will have a unique set of engineering plans based upon 8 distinct environmental and code requirements.  From this MAS™ computes 77 load combinations using its confidential and highly protected (secured) algorithms.  MAS™ does not keep these exposed to the outside world via internet, etc.  They are locked down and NO one person in MAS knows or has seen all these equations.

Without the solution to these 77 loading combinations you can NOT successfully build the MAS system.

You can NOT over design the MAS™ structures like you can in conventional construction.  Thin shell solutions are sensitive.  If you don’t put the rebar where MAS™ engineers tell you or layer the shotcrete like MAS™ engineers say, the results will be either a catastrophic failure, or you will get severe cracking immediately.

When you visit MAS™ and see the Discover Model built at Southern Utah University, you can see for yourself how critical this engineering really is.  MAS™ will show you cracked panels that resulted when procedures are not followed, and flawless panels that are made by following the MAS™ engineering and procedures.

The rebar solution provided by MAS™ engineering is NOT evenly spaced or systematically directed.  The thickness of the concrete varies, as does the placement of the re-bar chairs. It is a puzzle for which the solution can ONLY  be provided by MAS™ and this solution must be provided on a structure by structure basis.

Someone could try to copy the MAS system only to find out a year down the road they built 100,000 units that are cracked and must be destroyed.  It defies logic that someone would take this chance to avoid paying a ADELS Fee that includes architecture, design, engineering, technical & logistical support and a 20 year warranty.

This ADELS Fee is far less than the cost for an individual to do their own architecture, design, engineering and includes full technical and logistical support as well as a 20 year warranty!

NO, that is NOT the purpose of the MAS™ training classes.

Other than the T1 Orientation class, the MAS™ training classes are designed to educate an experienced contractor on how to apply their existing trade to the MAS™ construction process.

MAS™ suggests that you employ a local contractor who has construction experience and knows how to work with local engineers, pull permits and build in your locality.  MAS offers Proficiency Training Courses if your contractor wants to achieve an optional Proficiency Certification.  Most contractors have no problem building a MAS structure and will often employ a field trainer on their first try to shorten any learning curve.

Trying to train persons with NO construction experience is a longer process and not recommended. The logistics involved with supervising a construction project is best done by a contractor with local experience and who understands the laws and requirements unique to the territory where the MAS™ structures are being built.

NO

Other than the License and engineering, MAS™ only supplies the forms and SPiFolding as these are specialty items that are used over and over.  The raw material to build should be purchased locally.  Thus MAS™ does NOT provide material.   MAS™ can help coordinate the procurement of shotcrete pumps etc. from 3rd party vendors if they are not available locally.  The MAS™ logistics and support division will help the contractor with engineering coordination as well as material specification and material procurement from local suppliers.

MAS™ also provides training for contractor certification.

Marketing personnel working for a MAS Distributor are NOT required to attend any courses.  However, the MAS™ T1 orientation course is helpful to formulate a basic understanding of the MAS™ concept.

Marketing personnel who may need to assist a contractor with the bidding process, involved with the construction of the MAS™ system, are well advised to complete the MAS™ T2 Familiarization and Bidding course.

Finally, those marketing personnel who must educate potential contractors as to what it takes to construct a MAS™ structure are advised to take the first day of the MAS™ T3 Construction Orientation and Familiarization course.  The first day of the MAS™ T3 course specifically outlines the differences between traditional construction and MAS™ construction.  A thorough understanding of these differences is a quick way of orienting a potential Contractor to the MAS™ construction process.

The MAS™ Training and Field support department can tailor specialized classes designed for your specific marketing needs.  The daily cost of such classes will be similar to those listed in the Training Area of the MAS™ website when 4 or more personnel attend.

Please contact the MAS™ Training and Field support department for any questions or to book your training classes.

YES – ABSOLUTELY!

The entire MAS™ concept is based upon 3rd party vendors coming forward to offer solutions that are complementary to the MAS™ system.  MAS™ has patents or pending patents on the MAS™ Forming and SPiFolding™ systems which are an integral part of the MAS™ construction process.  However, MAS™ will license 3rd party vendors to manufacture such equipment for ZERO royalty or licensing fees so long as such equipment is ONLY sold to MAS™ certified users, and such equipment is only used on structures with a MAS™ Unit License.

