Challenges In Store Remodels
For one solution, start looking up (at the ceiling, that is).
By Ken Woolf
Top construction professionals in the retail industry manage to remodel stores and still come in on schedule and within budget, even during challenging economic times. In addition, they face this challenge while also addressing environmental considerations, i.e. LEED. To succeed, they rely heavily on identifying alternative systems for achieving more, while spending less. The purpose here is to discuss one such approach that retailers are increasingly turning to — acoustical ceiling restoration as an alternative to replacement with new materials.
Project managers who are responsible for store remodels operate under a set of criteria unique to the retail industry. To mention a few:
• Fast track is an understatement (we need it yesterday).
• Most work must be conducted at night so as not to interfere with daytime sales.
• Construction budgets are continuously being reduced.
• Matching special colors is a challenge.
• Sustainable solutions are preferable.
The treatment of aged/discolored acoustical ceilings should be looked at with respect to the foregoing criteria. The ceiling represents the greatest source of light reflectance in the store. An older ceiling will detract more from a well lit, sales-oriented environment than any other surface in the store. When confronted with these conditions, those who may be unaware of a better alternative will absorb the cost and inconvenience of removing and replacing the ceiling with new materials. Alternatively, rather than replacing the ceiling with new materials, many retailers have adopted ceiling restoration as a cost-effective alternative that has far more benefits than merely saving money.
What is Acoustical Ceiling Restoration?
Imagine buying a new car. The tires that come as standard equipment can yield as little as 30,000 to 40,000 miles before they are worn out. It isn’t until the originals are replaced with better quality ones that 80,000 to 100,000 miles can be expected from one set. Similarly, the surface finish that is applied to ceiling tiles during the manufacturing process, under mass production conditions, may not necessarily be the best in terms of light reflectance, and holding their color long term. That is why an old, structurally sound ceiling system can receive an acoustical coating on the surface and the result is a superior finish that can even exceed the life of new material. An acoustical coating is chemically different than a conventional paint in terms of appearance, application and performance. Furthermore, it is not a cleaning product.
Why do Savvy Directors of Construction Take the Restoration Route?
There are many reasons why this system is so popular and appreciated in the retail industry. Utilizing the better available products on the market — and when compared to replacement with new materials — the restoration process can:
• Improve the acoustical and fire retardant characteristics of the ceiling.
• Cost less than half.
• Be whiter, thus increasing the light reflectance of the ceiling and decreasing dependence on artificial lighting.
• Hold its white color longer than a new tile.
• Be installed in one-third of the time (even in fully merchandised stores).
• Avoid discarding old materials into landfills — contributes to earning LEED credits.
• Provide any designer color without time delays or significant up-charges.
A Little on Economics
Ceiling restoration is typically quoted as a cost per square foot that includes all labor, materials and supplies, plus applicable taxes. The cost will vary, depending on a number of contributing factors. The larger the project, the less per square foot. A ceiling that is 20 feet in the air will cost more to do than one that is 12 feet above the floor. Union labor vs. non-union is another variable. And there are more but they also apply to new tile installation, so the savings remain proportionally positive.
When comparing to new ceiling replacement, one should look at the cost of replacing tiles, and painting t-bars and air diffusers, speaker plates, etc. Ceiling restoration, treating those same surfaces, can average between $0.85 and $1.50, based on non-union labor. Depending on the quality of tile, the savings should be no less than $1.00 per square foot and is generally much more than that.
Another financial consideration is the value that can be attributed to completing the process is one third of the time. For the general contractor it can mean the difference between project completion on schedule or not.
The architects and designers frequently prefer the use of color to achieve a particular effect, but when faced with the extreme up-charge and extended delivery time by the tile manufacturers, they are forced to accept a standard off-the-shelf color. With ceiling restoration, any color is available without time delays.
