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Optimizing “Big Box” Construction

Optimizing “Big Box” Construction. Rose-Hulman Institute of Technology. Lauren Hughes Josh Hogan Kevin Hanson Joseph Garrott. Optimizing “Big Box” Construction. Project Description Project Approach Research Results Future Work. Owners want to know…. Which wall to use?.

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Optimizing “Big Box” Construction

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  1. Optimizing “Big Box” Construction Rose-Hulman Institute of Technology Lauren Hughes Josh Hogan Kevin Hanson Joseph Garrott

  2. Optimizing “Big Box” Construction • Project Description • Project Approach • Research Results • Future Work

  3. Owners want to know…. Which wall to use?

  4. Optimizing “Big Box” Construction Our Task Consider four different wall systems Perform a structural design of all four wall systems Complete cost estimate for all wall systems Create decision tool to determine most efficient wall system

  5. Project Description Client • Dr. Ed Alsamsam • Portland Cement Association • Concrete as a building material • Wants to make the decision easier for designers

  6. Project Approach • Interviews with professionals • Investigation of wall systems • Design load calculations • Structural design • Construction planning & scheduling • Cost estimate

  7. Concrete Masonry Shear Walls DISADVANTAGES • Labor intensive • Locations of CMU plants ADVANTAGES • Elimination of formwork • Simple erection

  8. Site-Cast Tilt-Up Panels DISADVANTAGES • Forming labor & materials • Curing time ADVANTAGES • Versatility • Simple erection

  9. Factory-Cast Tilt-Up Panels ADVANTAGES • Quality control • Time savings • Elimination of formwork DISADVANTAGES • Transportation constraints • Limited locations of plants • Site constraints

  10. Insulated Concrete Form Walls DISADVANTAGES • Height constraints • Limited shapes and sizes ADVANTAGES • Extra insulation • Little or no maintenance

  11. Construction Planning & Scheduling

  12. Cost 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 wall

  13. Cost Estimate

  14. Decision Tool Criteria • Is the building height greater than 20 feet tall? • Is there a precast plant within 100 miles? • Is there a masonry plant within 100 miles? • Are you willing to pay a premium for a faster completion? • Does the site have room for curing of site cast panels? • Does the site have crane access?

  15. Decision Tool Example • An 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 access

  16. Decision Tool Example • An 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 access

  17. Decision Tool Example • An 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 access

  18. Decision Tool Example • An 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 access

  19. Decision Tool Example • An 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 access

  20. Decision Tool Example • An 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 access The most efficient wall system is Factory-Cast Tilt-Up Panels!

  21. 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 systems

  22. Future Work Continuing Research • Greater detail in cost inputs • Fully automated tool • Interaction with professionals Project Recommendations • Works well as a senior level design project  • Project is better as a team project  • Scope and direction of the project

  23. Summary Optimizing “Big Box” Construction • Purpose – develop a decision tool to find most cost-efficient concrete wall system • Results – flow chart to aid designers

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