MAS™ must be able to monitor the quality and production of all such equipment and such costs will be the responsibility of the the 3rd party doing the manufacturing.  Many large projects contemplating the use of the MAS™ system have recognized the great savings that can be had by manufacturing the MAS™ Forming and SPiFolding™ Systems locally.

MAS™ is encouraging such “local” 3rd party manufacturing and will allow such 3rd parties to be listed on the MAS™ website in order to market such equipment to other MAS™ System users.  This is clearly a WIN WIN for all parties involved.

MAS™ has sophisticated CAD drawings for all of the MAS™ Forms and SPiFolding Systems.  Please contact the the MAS™ Producibility Department for information on becoming a 3rd party vendor for the MAS™ Forming or SPiFolding™ Systems or any other complementary system(s).

NO

You can NOT replace an arch with a corner therefore you can NOT have 4 square corners on a MAS-570™.  The arches are the key structural components of the MAS™ system.

There are NO round corners on any MAS™ structure.  It may be possible to perform a faux “rounding” of the two square corners on the exterior. A interior finish crew may be able to perform a faux “rounding” of the interior of these same two square corners.

It possible that you are confusing the ARCHES with a round corner.

If you want a MAS™ system with 4 corners please consider the MAS-1300™.

There are walls to the ceiling separating the two duplex units.

There is a dividing wall between the two duplex units.  Therefore the loft of one unit is ONLY open to this same unit.  One unit can NOT see into the other unit.  The dividing wall is a two piece wall that meets in the middle and overlaps.  This allows for thermal expansion and contraction.  I.e. it is staggered.  This is a detail that is probably unimportant to you at this point, but it may be helpful to understand how such a wall does not violate the requirement that “NO interior walls can be built that extend between two opposite arches”.

The plumbing trough is designed for homes that will be built without plumbing initially.  I.e.certain regions do not typically provide electrical or plumbing connections as the bathrooms and kitchens are located outside.

However, at some point in the future, it is likely that plumbing and electrical will be required.  Thus the plumbing trough is installed to allow a bathroom, kitchen etc. to be installed at a future point in time without a major ordeal.

All MAS™ structures are built with embedded electrical raceways (formed via inexpensive and highly flexible plastic tubing) in the concrete foundation.  Thus outside and internal electrical is easily added at any time.

• DEVELOPER
• CONTRACTOR
• FOREMAN
• SPECIALTY WORKER (Sub-Contractors) (such as Concrete Finisher, Excavator, etc.)

A simple way to look at it: A DEVELOPER hires a CONTRACTOR who employs one or more FOREMEN who oversee and inspect the work done by the SPECIALTY WORKERS (Sub-Contractors).

This is something that your local engineer will specify.  A lot of this depends on the amount of precipitation your area gets as well as the quality of your cement and aggregate.

An excellent article on water & concrete was published in 2006  by K Howes & J McDonald and is reprinted below.  Keep in mind that shotcrete has a very low slump and thus a low water to cement ratio which helps naturally waterproof concrete.

———————-

WATERPROOF CONCRETE

WHAT IS WATERPROOF CONCRETE?

Isn’t normal, good quality concrete waterproof?

In order to provide sufficient workability for proper placing & compaction and to facilitate proper mixing and transportation to site, most plant-batched concrete will contain water in excess of that required to simply hydrate the cement. As concrete hardens, this excess water leaves the concrete and creates a network of fine capillaries and internal pores. Natural capillary absorption is the predominant mechanism of water transport through concrete whether or not a head of hydrostatic pressure is present. In essence, as far as water is concerned, normal concrete behaves like a dense sponge.

One cubic metre of normal, good quality dry concrete will absorb the equivalent of roughly 60 litres of water in just 30 minutes! (Test in accordance with BS 1881, part 122). It is the speed of this absorption that is important as this will directly affect the level of dampness, say in a basement, or the onset of reinforcement corrosion due to dissolved chlorides being carried into the concrete by water, say in a sub-sea tunnel, the tidal zone of bridge supports or from melting slush after de-icing salt has been applied.

