Calstar Opens Manufacturing Facility in Mississippi

CalStar has reached an agreement with Columbus Lowndes Development LINK to open its newest manufacturing facility in Columbus, Miss. The deal closed June 3, and the plant is expected to open for production in Q1 or Q2 2014.

CalStar has taken ownership of a 100,000-square-foot shell building on 23 acres inthe Golden Triangle Industrial Park in Columbus, located in east-central Mississippi near the Alabama border; build-out of the facility will begin mid-summer. An initial staff of 17 employees is anticipated to increase to almost 60 during a three-year period.

“Situated to supply the entire Gulf Coast region from Texas to the Florida panhandle, the new Columbus facility will enable us to meet growing product demand in the nation’s largest brick market within a smaller delivery radius,” says Michael Telischak, VP of manufacturing for CalStar. “This means quicker turnaround times on orders and reduced freight costs, further contributing to our products’ existing economic advantages versus traditional masonry.”

The plant will produce the full line of CalStar’s sustainably manufactured masonry products currently available from its Caledonia, Wis., facility, including bricks, pavers, and Thru-Wall units, and will feature expanded capabilities for trim and accent shapes through the inclusion of an automated cast stone production line. Existing color offerings will be available, along with additions to the color palette made possible by the use of regional materials.

“I am grateful to the CalStar team for selecting Columbus as the home of its new manufacturing operations. I know our skilled workforce and our favorable business climate will help guarantee the company enjoys years of success in Lowndes County,” says Mississippi Gov. Phil Bryant. “CalStar’s decision to locate in our state reinforces the fact that ‘Mississippi Works!’”

“CalStar is undergoing rapid, exciting changes as we continue to expand our product offerings and grow our manufacturing footprint,” says CalStar CEO Joel Rood. “Columbus is an ideal setting for the new plant, with a central location in the South, an able labor force, and strong government and business leadership. We’re thrilled to call Columbus our new second home.”

CalStar masonry products incorporate up to 37 percent recycled content and eliminate the need for kiln-firing, typical of traditional clay brick, or the use of Portland cement, used to bind concrete masonry products. As a result, each product requires up to 81 percent less energy to make while emitting up to 84 percent less CO2. This dramatic reduction in environmental footprint comes with no sacrifice to aesthetics or performance, and the raw material and energy savings actually equate to more affordable per-unit costs.

“We are pleased to welcome CalStar to Lowndes County,” says Harry Sanders, president of the Lowndes County Board of Supervisors. “We look forward to a successful relationship with a great company.”

The plant opening comes on the heels of an expansion at CalStar’s Caledonia manufacturing facility, which added a second shift in May.

Acme Reopens Bennett, Texas, Plant

Acme Brick Co. hosted a ceremony Feb. 5 at Acme’s Bennett, Texas, plant observing the first load of brick produced by the company’s newly reopened Bennett location. This plant, just west of Dallas/Fort Worth and built in 1996, is located on the site of Acme’s first brick-making facility that began producing hard-fired brick in April, 1891. Acme is also reopening a portion of the company’s Texas Clay plant located in Malakoff near Athens, Texas.

     

Dennis Knautz, Acme president and CEO said, “It’s very exciting and to see this brick plant back in the business of making quality brick for our region’s homes. In December 2006, annual construction activity in the DFW area peaked at 182 million square feet. We then witnessed plummet by nearly 70 percent, to a low of only 57 million square feet by the start of 2011. Over the course of the past year, we have seen a rebirth of activity here in the Metroplex with construction now totaling 83 million square feet and forecasted to rise by double digits in 2013.

"Nearly the same story can be told about our Texas Clay plant in Malakoff," he continues. "The year 2012 witnessed greater order demand for that plant's brick products. In response, we restarted that plant's third kiln in late-December with the plan to bring Texas Clay to full capacity as quickly as possible.

