Construction Materials — Are You Considering Long-Term Maintenance Costs?
By Jaret Breckenridge

A rurally located wash may need to withstand highly corrosive elements such as greases or agrichemicals.

Harsh chemicals, constant heat, dirt and grime — not many commercial structures must be built to withstand the challenges a vehicle wash endures each and every operating hour. And that’s just what’s affecting the inside of the wash bay. There are usually external elements to contend with as well, which, depending on your location, could include harsh sun, extreme temperatures, salt, city pollution, or all of the above.

That’s why one of the most important considerations for new vehicle wash buildings is the type of materials that will be used for construction. And like so many aspects of design, choosing the right materials is about walking the fine line between aesthetics and functionality.

LOCATION AFFECTS CONSTRUCTION MATERIALS

An influential factor governing the choice between aesthetics and functionality is your vehicle wash location and clientele. The most suitable materials for an urban-situated vehicle wash can vary greatly from those required for a wash built in a small town or rural location.

When building an urban vehicle wash the visual appeal is likely to be a significant factor in attracting passing motorists. Often there is a desire to “theme” or brand the building or blend its appearance with surrounding building facades. The majority of your customers are likely to only be washing off dirt and grime from city living.

Contrast this with a small town or rural vehicle wash. Your customers are likely to fit under a different demographic — commercial vehicle, truck owners, and farmers. You’re likely to be washing off more corrosive elements such as heavy greases or agrichemicals that would quickly erode a vehicle-wash structure that is not properly protected.

Other factors can influence the building material choice. If your wash is in a location where salt is used to keep roads ice-free during winter, you will need to consider the corrosive effect salt would have on both the interior and exterior walls. And if you build in areas of harsh sun, you need to think about the effects of UV rays on the exterior finish.

JUST LIKE DOING THE DISHES

When you build a vehicle wash you’re building the equivalent of a very large dishwasher. Now ask yourself how long would you expect your dishwasher to last — seven to 10 years at least? Even then it’s probably not the inner tub or outer shell of the dishwasher that will need replacing.

You should be constructing your vehicle wash structure with at least the same life expectancy in mind (and if you plan to be in the business for a while, double the above number).

The materials you use will greatly affect how long your wash will last and how much time and money you will need to spend maintaining it over the years. Many operators who have looked to cut the price on vehicle wash building materials or maintenance often end up paying a bigger cost, in time or money, in the long run.

WHAT ARE THE OPTIONS?

A typical steel vehicle wash.

Mold and mildew can quickly infiltrate porous CMU block and progress right through to the exterior surface of the wall.

CMU block, unmaintained with waterproof paint, can quickly deteriorate.

A finished forming system provides the concrete wall and surface finish in one step.

Let’s take a look at some of the common building materials for vehicle wash construction and the pros and cons of each.

Cinder Block/CMU

Pros
One of the most common construction methods, CMU blocks provide a solid building structure and can be extremely cost effective in areas where labor rates are cheap. As CMU’s are a common building material, it should be easy to source them wherever you are building. CMU’s also provide a degree of flexibility for exterior cladding options, which can enhance the aesthetics of your vehicle wash.

Cons
CMU construction is generally limited to spring/summer months, as the masonry work required to construct the building cannot be completed in cold weather conditions. You may need to heat and hoard a build that is affected by winter temperatures — an expensive option for many owners. Being quite porous, CMU block will also deteriorate very quickly in the harsh conditions of a vehicle wash unless the wall surfaces are properly protected. This is an extra cost that will often require ongoing maintenance of both the interior and exterior finishes.

Steel and Wood

Pros
Steel and wood structures are very cost effective options that are erected quickly and easily. You shouldn’t have a problem finding a local contractor to construct a steel or wood structure. The ability for these structures to incorporate insulation can also provide you with a more energy efficient wash. Building with wood or steel allows for a large degree of flexibility in design. Often these washes incorporate large amounts of glass, which, if well maintained, can enhance your vehicle wash’s appearance.

