Contravest Multi-Family Study

Transcription

Contravest Multi-Family Study
Study for Contravest
Prepared by Civic Consultants Inc.
For
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Nov. 2015
1
Table of Contents
Introduction
3
Recommendations
4-9
Cost Savings
10
Benefits of Recommended Costruction
11-13
Benefits of Increased Footprint and Decreased Building Height
14-15
16
Executive Summary
Bibliography
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www.bayelectricco.com
www.americandreamgeothermal.com
www.southface.org
www.quadomated.com
www.bluelinxco.com
www.sustainablesolarhome.com
www.halcoenergy.com
www.proudgreenhome.com
www.greenbuildermedia.com
www.residentialarchitect.com
www.brokensidewalk.com
www.lmhai.com
www.guidetonursinghomes.com
www.usbr.gov
“R-U Vindicated by the New Energy Code?,” - Cameron
Ware ICF Builder Magazine Feature
“The ICF Tipping Point” - Cameron Ware March/April
2012: ICF Builder Magazine
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“Sloped Concrete Roofs” - Anonymous ICF Builders
Magazine August/September 2008
Concrete Planet: The Strange and Fascinating Story of
the World’s Most Common Man-Made Material Robert
Courland Prometheus Books 2011
It’s Raining Fish and Spiders - Bill Evans Forge Books
2012
Lawrence Berkeley National Laboratory Cool Roofing
Materials Database
Massachusetts Institute of Technology
Portland Cement Association
National Ready-Mix Concrete Association
National Institute of Building Science
The Smithsonian Institute
U.S. Department of Housing and Urban Development
The Corp of Engineers
The Department of Energy - Building America Program
Kentucky Ready-Mix Concrete Association
As well as many other sources
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2
Introduction
“The Addison on Millenia”, is a 300,000 sq.ft. Multi-family
project developed by Contravest with 292 residential units
and supporting structures and facilities. NRMCA hired
Civic Consultants in the fall of 2015 to review the wood
structured facilities and evaluate how this could be converted
to a predominantly steel reinforced concrete structure. In
addition this evaluation considers the costs associated
with both systems and offers an opinion of probable costs
associated with the recommendations.
In order to consider a steel reinforced concrete construction
method, the costs - including the costs associated with time
- must be similar or less. The investors that will purchase
this property are looking for a return on their investment.
The entire project is designed to attract renters who will pay
a premium for the amenities included. Structure hidden
behind the finishes is something that will not increase rent.
Sustainability, or long term structural integrity and energy
efficiency, cannot increase profits at this time.
on Millenia”, is a 300,000 sq.ft. Multi“ “The Addison
family project developed by Contravest
”
Contravest, represented by Mr. Steve Ogier, builds apartment
complexes in the Orlando, Florida area. The developments
are intended to be completed and sold within months of
construction. Mr. Ogier is a developer / contractor. His
job is writing contracts and hiring the correct people,
consultants, and sub-contractors to complete the complexes
in the least amount of time, for the least amount of money.
He has attempted to work with insulated concrete forms in
the past, and he was very impressed with their performance
and ease of construction. He agreed to allow us to study his
model for these wood apartment buildings
because he understands that, if it truly is
possible to build with ICF for about the same
cost as wood, he will have an advantage over
his competition and he will be able to build
in coastal Florida where the codes require
more structural stability. He believes that
ICF construction will add approximately ten
dollars ($10.00) per square foot based on his
earlier experience. The complex Mr. Ogier is
currently working on will be 300,000 square
feet so he can’t consider ICF, or other concrete
construction methods, because that would be
a three million dollar ($3,000,000) increase
in the overall cost of the development. The
investors who will purchase his buildings
will not pay extra unless it will increase the return on their
investment.
This study shows methods to reduce costs in
some areas while increasing costs in other areas
so that “The Addison” or a similar project, can
be built with steel reinforced concrete for about the same
overall costs as a wood structure.
The study is based on information provided by Contravest.
Information provided includes the construction documents
prepared by “Charlan Brock Associates” the Architects, along
with their sub-consultants, MiGre Engineers, LLC, and
Advanced Structural Design. The documents were dated
August 19, 2015 and are 95% complete.