     

"It is also important to note that during the "down time," we consciously retained a select group of key associates on the payroll who were assigned to a variety of projects - mostly at other Acme facilities - requiring them to travel and spend much time away from their families.  While this group welcomes the end of travel and the return to working locally, they will work with and help train about 60 new associates who will be joining the company."

      

At full production, the Bennett plant is capable of producing over 2 million residential brick per week or roughly enough brick for 150 average sized homes.

Brick Comparisons Burst Common Myths

Video and fact sheets comparing brick with other home exteriors debunks the common myths about genuine clay brick versus its competitors. With frank pros and cons on the latest in sustainability features, maintenance needs, costs, fire safety and more, the package stacks brick against the top alternatives - vinyl siding, concrete masonry, manufactured stone, fiber cement siding and Exterior Insulation and Finish System (EIFS), otherwise known as synthetic stucco.

“Especially in this economy and housing market, it’s necessary to offer a competitive picture of how clay brick stacks up to other exteriors in terms of its growing role in green building design, cost, durability, longevity, maintenance, lasting colors, enduring beauty and curb appeal,” says Gregg Borchelt, P.E., FASTM, FCSI, and BIA president and CEO. “Glossy brochures with gorgeous photography and few facts aren’t enough to offer a real narrative on brick."

Eliminating technical jargon, content areas for each product include major myths, strengths and weaknesses in all areas (aesthetics, initial cost, design flexibility, installation, maintenance and repairs, water management, color fading, fire resistance, wind damage, moisture resistance, insect infestation, damage resistance, environmental concerns, insurance issues); physical properties and construction basics; cross-section diagrams; the differences between brick and each product; sustainability comparisons and product performance.

BIA's new booklets include:

• The Facts: Brick v. Vinyl Siding 
• The Facts: Brick vs. Fiber Cement Siding
• The Facts: Brick vs. Manufactured Stone
• The Facts: Brick vs. EIFS 
• The Facts: Brick vs. Concrete Masonry Veneer

Non-profit Agency Takes 'Brick' Road to Affordability, Market Appeal

The Lower Rio Grande Valley of Texas is a housing paradox. On the one hand, the region ─ anchored by the cities of Brownsville and McAllen ─ is relatively poor. The per capita annual income is only slightly more than half that of the state average and the poverty rate is almost double the state average. Yet, at the same time, homeownership is slightly higher than the state average, or about 70 percent, versus 65 percent, according to the 2010 US Census.

Perhaps part of the explanation is Affordable Homes of South Texas, Inc. (AHSTI), the largest builder of affordable homes in the four-county region. Founded in 1976 as McAllen Housing Services Inc., the non-profit federally supported agency has helped about 3,400 low- and moderate-income working families buy homes.

The agency builds 110 to 120 new, single-family homes each year, according to long-time Construction Director Alfredo Munguia. The houses are in the price range of $52,000 to $58,000, not including land costs, and vary in size and floor plan.

Photo courtesy of AHSTI

The selection includes two-, three- and four-bedroom units, ranging in size of actual living area from 950 to 1,358 square feet. About 80 percent of the units are three-bedroom/two-bath houses with garage, utility room and front porch – a total footprint of about 1,600 square feet, Munguia says. And, since 1990, AHSTI has used bricks as the primary material for the exteriors of 95 percent of the homes it builds. Bricks cover all sides of the structure.

“That’s what our client prefers,” Munguia says. “They prefer bricks for safety, better insurance rates, overall looks, and variety of styles and colors. There’s something for everyone. It also holds up well in this hot, humid climate – no mold or mildew problems. And it requires very little maintenance.”

Munguia says bricks also are preferred, because they are a “green” material and provide superior protection from windstorms, such as hurricanes and tornadoes. Vendors of other (non-masonry) siding materials have approached the agency in the past about using such materials, but the agency could see no

reason to depart from the brick path.

“It never occurred to me that bricks and affordable housing didn’t go hand-in-hand,” says Munguia. “Because of the lower maintenance costs and lower insurance rates, bricks are the most economical choice.”

