When the dust settles, just sweep it away
USG finds a way to banish clouds of chalky dust from wallboard
Immordino, 37, is the brains behind a "dust control" joint compound whose patented formula prevents dust from forming when the joint compound in dry wall seams gets sanded. Instead of floating endlessly through the air until it covers workers and furniture, it falls to the floor in neat, tiny particles, where they are swept up and discarded, increasing worker productivity and reducing cleanup costs.
It's an innovation that earned USG its second Chicago Innovation Award in two years.
Immordino realized his lab experiments could be the answer to maddening dust after he accidentally flooded his newly finished basement. Construction workers created a dust storm when they replaced ruined dry wall. After Immordino's wife complained, he realized that the experimental joint compound he had taken home to work on in the basement had averted the dust problem.
The dust-free joint compound acts like Chapstick when it gets hot. The heat melts special additives in the compound, causing the additives to grab onto the dust particles, making the dust particles stick together and fall to the floor rather than become airborne.
USG showed the solution to its largest clients during a presentation at its Research and Technology Innovation Center in Libertyville. One of USG's largest customers insisted on its delivery as soon as possible, said Brett Link, USG's director of research and technology innovation.
The benefits are numerous: Time is saved because homeowners and contractors have no need to clean several times; the joint compound can be used in new markets, such as hospitals and "clean" rooms used in high-tech assembly and manufacturing, and the compound is proving to be a hot item at retail stores. A 3.5-gallon pail of the joint compound sells at Home Depot for $12.95. It is labeled Sheetrock Joint Compound With Dust Control. It flew off the shelves during test-marketing at a Home Depot store in Los Angeles, where it was advertised on Spanish-language radio stations, seeking to get the attention of Latino construction workers and do-it-yourselfers. In 4oe hours, 60 percent of a month's supply of the dust-control joint compound sold out, even though it is priced 30 percent higher than regular joint compound sold in 4.5-gallon pails.
The dust-control joint compound's sales are expected to grow from $6 million since it was introduced in test markets in late 2005, to $15 million to $20 million within the next year or two.
The market for joint compound in the United States totals $600 million to $700 million a year. Despite a slowdown in new-home construction in many markets, repair and renovation projects continue apace. Retirees and baby boomers are among the strongest spenders, either fixing up their homes or upgrading so they can sell their homes and move to a smaller place.
No surprise that Immordino has been promoted. He's group leader in the interior finishing systems lab.
sguy@suntimes.com