Even the highest quality concrete contains a network of pores and capillaries and, without adequate damp-proofing protection, this may result in dampness or leaks causing deterioration of internal finishes, mould formation and a health hazard, especially in heated environments where damp concrete is a haven for bacterial development. Where chlorides and oxygen are present, corrosion to the reinforcement will occur. Where sulfates are present in the surrounding soils and groundwater, serious deterioration of the cement matrix can occur, both situations causing untold damage to the structure.

What does ‘Waterproof’ mean?

British Standards set out to ensure that reinforced concrete structures provide the degree of protection, internal environment and functionality required by owners or developers.

The term ‘Waterproof’ therefore conjures up a whole range of ideas. If the structure in question is to retain water, say a water storage tank, then the designer may simply work to the design requirements of the water retaining code, BS 8007, which sets out to limit crack width. This may be achieved by utilising a good quality, ordinary concrete, close attention to joint details and providing extra crack control reinforcement; dampness being acceptable.

If on the other hand the structure is habitable or designed to house sensitive electronic equipment or valuable archives, then simply designing to the water retaining code is not sufficient. This is especially so given that ordinary good quality concrete provides little resistance to the passage of water vapour.

There are several degrees of waterproofing to be considered, all loosely defined under 4 categories in BS 8102.

At the lowest level, Grade 1, there is ‘Water-tight’ which simply means that water will not run or flow freely through the concrete; at the upper levels, Grades 3 & 4, there is ‘Damp-proof’, which not only requires there to be no visible water ingress but also that very high levels of water-vapour resistance will be achieved. This applies whether or not hydrostatic pressures are present.

“Watertight” VS “Waterproof” concrete

BS EN 934-2:2001 specifies absorption testing according to EN 480-5:1996 for ‘Water resisting admixtures’. This requires prism shaped samples 40mm x 40mm x 160mm long to be stood up in water 3mm deep. Interestingly, ordinary concrete samples become completely saturated within a couple of hours. The photo shows the control ordinary concrete and the sample incorporating a “Waterproofing” admixture after 12 hours

We must be clear here that the influence of cement replacement materials (*1) and water reducing admixtures, though they may improve the apparent resistance to the inflow of water under pressure, may in fact create a finer capillary structure with the effect that capillary ‘suction’ is greatly increased and thus the flow of water through the concrete by capillary absorption is speeded up. “… the narrower the pores in saturated concrete, the lower its permeability. The narrower the pores, the greater the resultant capillary pressure and so the greater the influx of water …” (*2)

*1 Pozzolanas are materials containing reactive silica and/or alumina which on their own have little or no binding property but, when mixed with lime in the presence of water, will set and harden like a cement, ie on their own they don’t do anything. E.G. pfa which is a by-product of coal fired electricity stations, also known as fly ash; ground granulated blastfurnace slag, a by-product of the steel industry sometimes called GGBS or slag; silica fume, a by-product of microprocessor silica production also known as CSF, and metakaolin, a product associated with the china clay industry

*2 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

CAPILLARY ABSORPTION VS PRESSURE PERMEABILITY

Permeability is a measure of flow under an external pressure and is a property of saturated materials: the narrower the pores in saturated concrete, the lower its permeability. Conversely, the narrower the pores, the greater the resultant capillary pressure and so the greater the depth of penetration and speed of ingress of water

But how important is ‘pressure permeability’ when compared with ‘capillary absorption’ in regard to water transport through concrete?

“Calculation of the water penetration depth during wetting showed that the speed of capillary absorption is of the order of a million times faster than permeability” (*1).

Thus, in terms of damp-proof concrete, ‘pressure permeability’ is irrelevant unless the capillary absorption problem is addressed. You will appreciate, therefore, that the idea that water passes through concrete depending on water pressure is a complete myth.

*1 Dr Andrew Butler, Transport Research Laboratory (TRL), ‘Capillary absorption by concrete’ (Concrete July/August 1997)

HOW CAN ‘ORDINARY’ CONCRETE BE DAMP-PROOFED?

