Quality Masonry Cleaning (Article)

Quality Masonry Cleaning

By Ron Baer, Unique Industries, Inc

Seen on page 13 of the April 2001 issue of Masonry a monthly magazine published by the Mason Contractors Association of America.

The construction business suffers from problematic practices unheard of in other industries. Holdbacks, demands for investment, and mandated wages rank high among these. For masonry contractors, another difficult situation arises at the end of most jobs: judging work solely by the quality of the cleaning. If the masonry project is clean, the job is acceptable; if the masonry is not well cleaned, the project is judged to be substandard. The quality of the cleaning becomes the yardstick by which the quality of the job is measured without regard for the soundness of the masonry work. There is a solution to this problem. Proper cleaning complements and enhances quality work and proper cleaning can be achieved one hundred percent of the time.

Quality masonry cleaning relies on three interdependent components: quality workmanship, quality chemicals, and quality equipment. For good results in masonry, workers who have basic knowledge of masonry techniques and the quality demanded must do the cleaning. Allowing a contractor to use unskilled laborers to finish high quality work is no more acceptable than using unskilled and untrained masons to lay brick and block. In addition, chemicals must be selected considering the type and color of brick and block being used; there is no "one size fits all" product to achieve required results. Finally, the equipment must be specifically made for cleaning masonry so the work will be done without damaging the surface, discoloring the brick, or destroying the joints. Moreover, from a financial perspective, the cleaning must be finished promptly so the work will be complete and the contractor can be paid. Since no one of the three elements needed to achieve superior cleaning quality workmanship, quality chemicals, and quality equipment - can operate efficiently or render an excellent result without the other two, it is imperative to consider each of these components critically.

Good workmanship begins with selecting the right person to do the cleaning. Choosing this worker needs to be approached in the same way any other key employee would be selected. Cleaning is not a job for whoever is least busy or is otherwise not useful. This is true whether the choice is to use an outside cleaning contractor or keep the responsibility in-house. Cleaning demands someone who is detail-oriented, who enjoys working independently, is more concerned with the task than with teamwork, and has good hand skills. Additionally, it is essential this worker appreciate the mason's skill and artistry. Many masons would rather leave their work uncleaned than do cleaning themselves. Why? Because the skills and attributes needed for cleaning are markedly different from those needed for masonry. Cleaners are not creators, they are steady implementers. They follow instructions to get their job done. Because selecting proper cleaning equipment eliminates some of the detail work, the choice of equipment can expand the field of those capable of doing the cleaning. This makes the hiring process easier because it is not necessary to find someone capable and willing to attend to the fine detail hand cleaning requires. For cleaning, a sound recommendation is to find someone who, though not the fastest at laying block, is steady and thorough. It is essential to select someone with an appreciation for the project, the necessary focus, and the attention to detail that will combine to produce an outstanding result.
Further, in consideration of excellent workmanship, contractors whose usual approach has been to subcontract cleaning, should consider keeping the work in-house. Doing so yields numerous advantages:

CONTROL OVER TIMELY COMPLETION
Scaffolding need not be left in place until an outside contractor gets around to the job. Moreover, the sooner the job is cleaned after the bricklayers finish, the easier the cleaning will be, and the faster the job can be billed and paid for.
PROPER INSURANCE COVERAGE
Many cleaning contractors do not have sufficient insurance, if any, to cover their liability. If a claim is made, the primary contractor is involved. It is preferable to cover an employee's work rather than the work of others.
KNOWLEDGE OF CONSTRUCTION MATERIALS & QUALITY CONTROL
The masonry contractor who does the work knows the characteristics of the brick or blocks used. Proper chemicals need to be selected to insure the best finish to the project. Often, an outside contractor will choose chemicals based solely on cost and without consideration of quality.
CONSISTENCY IN WORKMANSHIP
The masonry contractor can assure that a skilled worker is doing the work and completing the job, not a different crew from day to day.
EFFICIENCY OF EQUIPMENT USE
The equipment needed for cleaning can be utilized for equipment cleaning and other general cleaning purposes.
PROFITABILITY
There is no middleman so the masonry contractor can keep the profits an outside contractor would pocket.
BUSINESS OPPORTUNITY
Some masonry contractors have launched a new business activity, cleaning for other contractors. There is great demand for expert cleaners and doing cleaning, in addition to masonry construction, broadening the business base.Finally, masonry contractors do not subcontract bricklaying, why should cleaning, also an integral part of the work, be subcontracted?

In summation, after deciding to either outsource the work or maintain control of the quality and keep the profits and overhead allocation in house, finding the right person to do cleaning takes consideration of the work requirements and the skills needed.
Not only is it important to have the right person cleaning masonry, selection of the proper chemical is an equally important consideration. Often a job specifies a particular branded product. However, it is possible that the architect has selected the chemical without full working knowledge. Chemical manufacturers make specifications available to architects for inclusion in the work specifications, yet the specification used may not be consistent with the requirements of a particular job. The manufacturer writes the specification without specific knowledge of the brick and block. Therefore, experimenting with different chemicals on a mock-up panel of the actual block and brick being used can be an essential and worthwhile step to a satisfying result and a satisfied customer. When doing this, trying to duplicate, as closely as possible, all conditions is essential. This includes using the same application method that will be used in cleaning the finished project. It is important to determine which chemical yields the right combination of cost, speed, and, most important, quality. Because bricks and blocks are made up of natural elements, it is possible that different lots of the same bricks will react differently. In this case, using a mock-up constructed from different lots is advisable. If a particular chemical is specified for the job, but is not the one found best by trial, the architect should be asked to view the sample and judge the quality of finish. In many cases, architects look to contractors as experts and appreciate good advice and proven results.

