Optimizing “Big Box” ConstructionOptimizing “Big Box” ConstructionSlide 3Slide 4Project DescriptionSlide 6Concrete Masonry Shear WallsSlide 8Factory-Cast Tilt-Up PanelsInsulated Concrete Form WallsConstruction Planning & SchedulingSlide 12Slide 13Slide 14Slide 15Slide 16Slide 17Slide 18Slide 19Slide 20Slide 21Slide 22Slide 23Slide 24Slide 25Slide 26Slide 27Future WorkSummaryOptimizing “Big Box” ConstructionLauren HughesJosh HoganKevin HansonJoseph GarrottRose-Hulman Institute of TechnologyOptimizing “Big Box” Construction•Project Description •Project Approach•Research Results•Future WorkOwners want to know….Which wall to use?Our Task•Consider four different wall systems•Perform a structural design of all four wall systems•Complete cost estimate for all wall systemsOptimizing “Big Box” ConstructionCreate decision tool to determine most efficient wall systemProject Description•Dr. Ed Alsamsam•Portland Cement Association•Concrete as a building material•Wants to make the decision easier for designersClient•Interviews with professionals •Investigation of wall systems•Design load calculations•Structural design •Construction planning & scheduling•Cost estimateProject ApproachADVANTAGES•Elimination of formwork•Simple erectionDISADVANTAGES•Labor intensive•Locations of CMU plantsConcrete Masonry Shear WallsADVANTAGES•Versatility•Simple erectionDISADVANTAGES•Forming labor & materials•Curing timeSite-Cast Tilt-Up PanelsADVANTAGES•Quality control •Time savings •Elimination of formworkDISADVANTAGES•Transportation constraints•Limited locations of plants•Site constraintsFactory-Cast Tilt-Up PanelsADVANTAGES•Extra insulation •Little or no maintenance DISADVANTAGES•Height constraints •Limited shapes and sizesInsulated Concrete Form WallsConstruction Planning & SchedulingCost Estimate•Microsoft Excel spreadsheet•Based on Means Building Construction Cost Data•Itemizes individual labor and material components of each wall system•Input critical labor and material unit costs•Output cost index per square foot of wallCost EstimateDecision Tool Criteria1. Is the building height greater than 20 feet tall?2. Is there a precast plant within 100 miles?3. Is there a masonry plant within 100 miles?4. Are you willing to pay a premium for a faster completion?5. Does the site have room for curing of site cast panels?6. Does the site have crane access?Decision Tool ExampleAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessDecision Tool ExampleAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessDecision Tool ExampleAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessDecision Tool ExampleAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessDecision Tool ExampleAn owner wants to build….•30 foot tall building•Nearest precast plant 50 miles •Nearest masonry plant 200 miles •Owner willing to pay for quicker completion•Sufficient flat space for formwork•Sufficient crane accessDecision Tool ExampleThe most efficient wall system is Factory-Cast Tilt-Up Panels!Research Results•Most significant components of total cost:•Material delivery•Regional variations in labor wages•Cost of steel reinforcement varies little among the four wall systemsFuture WorkContinuing Research•Greater detail in cost inputs•Fully automated tool•Interaction with professionalsProject Recommendations•Works well as a senior level design project •Project is better as a team project •Scope and direction of the projectSummary•Purpose – develop a decision tool to find most cost-efficient concrete wall system•Results – flow chart to aid designersOptimizing “Big Box”
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