The traditional approach has been to attempt to ‘wrap up’ the concrete with a ‘waterproof coating’ of some kind, be it a tanking system, external membrane, surface coating or built up treatment in the case of a roof. Another approach is simply to accept that the structure will inevitably leak and to provide a drained cavity system inside the structure.

Membranes, tanking and surface coatings are invariably thin section, difficult to apply and rely heavily on the skill of the applicator to ensure integrity. If and when barrier systems fail, they may be on the wrong side of the structure (in the case of basement tanking) severely limiting the options for repair. Failure may be from bad jointing, pin holing, damage during back-filling operations or simply down to poor workmanship. Water or damp ingress seen on the inside of the structure may be at an area remote from the actual point of damage to the barrier system.

With cavity drained structures there is a loss or reduction in internal useable space and a potential maintenance liability as problems can arise unexpectedly, for example, failed pump, drainage channels silt up, over-loading due to local burst water main and the effects of rising water tables in many cities. Once such a system fails, water will usually run freely into the inner structure causing untold damage.

Attempted repair of a failed barrier or cavity drained system may not only cause significant delay in handing over a project but will be a concern to the owner and the cost of repair may be disproportionate to the cost of the original damp-proofing system used.

IS THERE NOT A BETTER OPTION? POSSIBLY

If concrete could be produced which was intrinsically waterproof, damp-proof and corrosion resistant, the Industry would no longer have to rely on the risky business of applying membranes, coatings or other temporary barrier systems. This concept is not new; there have been numerous ‘so-called’ integral waterproofing systems developed over the years that purport to make concrete ‘damp-proof’. Many have been shown to be severely limited in their long-term performance due to low dosage or failure to address the mechanism of water ingress by capillary absorption.

To ensure that an effective and reliable system of integral damp proofing is adopted, it must meet the following important performance requirements:

• Water absorption less than 1% when tested under BS 1881-122
• Comply with the European mandatory requirements of BS EN 934-2:2000 as a water resisting admixture under table 9
• Be supported by independent certification by a certifying body able and willing to stand behind that certificate and stating that the system has a proven track record of at least 30 years without loss of performance, e.g. the British Board of Agrément
• If a housing project, the product must be approved by NHBC or Zurich or other insurer as a stand-alone waterproofing system
• Have a demonstrable, proven track record in the environment where it is to be used confirming its long lasting effectiveness in that situation
• Meet the water quality test requirements under BS 6920:2000 (Testing of non-metallic materials for use with drinking water)
• Come with a proven effective warranty for the waterproofing of the structure not simply a guarantee for the product, inclusive of day-joints and service penetrations
• Be systematically monitored during construction to a comprehensive quality assurance scheme
• Have specialist technical support and back up to ensure that what is proposed is ‘fit for intended use’, that the design is sympathetic to the use of an integral waterproofer and to assist the designer and contractor as required
• The supplier and manufacturer must be of appropriate financial standing to support the guarantee and the level of service required
• Dosing must be accurate and subject to the manufacturer’s quality assurance procedures

PROFESSIONAL DUTY OF CARE AND RESPONSIBILITY!

The selection of any construction product must be done with care and this is especially the case with waterproofing of concrete structures. Failure here has been the subject of numerous claims and litigation, something that no professional person wants to be the subject of.

The problem is neatly summed up in a quote by John Ruskin (1819 – 1900): “There is hardly anything in the world that some man can’t make just a little worse and sell just a little cheaper, and the people who buy on price alone are this man’s lawful prey”

To demonstrate this point, in 1985, the Building Research Establishment carried out tests on behalf of the British Standards Institution with the idea of looking at the possibility of creating a standard for integral concrete waterproofing admixtures(*3).

Suppliers of waterproofing admixtures were asked to submit their products for testing. 15 different tests were carried out on each of the nine products put forward and compared with a ‘Control’ mix. Most of the products were worse than the control in more than 8 of the tests.