In some cases, the specification will not only identify the chemical to be used, but also the application process. Chemical manufacturers may do this to protect themselves from liability. As a result, some encourage use of the most timid application process as a protection from the results of poor workmanship. The suggested process may also result in use of the highest quantity of chemical and the longest completion time. Even with the most basically trained workers, cleaning can be done safely and without incident if the right combination of equipment and chemicals is used. When doing recommended testing on a mock wall, it is beneficial not only to use the application process recommended by the manufacturers of the different chemicals, but an application process proven by knowledge and experience. Again, proven and demonstrated contractor expertise is appreciated and respected by an architect whose goal is a quality finish.

Responsibility for selecting the proper chemical for cleaning is an important obligation that benefits from input not only from the chemical supplier and the architect, but the masonry contractor. The contractor has the practical experience to influence the decision-making process and the practical responsibility to recommend the proper chemical.

With a well-selected worker using the proper chemical, the final element to ensure excellent cleaning can be considered: the cleaning equipment. Available equipment ranges broadly, from buckets, brushes, scrapers, and burlap bags to high-pressure washers specifically designed for cleaning masonry. The selection of proper equipment is a function of how much cleaning is to be done, the time available to complete the work, and the capabilities of the equipment.

The initial and basic function accomplished by all equipment, from the simplest to the most specialized, is thorough wetting of the masonry surface in preparation for the application of cleaning chemicals. Whether a brush is used to create friction and heat or a hot water washer is used, heating both the wall and chemical increases cleaning efficiency and reduces overall chemical usage. Typically, for every 35'F of temperature increase, the cleaning power of the chemical is doubled. Any experienced cleaner knows cleaning proceeds faster in warm weather than cold, though the reason for this may not be understood. In addition to readying a wall for application of chemical, once the cleaning is accomplished, the wall must be rinsed well. Again, in the final rinse, hot water is useful to dry the wall quickly and reduce the absorption of chemical and water into the masonry that can cause efflorescence.

Though there are numerous companies making pressure washers, there is little choice to achieve a cost-effective, quality result in cleaning masonry. Companies around the country manufacture very similar standard washers that are usually used for general cleaning. However, a specialized washer with an acid handling system is especially suited to cleaning masonry. While standard washers have the ability to handle detergents, they do not tolerate the harsh chemicals used in cleaning masonry. Using a standard washer to apply acid-based chemicals wears metal parts and creates high-pressure leaks. High maintenance costs result and, over the life of the washer, consume the difference in initial purchase price. Standard washers, those referred to as having a "chemical injection system," use a venturi or siphon system to handle chemicals and require the use of water to carry the chemical through the washer. There are cases when introducing water into the chemical is unwelcome, especially in restoration cleaning, when it is desirable to apply only pure chemical or a carefully measured dilution of chemical. In addition, venturi and siphon systems require water pressure be reduced to carry chemical. Chemicals can be introduced into the water stream either before the water is pressurized by the water pump or at the end of the wand. In either case, care must be taken when moving an open container of chemical so it is not spilled or splashed on the operator or other workers. Moreover, siphon systems can carry chemical only about 25 feet. The alternative to avoiding the above problems is to apply the cleaning chemical by hand or with a garden sprayer and to wash it off with a washer, a tedious, time-and cost-consuming double work.

Washers made specifically for cleaning masonry, referred to as "acid induction" machines, avoid double work. In addition, acid induction machines are designed to handle the harsh chemicals used in masonry cleaning. They do away with open buckets of chemicals by providing sealed, delivery-ready storage. Besides the consideration of hot water or an acid induction system, other features should be sought when buying cleaning equipment:

Hoses - double-steel, wire-reinforced pressure hose of substantial length precludes the need to constantly move the unit as work progresses. Double reinforcement provides longer useful life because of the extra protection against nicks and cuts.
Water recirculating tank - a water recirculating tank allows the washer to idle without overheating the water pump. This keeps the operator from having to climb down to shut off the washer each time work pauses.
Trigger gun - a trigger gun is preferable to a weep system that allows small amounts of water to flow through the wand whenever the pump is on.
Flexible acid handling system- a chemical handling system enables the application of acid-based cleaners, waterproofing materials, and sealers without the use of water to carry the material.Whether doing in-house cleaning or contracting it out, contractors need to assure the proper equipment is being used. The right equipment will deliver the best quality job most economically. If the cleaning is accomplished in-house, having the right equipment makes the selection of the right person to do cleaning easier. Proper equipment eliminates the need for tedious scraping and handwork and thereby elevates the level of work. In turn, appreciation of the importance placed on cleaning, demonstrated by having the right equipment, motivates the cleaner to do a good job. Reason and experience prove people do better work when proper tools and equipment are provided.

Finding the right combination of workmanship, chemicals, and equipment for cleaning a quality masonry job deserves and needs thoughtful attention. Strategically, it is important to weigh the benefits of contracting for cleaning or keeping it as part of a masonry business practice, a classic 94 make-or-buy" decision. Tactically, masonry contractors must assure the proper person is using the proper chemical for each job and that the equipment utilized is both appropriate and efficient. Quality results rely on many elements coming together in an on-time, on-budget project. The reality is that if cleaning, the final step, is not done right, the entire job is not done right. Not only are there financial consequences such as delay or reduction in payment, the bottom line persists. If a job is cleaned right, the job is right.