Dow Chemical Company v. Royal Indemnity Company, R. B. Butler, Incorporated

635 F.2d 379, 1981 U.S. App. LEXIS 20689
CourtCourt of Appeals for the Fifth Circuit
DecidedJanuary 26, 1981
Docket79-2314
StatusPublished
Cited by40 cases

This text of 635 F.2d 379 (Dow Chemical Company v. Royal Indemnity Company, R. B. Butler, Incorporated) is published on Counsel Stack Legal Research, covering Court of Appeals for the Fifth Circuit primary law. Counsel Stack provides free access to over 12 million legal documents including statutes, case law, regulations, and constitutions.

Bluebook
Dow Chemical Company v. Royal Indemnity Company, R. B. Butler, Incorporated, 635 F.2d 379, 1981 U.S. App. LEXIS 20689 (5th Cir. 1981).

Opinion

TATE, Circuit Judge:

Jurisdiction is based on diversity, with Texas substantive law governing. At issue is liability for a loss of some three hundred thousand dollars resulting from the collapse of a structure under construction. The present appeal arises from the dismissal of a cross-action in this suit. By it, R. B. Butler, Incorporated, sued Royal Indemnity Company to recover proceeds on an “all risks” builder’s risk insurance policy issued to Butler by Royal that covered the construction of a thin-shell concrete dome, which collapsed before completion. The factual causes of the collapse are essentially undisputed. The district court held that the causes of the collapse were within exclusions from coverage under the policy, and denied Butler recovery.

On Butler’s appeal, we reverse the district court’s holding that the exclusion clauses apply to the loss sustained by Butler. We do so primarily on our finding that the district court erred as a matter of law in interpreting the exclusion clauses of an “all risks” insurance policy so broadly as to include the present factual causes of the loss and thus to exclude coverage for it.

Before setting forth the facts and issues in more detail, we note that both parties’ experts agree that the inadequacy of the welds was the primary cause of the collapse and that, in our view, the central issue of this appeal is whether this inadequacy was due to faulty workmanship by the subcontractor’s employees (a covered risk) or was instead due to defects in “design” or in “testing”, risks excluded from coverage by clauses 7(g)(1) and 7(g)(3) respectively. Because we find that, within the meaning of the policy, the inadequacy of the welds was due to faulty workmanship rather than to faulty design or testing, we reverse the determination of the trial court that the loss fell within any exclusion clause of Royal’s “all risks” policy.

I. Relevant Facts

A. Construction of the Dome

R. B. Butler, Inc., had contracted with the Public Service Board of the City of El Paso, Texas, to construct four 221-foot thin-shell concrete domes over trickling filter units, one at the Delta Street Sewage Treatment Plant. Butler was the general contractor for this project, and Dow Chemical was the subcontractor directly responsible for the design and construction of these domes.

The domes to be constructed by Dow consisted of two separate structures-a sty-rofoam form and a concrete shell. The form was made of ten-by-six-inch styro-foam logs which were fused together with ten-gauge reinforcing wire by means of a *382 rotating fusion head (a machine into which the logs were fed). The styrofoam form was constructed in such a manner as to create a dome structure over which concrete would later be sprayed. The styro-foam structure served only as a form and, after the concrete dome had been sprayed over it, did not play any functional role in the support of the dome.

The following machinery was employed to construct the styrofoam dome: a control point (the center of the trickling filter over which the dome was being built), two beams, a rotating fusion head, and a rider bucket, from which an employee fed the styrofoam logs to the fusion head. (The functioning of the fusion head is later described with more detail.) The boom went in a circular direction and the styrofoam logs were fed into the fusion head and became welded to the other logs. As part of this welding process, there was a continuous feeding of ten-gauge wire reinforcement into each fusion interface (the point at which the two logs would meet).

Upon completion of the styrofoam dome, after a self-furring wire mesh was laid over the styrofoam, concrete was then sprayed over the form. The concrete was applied in sections; and, in order to monitor the depth of each layer of concrete, which was to be three-eighths to one-half inch thick, a device similar to an automobile’s “dip stick” could be utilized. By placing the stick in the wet cement, exact thickness could be gauged.

During the construction of the styrofoam dome, a depressed area (a “dimple”) appeared on the outer surface. In order to fill the depression to achieve the desired contour, Dow Chemical used “foam-in-place urethane” with mesh reinforcement. In addition, a scaffold was constructed on the inside of the styrofoam dome in order to provide additional support under this dimple.

Royal also points out, as relevant to its arguments of defective design or testing, that the present domes were the largest constructed by Dow, and the first to use 6 X 10 inch styrofoam logs or 10-gauge welding wire during the welding process. The previous domes successfully built by Dow had used 6X8 inch logs and a smaller gauge welding wire, and the largest of the previous domes had been 160' in diameter as compared with the 221' diameter in this instance. (The present dome had an arc length of 130', and it collapsed when concrete had been laid around the styrofoam form around the lower 55 feet or so of its arc length. The arc length measures the circumference surface of the dome from its bottom to its apex; actually, measured vertically, the apex of the present dome was 52' from the ground.)

B. The Causes of the Collapse of the Dome

Two experts testified, one for Butler and one for Dow. They were in substantial agreement as to the factual causes for the collapse of the dome. The issue before us, as will be more fully developed below, is whether these factual causes may be ascribed, within the meaning of the policy, to faulty workmanship on the part of the subcontractor Dow or its subcontractors, a covered risk; or, instead, to faulty design or to faulty testing within the meaning of exclusion clauses excepting these risks from coverage.

We will accept the description of the causes of the loss as set forth in the appel-lee Royal’s brief, with two slight omissions (indicated and explained by footnotes 1 and 5):

On August 22, 1973, the first of the 221-foot diameter domes collapsed during construction. (C.R. 760). An investigation was conducted by an expert from Dow, Steven Waling. His report, which was introduced upon trial of this cause, indicated that four factors, in combination, caused the collapse. (C.R. 763). One factor was termed a “capacity” and the other three factors were termed “impositions.” As the capacity Mr. Waling pointed to (1) incomplete thermal fusion and corresponding reduced tensile capacity of the interface of the foam logs. (C.R. 763). Tests performed following the collapse indicated the tensile stress *383 and tension were both consistently less than 10 psi (pounds per square inch) in the pass area where the fracture occurred. (Tr. 62). This simply means that the capacity of the welds was approximately 10 psi. The capacity of the welds should have been in the 27 psi range. (Tr. 59, 64). .. ,[ 1 ] see p. 63.
The next factor given, and the first imposition, was (2) unsymmetrical gravity loading of freshly placed concrete. (C.R. 763). On the day in question concrete was being placed at the 60 and 70 foot level (of a 130 foot arc) in many instances in layers of three-fourths to one and one-half inches. (Tr. 65).

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Bluebook (online)
635 F.2d 379, 1981 U.S. App. LEXIS 20689, Counsel Stack Legal Research, https://law.counselstack.com/opinion/dow-chemical-company-v-royal-indemnity-company-r-b-butler-incorporated-ca5-1981.