Up Front
Proper Order
There is a correct way to go about a construction project, and not doing so can have consequences.
The definition of proper order is “usually prenominal appropriate or suited for some purpose.” Proper order can be fun or serious. Watching movies with sequels is best done in the proper order so the viewer can follow along with the storyteller. Proper order is serious when we think of traffic lights. A four-way intersection with traffic lights not in proper order could result in serious injury. Proper order can also vary, even with streetlights. In America, traffic lights go from green to yellow to red. In much of Europe, the sequence of lights starts with a yellow light. This is to give the driver a warning that the light is about to turn green. The explanation is that the warning is needed due to the popularity of manual transmissions. This warning allows a driver to put the car into gear and begin easing the clutch out prior to a green light.
Sometimes we forget that proper order is also important in construction. Some sequences, like foundations and framing, are simple and obviously essential. However, countless other sequences are appropriate and best suited for some purpose. Schedule-pushers often overlook this.
Proper Order in Construction
Drywall installation is an example. The exterior envelope was traditionally in place prior to hanging and finishing drywall. It seems obvious, but failing to follow proper order must have been a problem at one point because that sequence was recently inserted into the building code under weather protection, and states that gypsum wallboard or gypsum plaster shall not be installed until the weather protection is provided. The 1997 code does not have this language about the proper order of installation. It seems unbelievable that proper order had to be put into the code.
I suspect that proper order or sequencing of construction materials, assemblies or systems is more common than most of us know. Another example is windows and exterior walls with stucco exteriors. The historical proper order was to install penetration flashing, then the windows before starting to lath. This sequence is most important on nail-flange-style windows. However, flangeless windows also benefit by this sequence. The set window frame allows the lather to set the casing bead around the window more accurately, with a perfect gap for a backer rod and sealant.
Several things have changed this traditional sequence. The first was the problem of the windows not being delivered on time and the builders pushing the lather to start before the windows were even on-site. The lather would be forced to preset the casing beads to established dimensions. How could this hurt? The window would slide in neatly. Yes, in a perfect world or factory conditions, that works, but in the real world, this is a recipe for disaster as the gap will not be uniform, making the joint subject to premature failure. To be fair, fluid-applied water-resistant barriers and flashings have made out-of-order sequencing possible. Contractors need to be aware that they need the architect’s approval for substituting products and a new process.
Why Proper Order is Important
A few years ago, I was on a panel of experts made up of carpenter superintendents. A publisher gave us all some basic details and instructions to develop a manual. One detail was presented that was very pretty to look at but had a fatal flaw. I notified the publisher and asked the others to look closely to find the flaw. The group quickly noticed that the detail as drawn was not constructible due to an error in sequencing. The room was unanimous in agreement that this was a serious problem.
The publisher had no experience in construction and failed to see why it was a concern. The publisher found it hard to believe, but the group confirmed my statement. I continued by noting that this is a problem for subcontractors because notifying the architect of the problem can often fall on deaf ears. Too often, the response to the concern is “build it as drawn.” The general contractor then becomes annoyed, as they see that this is delaying the project. The general contractor may demand work to continue or find the specialty contractor in violation of the contract. The group also agreed that this is an almost-daily occurrence in the real world. It can put a subcontractor in a no-win position.
A solution is often to install materials in a proper order. It may look like the drawn (flawed) detail, but it is different. This is the old-school way, prior to lawyers and experts. However, today, it will put the well-intended subcontractor at risk. If anything goes wrong, the investigator would note that what is built does not meet the drawing. That subcontractor will likely be blamed, even if it is not their fault. Protecting yourself is more important than ever, and it can be more difficult than ever.
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