“
”
- charlan brock associates
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Recommendations
Existing Wall Section
Walls
A
Exterior Walls should be Insulated Concrete Form walls, most
likely “eight inch” concrete walls (nominal 13.25” thick wall
structure) on the first floor, “six inch” concrete walls (nominal
11.25”) on the second floor (and third floor where a fourth floor
is included), and “four inch” concrete walls (nominal 9.25”) on
the top floor. The walls should be reinforced with #4 rebar at
16” o.c. vertically and could be reinforced with #4 rebar at 16”
o.c. horizontally, or steel fibers could replace the horizontal
steel. The form brands that should perform similarly include
Amvic, Cellox, Fox Blox, Logic, and Nudura.
Walls between the dwelling units should be “4 inch” concrete
walls with ½” of type X drywall on each side facing into
apartments. The type X drywall is to assist with sound
attenuation to meet the STC -50 rating required. It is possible
the A/E team could find that ½” drywall installed properly
could be used instead of the type X to meet all applicable codes.
The 4” of concrete should provide more than a 2 hour fire rating
for the wall assembly. This same assembly could be used in the
larger buildings where it has been determined a two hour fire
separation wall must be included.
B
Exterior Walls could alternatively be pre-cast concrete with
a pre-installed exterior system such as stone, brick, or even a
plank look. The pre-cast pieces come with insulation built-in
between the concrete and will be installed extremely quickly.
These systems are expensive; however, on highly repetitive
buildings they can fit into a budget due to the tremendous time
savings for installation and the slightly lowered cost of repeating
patterns. In addition pre-cast systems can be designed to go inbetween the dwelling units and have an STC of 50 along with
a two hour fire rating. This is not recommended because of
cost; however, the product is worth looking at because of the
repetitive nature of your development, and the time savings
could be tremendous. We’ve successfully used these on highly
repetitive buildings at reasonable prices.
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Recommendations
Recommended
Wall Section
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Recommendations
Floors
C
The floor systems between dwelling units shall be hollow core
pre-cast units, nominal 8” with a 2” concrete topping. In order
to achieve the required STC – 50 rating, a spray on ceiling system such as K-13 by International Cellulose Corporation can be
added, or a drywall system can be installed. Your A/E team can
look at various options for achieving STC-50, from simply applying layers of type X drywall, or the spray on systems available.
The hollow core system can be altered to add utilities as needed.
Any required ductwork would be installed in soffits.
D
The recommended alternate floor system is an ICF system, three
brands available are “lite deck,” “amdeck,” and “insuldeck”. Each
perform similarly. This system will be designed by your A/E
team. It is likely that a total 8” deep system with 2” to 6” of foam
and 2” to 6” of concrete creating six inch beams on 24” o.c. with
a 2” topping will be designed. The beams will have at least two
#4 rebars per beam, and concrete will have steel fibers included.
Traditional flooring materials can be applied to the slab, and 5/8”
drywall can be attached to the underside. Utilities can run in
the foam and pockets to install, and some types of lighting can
be cut into the foam. It is our assumption that this system will
be priced slightly higher than the hollow core system. Extensive
bracing will be required and this could take longer than the hollow core system the first few times the crews perform the work.
Roof
The recommended roof structure is the system designed slightly
altered. A wood truss system strapped into the concrete walls
with hurricane ties by Simpson Strong Ties is recommended.
E
The first alternate roof system, which will be more costly, would
be a system using the ICF “floor” systems. The design would
most likely be a simple hipped roof system sloped as shown in
your drawings (a 6/12 or less). The decorative additional hips
and gables could be built from wood and applied after the structural concrete is poured. A “5V” metal roof over 30 lb. felt on
the structure or a shingle system as originally specified could be
applied on top.
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Recommendations
F
The second alternate roof system could save costs and add structural integrity. Using either the hollow core flooring system
or the ICF flooring system as a low slope roof structure should be lower cost than the truss system currently specified. An
inexpensive low slope roof material such as an EDPM system can be used along with break metal flashing. A Parapet wall
structure with scuppers and downspouts can be designed to add aesthetic details. This will give a very different look to the
buildings, yet it could look just as attractive as the current designs.
G
With substantial design changes, a concrete roof structure could be designed using the ICF deck systems. The concrete can
be left as the roof material with the addition of a waterproofing system such as “hycrete” or “foxfire”. A roof system using
concrete with a waterproofing system would perform in a superior manner for many years; however, the initial costs will be
higher than the traditional wood system specified. This can look very similar to the existing aesthetic design.