Snyder Brick & Tile to Auction Assets

Former western Texas business Snyder Brick & Tile will auction its assets June 19 at 11 a.m., including a 63,950-square-foot industrial warehouse manufacturing property on 9.188 acres, equipment, and surplus tile inventory. 

Assets will be sold during a live and limited online auction by Maas Companies Inc., an auction company from Rochester, Minn., specializing in selling real estate, industrial plants, equipment and special assets. The auction will be held on site at 3097 Brick Plant Road, Snyder, Texas.

Snyder Tile’s large facility with multiple buildings has great curb appeal applicable to many businesses. The property has tremendous potential and offers an excellent opportunity for a new owner to either continue with the tile business or another business type.

The auction manner of sale will offer the real estate first, followed by the equipment selling by lots. The equipment includes material handling, brick-handling equipment, raw ingredients, automatic brick cutters, kiln transfer carts, thousands of install-ready bricks, office equipment, support equipment and tons of scrap metal.

Potential buyers are encouraged to view the lots prior during onsite inspections when auction personnel will be on site:

Tuesday, June 5, 12 to 5 p.m.

Monday, June 18, 12 to 5 p.m.

Tuesday, June 19, 8 – 11 a.m.

Other times by appointment

Details of the sale are available  at 507-285-1444.

Boral Is Official Brick of SPEC MIX BRICKLAYER 500

The 2012 SPEC MIX BRICKLAYER 500 will take place on Jan. 25, 2012. in Las Vegas. This annual championship bricklaying competition was established to showcase the skill and craftsmanship of masons from around the world. Drawing crowds of more than 3,000, it’s the most popular event at the World of Concrete/World of Masonry Show in Las Vegas every year.

As a platinum sponsor of the event, Boral Bricks will supply all the bricks to be used during the event. They also are supplying bricks for six of the regional qualifying events currently underway. The events will use various types of bricks within Boral Bricks’ Architectural Design Series, a series of four brick collections intended for commercial construction.

Boral Bricks has been named the official brick of the 2012 SPEC MIX BRICKLAYER 500 event.

Masonry has been around for more than 6,000 years, but it is a still a skilled trade that requires a great amount of time, effort and training. The SPEC MIX BRICKLAYER 500 is a test of strength, stamina, focus and creativity. It provides masons with a platform to showcase their talent and abilities.

“While the methods for producing brick have evolved over time, the skill and precision of a mason hasn’t changed. A true craftsman knows how to take a brick product and turn it into beautiful design,” said Shelley Ross, director of marketing for Boral Bricks. “Our sponsorship of the SPEC MIX BRICKLAYER 500 is one way to show our gratitude and support of the masonry trade.”

The 2012 SPEC MIX BRICKLAYER 500 National will be held at the Masonry Construction Challenge arena during the 2012 World of Concrete/World of Masonry Show on Wednesday, January 25, 2012. For more details about the SPEC MIX BRICKLAYER 500 program, visit www.specmixbricklayer500.com.

Brick NY to Honor Thompson

In October, the chairman of the Battery Park City Authority, William C. Thompson Jr., will be recognized for his long and distinguished record of public service to the City of New York and support of the brick industry and its participating unions at the Brick NY 2011 Awards. Sponsored by members of the Brick Industry Association’s New York/New Jersey Brick Distributor Council and the Associated Brick Mason Contractors of Greater New York, the biennial awards honor individuals and organizations who have contributed to the vitality and success of brick masonry construction in the New York area.

The Brick NY 2011 Awards also will honor, among others, seven New York City architects who have contributed to the infrastructure of New York. This year’s labor honoree will be Jerry Sullivan Jr., president of Bricklayers’ Local Union No. 1.

The awards dinner will take place Oct. 20, 2011. The remaining honorees will be announced in the near future. A list of 2009 honorees and more information about the 2011 event is available at www.gobrick.com/BrickNY.