How to Identify an Acoustical Coating for Specification Purposes
The best way to make any material selection is to first outline the exact performance criteria the product is expected to meet. In terms of acoustical coatings, there are a minimum of six specific criteria to be satisfied in order to differentiate them from a common paint. Specifically, the product must:
1. Maintain or preferably improve the acoustical properties.
2. Be a Class-A fire retardant material.
3. Provide light reflectance that is equal to or better than a new ceiling.
4. In the event of a fire, not give off dangerous toxic odors.
5. Hold its color as long or longer than a new tile would under the same conditions.
6. After drying, the ceiling tiles cannot be stuck to the supporting t-bar system.
7. Have a low VOC.
Legitimate coating manufacturers develop products and then have them tested by independent laboratories to ensure they meet the performance criteria such as those listed above. In selecting a product, it is a common practice to request test results that substantiate the manufacturer’s marketing claims. With an acoustical coating, the legitimate manufacturer should be able to provide test data for at least each of the first five criteria outlined above. If they cannot, buyers beware.
The extent of a manufacturer’s experience in the business is also critical. When an applicator or retailer runs into a situation that varies from the norm, they turn to the manufacturer for assistance. The ability of the manufacturer to respond effectively is directly related to the extent of their experience and technical expertise. The more of it they have, the better likelihood they can help.
Also, some manufacturers have access to nationwide networks of preferred ceiling restoration contractors and may offer special national account programs for multi-facility firms. These programs can provide fixed-cost per-square-foot commitments for all the chain’s stores, regardless of location, making it easier to budget remodels in advance.
A manufacturer who offers a certification program for contractors wishing to specialize in ceiling restoration is also a positive indicator. These programs serve two purposes. It can be a valuable credential for the contractor. But for the manufacturer, it is an opportunity to train the contractor in the best methods, so that successful application of their product is more likely. A manufacturer is always concerned that their product may not be applied properly, and this can result in a poor product experience for the retailer.
How to Identify a Qualified Applicator
When store sales personnel report for work in the morning following ceiling restoration, they should concentrate on sales-oriented activities. They should not be required to clean up debris or remove spray dust from merchandise and counters. Regardless of the quality of product that has been specified, if the applicator does a poor job of area preparation, the experience can be a disappointment.
There are many ceiling restoration applicators throughout the United States that are particularly skilled and experienced, working within the retail environment. They hold certification as a ceiling restoration applicator.
They know how to protect walls, floors, fixtures and merchandise with plastic sheeting. Where the sheets overlap, they seal the seam with an adhesive to ensure against spray dust getting through to protected items. As stated earlier, the manufacturer of the selected product can act as a conduit in identifying such applicators. It is in their best interest to help, for when the project is completed correctly, their product looks much better and the likelihood of continued use of the system is increased.
Another rule-of-thumb in identifying seasoned applicators is by asking specific questions of them, such as:
• Approximately, how many square feet of ceiling is typically completed each night? If they are experienced with retail work and utilize the preferred application procedure, a crew of six to eight people should complete 6,000 to 12,000 square feet between store closing at night and opening in the morning. If they claim to do even greater than that, it is likely they will not do an adequate job of area preparation. Less production than that suggests a questionably talented/experienced applicator.
• Is the area fully encapsulated prior to any material being sprayed on the ceiling? Contractors who claim that full encapsulation is not necessary should be avoided. They obviously are not familiar with the acoustical coating, the drifting dust that will be in the air, and the need to protect it from settling on the merchandise.
• Are retail references available (contact names and phone numbers) for whom the contractor has restored ceilings, utilizing the specified products? Failure to provide such references is a clear indication that they would be a gamble.
Many contractors service broad geographic areas with trained, well qualified personnel. On the other hand retailers should be on alert for and avoid those who send one or two capable workers to the project location where they pick up local untrained labor. For the job to be done right, all crew members must know what they are doing. And then there are others who subcontract all the work to unknown companies found in the local yellow pages.
Summary
A restored acoustical ceiling is typically completed in one-third the time required for removal and replacement of the old ceiling. This makes timely project management much easier. The cost of restoration should be less than one-half and the expected life of a restored ceiling is always equal to or greater than a new ceiling tile while offering a greater light reflectance capability.
The selection of a product is directly related to independent laboratory test results that support the manufacturer’s marketing claims in areas such as acoustical and fire retardant capabilities, light reflectance and life expectancy. Their ability to respond to unique situations is related to the length of time they have been in the business and crew experience. The manufacturer can also serve as the best source for qualified contractors. RFB
Ken Woolf is chairman and founder of ProCoat Products, Inc., in Holbrook, Massachusetts. |