Out of all the 9 so-called ‘Waterproofing’ admixtures tested, only one product out-performed the ‘Control’, and all the other products, in all 15 tests!

*3 Tests on waterproofing admixtures for concrete, 1987. B W Adderson and M H Robertson. Building Research Establishment report N159/85

SUMMARY

Waterproof = Watertight + Damp-proof. If you are not concerned about dampness or high humidity levels, then watertight is fine. If, for example, you want a truly dry basement or tunnel or corrosion resistant structure, then you need it to be waterproof.

The most important point with reinforced concrete structures is to design and build the structures properly in the first place as there is little point in having a design life stated at 100 years if repairs have to start virtually the day after construction is completed.

Premature deterioration of reinforced concrete structures all around the world is a major concern due to the vast amount of money that will have to be spent on future maintenance or re-construction.

Whether one looks at the billions of Dollars spent annually in North America on concrete repairs…

…or in the Middle East, Far East, Africa or Europe, most of the problems could have been averted.

The Öland Bridge repairs completed in 2005 after about 15 years involving renovation work to the corroded pier supports, replacement of 19 joints and restoration of the parapet walls cost:

“… twice the cost of the original bridge at current prices”.

Or as the project manager is quoted as saying:

“Buy cheap, repair expensively”

Copyright © K Howes & J McDonald 2006. All rights reserved

All reinforced concrete design (ACI) is based on a cracked concrete section called post-dominant crack.  It is all about yielding as a crack opens, Re-bar yields by stretching and Helix yields partially by stretching and the rest by untwisting  The Helix design method follows ACI in this regard and is 3 times more than the maximum allowed under the ACI 318 design code . So Helix is as good as re-bar in a post crack or “reactive” situation.  

MAS™ has a supply division that can supply Contractors with the MAS™ proprietary forms necessary to construct the MAS™ system.  This MAS™ supply division’s sole purpose is to supply such proprietary forms AT COST to assist the Contractor and NOT as a profit center.  I.e. MAS™ is producing such forms in bulk and selling at cost to allow the Contractor the least expensive method of procuring such specialty equipment.

Assuming a crew of 4 persons that work 8 hours per day and the construction site (lot) is excavated flat with proper compaction and ready to dig the foundation:

Schedule / Timeline:

Day 1: Dig foundation, form pad, install re-bar, run plumbing, run electrical.  Pre-cut re-bar & foam that will be needed on Day 3.

Day 2: Pour, & finish concrete pad and then cover with 6 mm plastic. Pre-tie re-bar cube roof panels. Construct all opening bucks (windows, dormers & doors) that will be used on Day 3.

Pad/Foundation must cure to strength required by local engineering.  This is usually 70% of its final cure strength and generally takes 7 days to obtain.

Day 3: (after cure time noted above): Remove pad/foundation forms, set up airform and corner cage forms, install foam (pre-cut) and begin re-bar (pre-cut & formed) installation.

Day 4: Complete re-bar installation and opening buck (windows, dormers & doors) installation. Final prep for shotcrete.  Prepare option Eve/Parapet Roofing System forms if being used on Day #6.

Day 5: Spray Shotcrete layer #1 (1.5 inches) on entire structure.

Day 6: Spray Shotcrete layer #2 (1.5 inches if using three structural layers, or 2.5 inches if using two structural layers).  The option Eve/Parapet Roofing System is installed on Day #6 and increase build time by 1 day unless a second 4 man crew is brought in.  The optional Eve/Parapet Roofing System requires the three structural layer process.

Day 7: Spray Shotcrete layer #3 (1.0 inches if using three structural layers), plus additional for stamping if required.  If all structural layers were completed on Day #6, then Day 7 is devoted to spraying additional stamping layers if required.  Dormers and entry areas are typically constructed on Day #7.

Note: Aggressive concrete stamps that imprint more than 1/4″ into the 4″ structural concrete layer, will require additional non-structural shotcrete layers to allow for the aggressive architectural design.  Non-aggressive concrete stamps such as “fractured slate” can be applied to the final structural layer, ONLY with an experienced crew of enough persons to keep up with the shotcrete application.  The majority of MAS units are built using a three layer process with the final 1″ layer being stamped with a non-aggressive architectural design at a rate the stamping crew can easily screed and stamp before the concrete is too hard to stamp.