HVAC
H
The HVAC systems specified will work with the more insulated wall systems. The individual units to each apartment could
be downsized, to save money. Should you switch to the concrete floor structure to save about 11 inches of building per floor,
then the system you are presently using will need some duct work, and soffits can be added to your 9 foot ceilings. In all cases
the soffits can be added along a wall or through a closet, so they shouldn’t alter the overall “feel” and design of each apartment. In analyzing each apartment plan it is possible with a very tight wall system such as the ICF that minimal ducts will be
needed with your existing system. The ICF wall system will retain the interior temperature much more evenly than the wood
stud walls with only R-13 batt insulation specified. This allows for the elimination of long duct runs to the outside walls to
“maximize comfort”. If the system is located in a central location only short runs will be required.
Ceiling fans are already included in the apartments, and should be maintained to
increase air flow. If possible the “Big Ass Fan, L Series Haiku” should be included
instead of the fans currently specified. The new BAF lower cost fan series is extremely
technologically advanced and will move the air and assist the HVAC system incredibly
well. This system moves air slowly so it will not create a ‘paper blowing’ wind in the
unit. This fan is approximately $450 retail, so this is an addition that may not be feasible.
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Recommendations
I
A Mitsubishi ductless system could be used instead of the system specified. The system will require a small “briefcase size”
unit mounted to the exterior wall within twenty feet of the interior units. They can be “ganged” with a screen masking them
on walls in public areas. The units are extremely quiet and also could be on or near a balcony, or mounted to the side wall/
railing of a balcony. The interior units can be ceiling units. It appears with all your apartment designs with 9’ ceilings, a false
8’ ceiling could be included in a closet to house the interior unit, and ducts only in the closet would be necessary to take the
cool or warm air to each space. HVAC units can be successfully housed the ceiling unit between floors in about 11 inches.
In addition we recommend an energy recovery ventilator be added to bring fresh air into each unit. This is not required, as
there are windows and doors on each unit, but it will assist in the overall comfort. This HVAC system will most likely run
over $4,000 per unit installed. We recommend you talk with a Mitsubishi diamond certified installer in your area for initial
pricing and initial design ideas. Similar systems are manufactured by other brands, however, we haven’t found a system that
preforms as well as the Mitsubishi yet.
Building Exterior
J
The exterior plank fiber cement siding and trim could be changed
out for a synthetic stucco (such as dryvit) or a concrete stucco system
(such as gigacrete). The style that is a low slope roof with parapets
and stucco exterior could be what we are calling “Florida vernacular
Italianate” a style that appears to be popular in most Florida communities. These systems are easily applied directly to the ICF, no need
for additional foam. So this will cost less than applying stucco to a
wood system. Foam details such as the details already included in
the current design can be applied more easily than the siding trim.
These systems can be installed in less time with a smaller crew than
the fiber cement siding and generally cost less. This is an aesthetic
decision. Synthetic Stucco has been eliminated from many projects
because water can find it’s way through the system. However, by using the ICF exterior wall system with synthetic stucco, any water that
might penetrate only finds water resistant foam, and concrete which
will absorb any water well before it makes it’s way to interior finishes.
Special care must be taken to properly install the windows and doors.
Window and door details are already something your Architecture
and Engineering team has taken care to show with the system specified. Of course new details specific to the ICF wall and Synthetic or
Concrete Stucco will be necessary.
Interior Hallway
K
The egress to the apartments is currently shown via “breezeways” that
the developer requested we analyze. With at least a “four inch” concrete ICF wall (9.25”) the hallways would be easily rated to surpass
the fire ratings required to make these interior hallways. With this
change the floor systems used could be identical to the system used
inside the apartments, and the exterior siding could be exchanged
for interior drywall in the halls. The flooring could be any normal
interior flooring or the concrete can be left exposed and sealed. It
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Recommendations
appears the doors as specified could be used to enter the units, but you might look at alternative doors as this is no longer an
exterior hallway. The HVAC cost will be extremely low because minimal HVAC will be required as this is an interior hallway
for conditioned spaces.
