Making panelized construction even more efficient with PermaBASE Cement Board
Using cement board instead of shop-fabricated mortar beds can improve the prefabrication process of exterior walls
Panelized construction is a modern building method involving the fabrication of exterior wall panels in an environmentally controlled factory setting. The prefabrication of exterior building components allows builders to better control construction schedules by eliminating variables such as weather conditions, which can result in labor and material cost savings.
Using cement board as the substrate for a panelized wall can make the construction process even more cost effective — and save more time. PermaBASE Building Products, LLC, an affiliate company of National Gypsum Company, recommends two of its premier cement boards for use in panelized construction:
- PermaBASE® Cement Board: Made with Portland cement, aggregate and fiberglass mesh, PermaBASE Cement Board works well as an underlayment for prefabricated wall panel systems.
- PermaBASE CI® Insulated Cement Board: Combining the strength and benefits of PermaBASE Cement Board with rigid insulation, PermaBASE CI is an ideal substrate for panelized exterior walls designed to meet continuous insulation requirements.
Replacing shop-fabricated mortar beds in panelized wall construction with cement board
Using shop-fabricated mortar beds as the foundation for the exterior wall finish requires multiple layers or coats of cement and reinforcements. These coats require up to 24 hours to cure or dry, meaning a potential multi-day application process before the builder can even begin to install the chosen cladding.
The PermaBASE family of products is proven to save time on adhered veneer installation, both in the field and in prefabrication. In fact, a time study by the independent Home Innovation Research Labs™ found that PermaBASE is 35% faster to install than the traditional lath-and-scratch method because it takes fewer steps and significantly reduces time-intensive curing.
In addition, PermaBASE cement boards simplify the use of multiple exterior finishes on a single facade, including:
- Manufactured stone
- Natural stone
- Stucco
- Thin brick
- Thin/large-format tile
- Thin stone
Cement board is lighter in weight than traditional alternatives
Given that two significant components of panelized construction involve the transportation and installation of large segments of exterior walls, using lighter-weight materials can make both steps even more efficient.
As an example, combining the base coats and the finish coat, traditional three-coat stucco weighs roughly 10 to 12 pounds per square foot.
Meanwhile, 1/2” PermaBASE Cement Board weighs less than 3 pounds per square foot, making it easier to handle and install. Other benefits include:
- Stays intact when exposed to water; will not rot, disintegrate or swell
- Achieves the industry’s lowest water-absorption rating (ASTM C473)
- Resists impact and remains dimensionally stable
- Is easy to cut — speeds up installation and reduces waste
The added benefit of continuous insulation
As building codes continue to demand higher R-values for energy efficiency, products like PermaBASE CI stand out as important components of forward-looking construction methods and are particularly well suited for panelized construction.
PermaBASE CI is made with PermaBASE Cement Board and polyiso insulation to provide durability and highly efficient insulation in one convenient package. By eliminating thermal bridges and providing uninterrupted insulation, PermaBASE CI significantly enhances energy performance, moisture control and indoor comfort.
Advantages of creating continuous insulation with PermaBASE:
- Helps mitigate the loss of heat or air conditioning by increasing the thermal efficiency of the exterior wall system
- Allows multiple finishes on one substrate
- Works in all climates — adaptable to varying regional system requirements with multiple thicknesses to choose from
For questions on continuous exterior insulation and anything else related to the use of PermaBASE Cement Board, National Gypsum provides technical expertise to help the panelized construction industry continue to innovate. Reach out to National Gypsum’s 1-800-NATIONAL® Construction Services team for advice and technical support on incorporating PermaBASE Cement Board into your next panelized construction project.