Note: In most cases, the forming system can be removed during day 7 (thus in use for 5 days).  Local engineering should conduct cylinder tests to verify the strength of shotcrete layer #1 and #2 to make the form removal decision.  This allows the forming system to be used to construct SIX structures per month.  If forms are removed on Day 7, it is suggested that all structural work, being performed on day #7, be completed before initiating such form removal.

AT this point the MAS™ system shell is complete and interior work can begin on Day #8 if structural concrete cure is approved by local engineering.  Also door & window installation should begin on Day #8 so that the structure is made weather proof as soon as possible.

If using interior concrete walls, these would usually be formed on day 8 and sprayed on day 9 and day 10 prior to the optional spraying of insulating foam.

Simple interiors can be completed in just a few days.  It depends on the complexity of the interiors.  Because the plumbing and electrical conduit has been installed on Day 1, the finish electrical and plumbing can be done in less than 1 day.

Note: If using stain coloring on the concrete floor, it is recommended that this be done after all interior work is completed, including painting, but excluding baseboards.  The 6 mm plastic coating on the concrete floor is removed just before the staining process is to begin but after all interior work is complete.  After removing the 6 mm plastic slab coating, the slab should be cleaned (if necessary) and prepared consistent with the manufactures stain application instructions.  Once the stain is complete and SEALED, the pre-painted baseboard can be installed and the MAS unit is ready for occupancy if authorized by the local engineer of record.

NO!  The shotcrete process where low slump concrete is sprayed under high pressure is critical to the construction process.  Shotcrete does not create cold joints and it makes the concrete significantly stronger and with better consolidation (less voids).

Note: As shotcrete is simply a method for placing concrete, shotcrete enjoys all the sustainability advantages of concrete as a building material including use of recycled materials, SCMs, and the very broad topics related to durability, reparability, etc.  The sustainability advantages unique to shotcrete are inherent in the placement process.

Shotcrete
Shotcrete is a process where concrete is projected or “shot” under pressure using a feeder gun onto a surface to form structural shapes including walls, floors, and roofs. The surface can be any surface that concrete can be projected onto. The surface can be smoothed or stamped while the concrete is still wet.

Architects, engineers, developers, and contractors are under ever-growing pressure to use more efficient methods in construction.  Shotcrete construction has many unique characteristics that substantially increase the sustainability aspects of both new construction and repair.  Shotcrete enables key savings in labor, materials, material handling and construction time, as well as providing increased flexibility and efficiency in shapes and thicknesses.

YES!  Unlike many forming systems, such as those used to create concrete domes, the MAS™ forms are entirely reusable.  There are NO sacrificial components in any of the MAS™ forms.  MAS™ anticipates the forms will have a useful life of 1,000 buildings making their amortized cost per structure negligible.

One of the most significant advantages of MAS™ systems is realized in formwork material savings. With the shotcrete process, the material is gunned or sprayed in place, so encapsulated forming becomes entirely unnecessary.  The single sided forming system is composed of an inflatable spherical form with collapsible metal cage forms for the corners and entry area.   This not only reduces or eliminates the amount of wood or other material used in forming, but also reduces or eliminates the milling and transportation environmental impact involved in providing the lumber on thousands upon thousands of construction sites.

The forming system is lightweight and easy to transport because the formwork design is greatly simplified and the materials required are significantly reduced because there is no need to design for internal pressure from fluid concrete within a form.

The most popular forming and scaffolding (SPiFolding) package ordered from MAS™ can construct two each MAS-570™s concurrently or a single MAS-1300™.  This set will form a TYPE G or TYPE R.  This popular Form/SPiFolding set can be shipped in a 20′ shipping container anywhere in the world.

You can add a partial loft (not complete), however it will not double the square footage.  Due to the sloping side of the arches that make up the structure on the MAS-1300™ it is not possible to use all the floor space of a 2nd floor deck system.  A 2nd floor deck system that covers approximately 1/3 the foot print of the MAS-1300™ structure will only give a usable area of approximately 200 to 250 square feet.