The dryer locations in some of the apartment plans are against the hall wall, therefore they could be vented into the hallway if
it is an exterior hallway. It appears your Architecture and Engineering team are already planning for the possibility of enclosing these halls because the dryer vents are routed in an unusual manner to the exterior of the building. While they have made
special provisions to allow this per code, it is not recommended to route the dryer vents in the manner currently designed just
to achieve an interior hallway. Space plan changes are recommended in the apartments with dryers at long distances from
the exterior of the dwelling units.
Building Height
L
The concrete floor structure can eliminate 11” of height per floor in the building. The external wall system with finish can be
reduced in the building by 22” to 33”. This could save about $300,000 or about $1.00 per s.f. for the whole building complex.
Additionally this can ease concerns on overall building height with the area Fire Marshalls and Code Officials.
Lighting
We recommend switching the can lights and lights that need to be housed in the structure between floors to a LED flush
mount light. The new “disk lights” can be quickly installed in ordinary junction boxes, and only protrude from the ceiling
by about 1.5 inches. They are dimmable, warm (3000K) lights that should last over 35,000 hours, or about 20 years. The
cost is about $30 each, and they could take the electrician about half the time to install as traditional can lights. Everything
including the “trim”, the “lamp”, and the “housing”, is included in this one fixture. This light will work well with the hollow
core plank, or the ICF floor system. There are several brands available, we’ve successfully used the Canarm LED 6” disk light.
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Cost Savings
Potential Combined Options Include:
ACFHJKL Total Savings: 8 to 9 weeks of construction time and Deduct $1,975,000
ACHKL Total Savings: 6 to 7 weeks of construction time and Deduct $1,375,000
BCHKL Total Savings: 6 to 7 weeks of construction time and Deduct $175,000
Additional Cost Savings Measures to Consider:
Bid at least three insulated concrete form systems:
The bid process will assist the ICF companies to provide their best cost, probably factory direct instead of through a distributor. At times distribution systems in place with some companies can artificially increase the cost of the product because the
product is transferred through so many hands before your purchase is completed. When a competitive bid process is in place
generally the price of the ICF wall, installed with the steel and concrete included, costs between $11 and $14, or about the
same cost as a competitively bid wood wall with insulation, sheathing, and building wrap. Five competitive similar systems
are generally considered as “equal” in bids. Amvic, Cellox, Fox Blocks, Logix, and Nudura make blocks that can be installed
in similar manners and will perform in an equivalent manner.
Develop and train a workforce for your projects:
The ICF is often considered a new mysterious product. The ICF system is simple to use. Any good carpenter, concrete form
worker, or mason has more than enough skill to run a small crew of laborers. Workers can be trained with about six classroom hours and two full days in the field observing and assisting an experienced installer. This is a growing industry, so
experienced installers can charge much more than a “green” crew. To reduce costs bid the project with experienced skilled
construction workers prepared to learn a new trade. Training is essential for electricians, plumbers, and HVAC installers as
well. The ICF system can lower their time on a job, however, without knowledge, training, and CDs that explain how to install
their systems the trade can often over price their work.
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Benefits of Recommended Construction
Short term and Long term investment savings:
The cost of an ICF wall installed is similar to the cost of a
wood stud wall once the insulation, sheathing, house wrap
are all installed. The financial benefits include lower utility
bills and a long term structural system that should outlast a
wood structure by three times.
considered the fire barrier and it often is one of the last finish
materials installed. The insurance industry has noticed a
rise in fires in low-rise wood buildings under construction.
Due to this, the cost to purchase construction insurance
for a wood structure is approximately $1.00 per square foot
more than a concrete structure. Codes continue to become
more stringent and now include costly temporary egress stair
systems for construction workers, because construction fires
in wood structures can spread so quickly.
After the building is complete building Insurance costs are
generally 20% to 40% lower for a building constructed with
concrete compared to a building constructed with wood.
Limited water damage:
Concrete loves water! You will rarely experience construction
delays due to wet building materials or rain days while using
Insulated Concrete Forms. Builders often have issues with
damp wood, or ruined plywood and sheathing as well as
waiting for Concrete Block walls to dry out after rain days.
The ICF is not effected by water, and concrete only increases
strength if small amounts of water find a way inside the ICF
forms.
Limited storm damage:
Steel reinforced concrete structures can withstand
tremendous storms. The ICF design prescribed to replace
the wood system currently specified will meet the most
stringent codes for storms in the USA, including the code in
Dade County Florida.