Cons
Rust and rot are the two biggest inhibitors to the life of a steel or wood vehicle wash. The harsh interior environment quickly deteriorates both of these materials and each would require a protective finish and constant maintenance to ensure no water comes into contact with an exposed steel or wood surface. For designs that incorporate glass, a reverse-osmosis water spray will need to be applied after every wash to maintain a clean glass appearance.

Pre-Cast Concrete

Pros
Pre-cast concrete walls provide a sturdy structure that can be finished smooth, providing fewer inconsistencies in the finish compared to CMU blocks. The exterior can be easily clad to meet your aesthetic requirements.

Cons
You may find it difficult to locate a local pre-cast supplier. If you do pursue this option, you may be paying extra costs for transportation of the pre-cast walls to your location. Structures built of concrete should be considered long-term investments, so if you’re looking for flexibility of land use, then building with concrete is not the most cost-effective option.

Finished Forming Systems

Pros
Finished Forming Systems provide both a concrete wall and finished wall surface in one system. Construction is similar to that of regular concrete formwork but instead of removing the forms once the concrete has cured the finished wall panels remain as part of the wall. Wall panels are often made from high grade PVC that is resistant to harsh chemicals and is easy to clean. There is no need for coatings or extra liners. Finished forming systems can decrease construction time and long-term maintenance costs.

Cons
Because the finish is incorporated into the wall from day one, upfront costs are generally more expensive. Labor rates can vary depending on whether the contractors have experience with installing finished forming systems. If you want to clad the exterior of your wash in a specific material you will be paying an additional cost to cover an already finished wall.

MOLD AND MILDEW

No matter which construction method you choose, there’s always the threat of the onset of mold and mildew. Add in the effects of harsh cleaning chemicals and the structural integrity of your building is quickly compromised if it is not well maintained. Aesthetically, a wash that looked great a year ago can, with the onset of mold and mildew, look tired and unappealing very quickly.

The right interior wall finish for your wash bay can significantly decrease the amount of time and money you will need to spend on maintenance. Common options are:

• Waterproof paints and sealants
• Epoxy coatings
• FRP paneling
• PVC paneling

Waterproof paints, sealants, and epoxy coatings are cheap to apply but require regular reapplication to keep your wall structure protected. Left unmaintained, mold, mildew, and harsh chemicals will quickly deteriorate the building structure, resulting in an expensive retrofit or in some cases a complete rebuild.

FRP paneling has been a common choice for many interior wash bays, especially as a retrofit for CMU block interiors. Usually glued to interior walls, FRP offers better resistance to moisture than paints and coatings. However, it is also porous and therefore can be quite susceptible to mildew growth and permanent staining if not constantly maintained.

PVC paneling is quickly overtaking FRP panels as a popular choice for wall finishing. PVC paneling functions in a similar way to FRP panels, however the PVC finish is highly durable and offers better resistance to mold and mildew.

If you are considering a finished forming system for your vehicle wash, then your wall finish is part of the concrete wall from day one. This approach greatly minimizes the areas in which mold and mildew can infiltrate the concrete structure and removes additional costs for finishing the wall with paneling or coatings. Owners of finished forming system structures have generally found maintenance cost to be almost non-existent due to the highly durable nature of the PVC finish.

INVEST IN YOUR STRUCTURE FIRST, EQUIPMENT SECOND.

Most vehicle wash operators tend to allocate a high proportion of initial investment to wash bay equipment. Investment in the vehicle wash structure is really an afterthought — determined by how much money is left in the bank. Operators need to rethink this priority.

While equipment costs are generally fixed year by year, structural maintenance can vary greatly depending on environmental conditions, construction materials, and regularity of vehicle wash cycles.

However it is quite possible to minimize or regulate structural maintenance costs by investing in a vehicle wash structure that is:

• Suited to your build location and customer demographic
• Resistant to the harsh environment of a vehicle wash
• Durable and structurally sound enough to last as long as your planned investment period

Satisfy these three requirements and you will soon be on the road to realizing a low-maintenance and worry-free vehicle wash structure.

Jaret Breckenridge is field services manager and vehicle wash specialist for Octaform Systems Inc. Octaform designs and markets the Octaform Finished Forming System and specializes in vehicle wash structures. You can contact Jaret at jbreckenridge@octaform.com.