You can NOT add a deck that spans from wall to wall due to thermal expansion limitations.  MAS™ only recommends the use of a 2nd floor decking system for storage or situations where personnel need to be located above other works for strategic reasons.

It is more cost effective to attach a MAS-570™ to the MAS-1300™ to create additional square footage then it is to install a 2nd floor deck system.

NO.  However, the MAS-570™ and the MAS-1300™ can be connected at the corners to provide for an unlimited amount of square footage and floor plan configuration.  The two models provided by MAS™ mathematically represent the most efficient two sizes that can be produced.  Therefore, if MAS™ were to create more sizes it would cost more and provide less thus making such sizes undesirable compared to the low cost and highly efficient MAS-570™ and MAS-1300™.

NO.  The MAS™ system does NOT contain any interior walls.  The MAS-570™ has a clear span of 24 feet and the MAS-1300™ has a clear span of 36 feet.  Therefore, the interior walls can be positioned in any conceivable manner and removed or relocated without regard to structural integrity.

No.  The interior windows must go in the envelope specified by the MAS™ engineers.  The MAS™ engineers allow for a great variety of window locations all on the corner areas and NONE in the arch areas.  Although there are dormers in the arch support, no other penetrations, except those for venting, are allowed by the MAS-™ engineers in the arch sections.

Multiple windows can easily be accommodated on each side of every corner.  This allows for 8 window locations which can accommodate several windows each of various sizes at each location.  Thus the number of windows, and flexibility in placement is far greater than is possible using traditional construction techniques.

There is NO additional cost to create a window opening, other than the purchase and installation of the actual window assembly.

There is NO exclusivity, however a MAS Distributor can receive a geographical region and no other MAS Distributor can operate in that region without permission from the MAS Distributor that has been given that area. In essence, this is exclusivity while allowing MAS™ to accept others if a MAS Distributor cannot provide the level of service being demanded in such area.

A “geographical area” is just one of four arenas that a MAS Distributor can receive an authorization for.  MAS™ calls this a “FAD” designation.

• A specific Project (example: “ABC City low income housing bid #340-16-C”) or;
• A specific Field (example: “Military Bunkers, for ammunition storage”) or;
• A specific Area (example: The Southern Portion of Mexico) or;
• A specific Department (example: US Federal Emergency Management Agency)

A carpenter generally would generally be a Foreman or Specialty Worker (Sub-Contractor).  MAS™ offers several Training Courses that allow proficiency in all areas of MAS construction should it be desired.  A carpenter will generally start with MAS™ Training Course Number T.  This is a two day training course.  Additional days of Specialty Training is available in MAS™ Training Course Number T4 to allow persons/contractors to gain expertise in individual specialty areas.  Some 3rd party companies, that have already completed training, also offer field training and support to assist a carpenter with their first project which generally provides all the familiarization with the MAS system that is required.

Please visit the following link for more information on training: http://www.modernarchstructures.com/technology/mas-certification-overview/mas-training

Although the structure cost will be significantly less than ANY other form of construction, that is a difficult question to answer as MAS™ does NOT actually build structures.

If you want to know what a turn-key system, fully finished with rooms, appliances etc. will cost it is necessary to speak with a contractor.  Although MAS™ works with a great number of 3rd party vendors that can supply interior packages, etc. MAS™ is not involved with the pricing of these options.

The cost to build the shell, before windows, doors and any interior options other than insulation is something that MAS™ is familiar with.  A contractor can look up the required material as well as material quote sheets by visiting: http://www.modernarchstructures.com/technology/material-material-list

One of the key features of MAS™ structures is the ability to have a rock/brick/stone etc. exterior finish molded (stamped) into the last shotcrete layer for no additional material costs.  This allows a very upscale, top of the line, exterior look for NO additional cost other than a VERY small amount of finish labor.  This alone, coupled with NO required roofing material can represent a 25%  or more savings on the cost of construction when building an otherwise “architecturally expensive” building.

