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

Owners 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 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

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

Cost Estimate

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 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

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