Optimizing “Big Box” Construction Lauren Hughes Josh Hogan Kevin Hanson Joseph Garrott Rose-Hulman Institute of Technology
Dec 22, 2015
Optimizing “Big Box”
Construction
Lauren Hughes
Josh Hogan
Kevin Hanson
Joseph Garrott
Rose-Hulman Institute of Technology
Optimizing “Big Box” Construction
• Project Description
• Project Approach
• Research Results
• Future Work
Our Task
• Consider four different wall systems
• Perform a structural design of all four wall systems
• Complete cost estimate for all wall systems
Optimizing “Big Box” Construction
Create decision tool to determine most efficient wall system
Project Description
• Dr. Ed Alsamsam• Portland Cement Association
• Concrete as a building material
• Wants to make the decision easier for designers
Client
• Interviews with professionals • Investigation of wall systems• Design load calculations• Structural design • Construction planning &
scheduling• Cost estimate
Project Approach
ADVANTAGES• Elimination of formwork• Simple erection
DISADVANTAGES
• Labor intensive
• Locations of CMU plants
Concrete Masonry Shear Walls
ADVANTAGES• Versatility• Simple erection
DISADVANTAGES
• Forming labor & materials
• Curing time
Site-Cast Tilt-Up Panels
ADVANTAGES
• Quality control • Time savings • Elimination of formwork
DISADVANTAGES
• Transportation constraints
• Limited locations of plants
• Site constraints
Factory-Cast Tilt-Up Panels
ADVANTAGES
• Extra insulation
• Little or no maintenance
DISADVANTAGES• Height constraints • Limited shapes and sizes
Insulated Concrete Form Walls
Construction Planning & Scheduling
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
InsulatedConcrete Form
Walls
Site-Cast Tilt-UpPanels
Pre-Cast Tilt-UpPanels
Concrete MasonryUnits
Duration (Weeks)
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
Decision Tool Criteria
1. 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 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
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
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
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
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
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
Decision Tool Example
The 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 systems
Future WorkContinuing 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