Less Job Site Injuries:
Light weight, mostly portable components can reduce worker
injuries and extend productivity with an older workforce.
Available workforce:
Workforces such as carpenters, masons, and traditional
concrete form workers can adapt to this technology quickly.
Eliminate Mold growth:
The ICF and the concrete will not support mold growth.
Limited fire damage:
Apartment complexes constructed from wood can easily
catch fire and burn during construction. The drywall is
Sound Attenuation, STC equals 50 or more:
The details to build a wall or floor structure that will achieve
the required STC of 50 or greater are difficult when using
a wood system. The 4” of concrete ICF wall with type X
drywall on both sides simply achieves STC-50.
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Benefits of Recommended Construction
Energy Efficient:
The very tight wall system that can result from a well-designed
ICF wall structure will reduce HVAC tonnage by about 30%.
An ICF wall will achieve approximately a R-26 when tested
as a complete wall assembly. A typical stud wall with R-13
insulation as designed for “The Addison” will barely meet R-5
when tested as a complete wall assembly.
In addition, the thermal mass of the concrete will reduce utility
bills by 6-8% by moderating the temperature fluctuations.
Federal Legislation gives developers a one-time $0.30 to $1.80/
sq.ft. tax deduction for commercial buildings that are 50% or
more energy efficient than ASHRAE 90.1. The legislation also
gives $2000 per dwelling unit to multi-family contractors that
are 50% or more energy efficient than ASHRAE 90.2. Congress
has extended the Tax Code Section 45L tax credit providing
multifamily/apartment builders with a tax credit of $2,000
per energy efficient unit a few times. It is fully expected that
this will be extended again. This credit has the potential for
lowering the tax liability for Contravest dollar for dollar. The
recommended construction should qualify for the full $2000.
A project the size of “The Addison” can result in a tax credit
of $584,000. Additional credits are available depending on the
location of individual properties. Testing is required, and a
commissioning agent is recommended to fully utilize tax credit
benefits. Energy tax benefits change each year, therefore this
is a cost savings that we did not include in our findings totals.
Above: Thermal Image of Wooden Construction
Below: Thermal Image of ICF Construction
Both images taken on the same day and on the same site.
Both buildings use the same plans.
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Benefits of Recommended Construction
Lower Time of Construction:
The light weight forms are easy to install, go up quickly,
and combine six traditional construction tasks in one. The
structural system, the insulation system, the vapor barrier,
the sheathing, and the interior and exterior finish anchorage
systems are all included in this one wall system. CMU systems
and wood systems can preform well; however, the time to
add all the components required as seen in these sections can
often be two to six times the labor hours. This costs money
and construction time.
Minimal Wall Thickness Changes:
Generally the ICF is considered to cost more because of
the thicker wall construction. The exterior walls on “the
Addison” will be thicker; however, with simple drywall trim
details it will not cost more to detail the wall. The additional
exterior wall square footage will actually add to the calculated
apartment square footage which, with no additional interior
space, will appear as if there is additional interior space. The
footprint and possibly the rent will grow, with no additional
costs. The ICF used to separate the units will not be wider
than the fire rated walls shown.
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Benefits of Increased Footprint and Decreased Building Height
Decreased Height Savings
Existing Wood Plans for 1 Building Type II
884.75’ Building Perimeter x 41.56’ wall height =
36,770.21 sq. ft of wall
x $13/sq. ft 1
$478,012.73
Proposed ICF Plans for 1 Building Type II
884.75’ Building Perimeter x 38.81’ wall height =
34,337.15 sq. ft of wall
x $13/sq. ft
$446,382.95
For a savings of $31,629.78 -- For Exterior Structure
1 assumed cost for both ICF/concrete and wood
Increased footprints can earn higher rents with “higher” total calculated square footage.