Yes.  The MAS™ system is very strong and is likely to withstand a severe impact by a tree.  However, it is difficult to quantify the size of the tree due to the many angles that it could strike the structure.  The larger the surface area of the strike, the better the chance for the object to be deflected without structural penetration or damage.

The MAS-1300 arches are built with a thickness of  8″ of concrete to the height of approximately 14.5 feet above the ground.  The remaining portion of the arches and structure are built with thickness of 4″.

The MAS™ consists of the exterior shell only.  However, MAS™ has worked with numerous 3rd party vendors to provide interior options.  The MAS™ system can use any standard interior configuration used typical construction.  However, the MAS™ interior is often constructed of concrete partitions to allow a virtually damage proof configuration.  MAS™ provides many interior floor plans to help guide those incorporating the MAS™ system into their projects.

The MAS™ engineers generally specify 4,000 PSI concrete.  However, please consult with MAS™ engineering for your specific project.

No, however all the openings for such doors and windows are formed as part of the construction of the MAS™ system.  There are no “bucks”, channels, stops, etc. required.  Once the MAS™ system shell is complete it is a simple matter to install windows and doors in the formed opening.  In addition, there is no increased cost to have one or more windows as the MAS™ patented forming system allows for great flexibility in such placement within the areas so designated by MAS™ engineering.

Yes.  MAS™ has designed a scaffolding system called “SPiFolding” that surrounds the entire structure and therefore eliminates any need for a mechanical lift.  The SPiFolding system allows multiple persons to work concurrently on the MAS™ structure without interference.  The SPiFolding can be ordered separately or as part of the forming package.

No, the MAS™ shell is a monolithic structure (formed and composed of concrete without joints or seams).

GWB or paneling can be attached directly to the concrete interior shell using adhesives, or to the finished and insulated interior using any standard attachment method.

Puncture is not an issue.  The pressure is very low and the material is very strong.  Although a puncture is possible, it can be repaired with tape in the field in a few minutes time without a problem.  The repair material is stronger than the original material and thus there is no negative impact or worries about making such repairs.

That is NOT correct.  There are NO metal framed walls making up the MAS™ system.  There is a patented MAS™ cage forming system that can accept sacrificial foam for insulation or re-usable polycarbonate  substrate panels.  In both cases, the metal cage form is removed and reused.

This depends on the PFAD designation being requested.  The PFAD designations are listed below.  To receive an “A”rea, “F”ield, or “D”epartment MAS Distributor designation requires significantly more work than receiving a “P”roject MAS Distributor designation.  MAS Distributor “P”roject designations are routinely given by MAS™ to Contractors so they can incorporate the MAS™ system into their project.  It is rare for MAS™ to grant an MAS Distributor “P”roject designation to someone other than a Contractor.  MAS often refers to Contractors who also function as a MAS Distributor on their own projects as “Super Contractors”.

MAS Distributor (Certified Project Coordinator):  When a company is certified at MAS Distributor, it can be for:

• A specific Project (example: “ABC City low income housing bid #340-16-C”) or;
• A specific Field (example: “Military Bunkers, for ammunition storage”) or;
• A specific Area (example: The Southern Portion of Mexico) or;
• A specific Department (example: US Federal Emergency Management Agency).

For more information please select the MAS Distributor tab at: http://www.modernarchstructures.com/technology/mas-certification-overview/mas-certification-levels

MAS™ does NOT grant exclusive territories, however  MAS™ does allow the MAS Distributor to decide whether to allow one or more MAS Distributors to operate in an area if they are the holder of an MAS Distributor “A”rea certification.  So in essence this is exclusivity, but such exclusivity is granted by the MAS Distributors in the area.

There are many positive business reasons that would benefit multiple MAS Distributors to operate co-jointly in an area.  MAS™ leaves this decision up to the individual MAS Distributors.

The same is true with respect to the “F”ield and “Department” certifications.  If MAS™ receives an application for a MAS Distributor that would conflict with an existing MAS Distributor, the existing MAS Distributor would have to authorize MAS™ to proceed before MAS™ would issue such an MAS Distributor certification.