Current Sq. Additional
footage
Sq. Footage
(no Balcony)
592 sq. ft
21.74 sq. ft
Current Sq. Additional
footage
Sq. Footage
(no Balcony)
1,057 sq. ft
33.44 sq. ft
739 sq. ft
23.54 sq. ft
1,177 sq. ft
40.66 sq. ft
770 sq. ft
31.17 sq. ft
1,347 sq. ft
44.18 sq. ft
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Benefits of Increased Footprint and Decreased Building Height
An ICF wall, using 4” of concrete and 5 ¼” of foam as our baseline, will be only 5 ¾” wider than the existing stud wall and
interior breezeway wall. We used the dollar amount of $13.00
because when calculating the typical costs of each component,
and the labor for wood stud walls, that is the number we’ve
seen regularly. On the last few projects that we bid this year
in our area we’ve had 4” concrete, 6” concrete, and 8” concrete
ICF walls including labor and materials come in just at the
$11.00 mark. A project we have with some 12” concrete walls
is coming in at about $13.00. Therefore we are giving wood the
benefit of doubt here and assuming each wall system is equal,
while our in-house numbers are showing the wood is up to
$2.00 more per square foot of wall surface to build.
more per square foot of wall
“ Wood is up to $2.00
surface to build. ”
Using this and assuming the size of the apartments is calculated
to the exterior wall structure, the above chart shows the
“additional” sq. footage the owner could claim when rents are
calculated for each dwelling unit type. All in all, the building
will have up to 21” of total width added which will not cost
extra or effect the interior dimensions of each apartment at
all. Depending on the structural engineers calculation for the first floor walls, the foot print could increase by four to eight
more inches, then most likely the third and or fourth floor will be about 21” wider. We selected the least width wall to
show the additional square footage. The current site plan will be slightly changed; however, there is plenty of room for this
additional width.
The overall building footprint is increased, so it is possible that rents could be raised simply because each apartment is
“larger” without increasing finishes, or the actual interior square footage. This square footage is only added to the inside
of the walls. The decrease in building height will decrease costs of structure and exterior finishes while not changing the
interior ceiling heights in each apartment. Changing the structural system of these buildings should result in higher rents
and lower construction costs, or at minimum the same rents and the same construction costs.
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Executive Summary
The 292 dwelling unit development by Contravest
called “The Addison on Millenia” is designed similarly
to most new apartment complexes in the USA today.
The assumption that wood construction is the lowest
cost way to build is a myth perpetuated by the wood
industry for profit. In fact, it is not the most sustainable
construction material or the lowest cost to use in all
construction types any longer. Codes are changing,
additional fire protection, better paths of egress,
increased energy efficient construction all play a factor
in raising the costs to build with wood.
The costs to redesign the development and buildings is
significant. The potential savings are up to nine weeks
of construction time, and over 1.9 million dollars in
hard construction costs. The dollar savings alone will
be approximately 5.5% of the total construction budget.
The costs to completely redesign the buildings in this
particular development could be up to 4.5% of the total
costs. The true savings comes from the eight to nine
weeks of construction time saved as well as the ability
to transfer and use this technology on future projects as
codes continue to become more stringent.
Civic Consultants Inc. found that the use
of an Insulated Concrete Form wall system
The potential savings are up to nine weeks of
combined with a pre-cast hollow-core floor construction time, and over 1.9 million dollars in
system will reduce the construction costs
hard construction costs.
and time for this development. The result
is a lower cost completed building which is
more durable, and will continue to generate rent for We also considered traditionally poured concrete
the owners at least three times longer than a wood wall systems using steel or wood forms and CMU
structure generally lasts with planned regular interior structural systems. Both of these systems increased
finish updates. Additional options were considered construction time and costs significantly compared to
which are project specific. Changing the exterior finish the baseline wood design. Both of these systems result
to a synthetic or concrete stucco product attached in a structurally superior building; however, Once the
directly to the ICF will reduce construction costs and forms are removed and or the CMU walls completed
time. Changing the egress halls to interior halls instead significant time and cost is required to apply code
of exterior halls will save time and money. Changing required insulation and finishes.
the roof structure will save time and money.
The conclusion is at minimum the recommendation to
The current style and detailing of this development is redesign “The Addison on Millenia” to utilize Insulated
based on preference and marketability; therefore initial Concrete Form Exterior Walls and Walls between Units
cost may be offset by higher rents. The developer may as well as to use a pre-cast hollow core floor system, or
choose not to take the lowest initial cost options in an ICF floor system between dwelling units. Contravest
order to preserve a particular style. The costs to build is advised to consider these options carefully with their
this development with concrete can still remain lower estimator and their Architecture and Engineering
without sacrificing the current interior and exterior team. Civic Consultants Inc. can continue to assist you
as needed to make the changes recommended in this
materials and appearance of the project.
study.
“
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