Core Construction System Presented By: Aaron Rutledge CorTek, Inc. 999 Van Buren Ave. Loveland, CO 80537 Phone: 970-663-2222 Fax: 970-663-9969 [email_address] www.corteksystems.com

Service Cores 2+ hour fire rated egress shaft required for buildings over 2 stories Concrete a cost effective material to create this fire separation and resulting vertical structure Monolithic concrete structure naturally becomes integral part of buildings lateral system

2+ hour fire rated egress shaft required for buildings over 2 stories

Concrete a cost effective material to create this fire separation and resulting vertical structure

Monolithic concrete structure naturally becomes integral part of buildings lateral system

Problematic for Construction Cores must be in place before surrounding framing can be installed Slow to construct with highly unpredictable schedules Quality issues frequently arise Dangerous “ Like rolling the dice on every project”

Cores must be in place before surrounding framing can be installed

Slow to construct with highly unpredictable schedules

Quality issues frequently arise

Dangerous

A better way… Free up site schedule and resources by modularizing core off site in a specialized factory set up for quality and efficiency

Free up site schedule and resources by modularizing core off site in a specialized factory set up for quality and efficiency

The CorTek Core Construction System Stay-in-place modular form system for concrete core structures Factory built modules stack like building blocks. Custom-built to the specific requirements of each project.

Stay-in-place modular form system for concrete core structures

Factory built modules stack like building blocks.

Custom-built to the specific requirements of each project.

Features: High tolerance, all-steel construction. Modules are load-bearing before concrete. Pre-installed: Horizontal Rebar Stairs Embed Plates and Shear Tabs Ledger Angle Elevator Divider Beams Optional Finishing Connectors (hat channel, masonry ties)

High tolerance, all-steel construction.

Modules are load-bearing before concrete.

Pre-installed:

Horizontal Rebar

Stairs

Embed Plates and Shear Tabs

Ledger Angle

Elevator Divider Beams

Optional Finishing Connectors (hat channel, masonry ties)

A Load Bearing Form Vertical and horizontal structural elements support construction loads and allow form to be modularized. Structural skeleton allows for support of stairs, landings, structural framing, scaffolding, personnel, and other construction loads Form does not require stripping Finished wall structurally equal to a conventional 8”-12” CIP concrete wall

Vertical and horizontal structural elements support construction loads and allow form to be modularized.

Structural skeleton allows for support of stairs, landings, structural framing, scaffolding, personnel, and other construction loads

Form does not require stripping

Finished wall structurally equal to a conventional 8”-12” CIP concrete wall

Optional wall thickness Effective thickness: 8” 10” 12” Actual thickness: 10” 12” 14” Because of the much higher tolerances of the CorTek System, the resulting finished wall assembly can be thinner than conventional methods for many applications.

Pre-installed stairs

Railings shipped ready to bolt on

Optional Stair & Railing Designs Pan treads Checkered plate treads Grating treads Parallel tube rails Picket rails Wire mesh rails

Beam Attachments and Ledger Angle Pre-installed

Benefits: Immediate presence of stairs allows trades early and safe access to structure Elimination of many dangerous field operations Can eliminate the need for scaffolding Reduction of poor fit-up and coordination problems among trades Cores generally part of the critical path—the CorTek system cannot be beat for speed--reducing overall schedule by weeks or months on most projects.

Immediate presence of stairs allows trades early and safe access to structure

Elimination of many dangerous field operations

Can eliminate the need for scaffolding

Reduction of poor fit-up and coordination problems among trades

Cores generally part of the critical path—the CorTek system cannot be beat for speed--reducing overall schedule by weeks or months on most projects.

Job Site Efficiency >Enabling Lean Construction Drastic reduction of field labor. Just In Time Delivery minimizes site congestion. Core construction can be concurrent with frame construction. Re-work from misplaced embeds, doors, bulging concrete and leaning or twisted towers eliminated Several cores can be constructed simultaneously

Drastic reduction of field labor.

Just In Time Delivery minimizes site congestion.

Core construction can be concurrent with frame construction.

Re-work from misplaced embeds, doors, bulging concrete and leaning or twisted towers eliminated

Several cores can be constructed simultaneously

Safety—A Job Site’s Most Important Consideration Moving formwork to a controlled factory environment eliminates many dangerous field operations

Where’s the rest of the structure?

Concurrent Framing Framing does not wait for formwork—saving weeks to months on project schedule

Quality Parametric modeling essentially eliminates detailing mistakes. Controlled manufacturing environment. Multiple fail safing operations. Rigid Quality Assurance Program Jigs, Fixtures and Design provide extraordinarily tight tolerances

Parametric modeling essentially eliminates detailing mistakes.

Controlled manufacturing environment.

Multiple fail safing operations.

Rigid Quality Assurance Program

Jigs, Fixtures and Design provide extraordinarily tight tolerances

Green Benefits No wood forms and resulting site waste No form oil Greatly minimizes site labor installation Recycled and recyclable steel used in construction. Perfect delivery method for high volume fly ash concrete

No wood forms and resulting site waste

No form oil

Greatly minimizes site labor installation

Recycled and recyclable steel used in construction.

Perfect delivery method for high volume fly ash concrete

Target Projects MULTI-STORY BUILDINGS OF ALL TYPES . . . . . . Structural steel framed buildings. Wood framed buildings. Concrete framed buildings. Industrial Structures. Current production equipment tooled for 8” - 12” thick walls to target 3-12 story buildings.

MULTI-STORY BUILDINGS OF ALL TYPES . . . . . .

Structural steel framed buildings.

Wood framed buildings.

Concrete framed buildings.

Industrial Structures.

Current production equipment tooled for 8” - 12” thick walls to target 3-12 story buildings.

Attachment can be made to all floor framing materials

Design Direct Replacement for Conventional Cast-In-Place—no extra work required for Architect or Structural Engineer. Conventional concrete rebar configurations. No proprietary design methods or material strengths. No requirement for special code approvals.

Direct Replacement for Conventional Cast-In-Place—no extra work required for Architect or Structural Engineer.

Conventional concrete rebar configurations.

No proprietary design methods or material strengths.

No requirement for special code approvals.

Complete Detailed Shop Drawings Stair and Railing Layouts Rebar details Framing and Floor Connections 3D Revit model available for each project.

Stair and Railing Layouts

Rebar details

Framing and Floor Connections

3D Revit model available for each project.

Competition Price for a typical stair core story with 2 flights of stairs, 8 embeds and ledger angle at floor perimeter. Price includes placed concrete and all installation costs Conventional Methods Cast-In-Place: $38,574/Story* Pre-Cast: $49,219/Story* Masonry: $34,346/Story* CorTek: $36,786 *Based on independent estimate provided by the Icon Group September 2008

Price for a typical stair core story with 2 flights of stairs, 8 embeds and ledger angle at floor perimeter. Price includes placed concrete and all installation costs

Conventional Methods

Cast-In-Place: $38,574/Story*

Pre-Cast: $49,219/Story*

Masonry: $34,346/Story*

CorTek: $36,786

*Based on independent estimate provided by the Icon Group September 2008

Installation Sequence and Details

Foundation Embeds

Base Module

Core Leveling Detail

Install Vertical Reinforcement

Vertical Reinforcement In Place

Base Connection Weld

Going Vertical

Module Alignment Detail

Non-contact Vertical Splice Bars

Non-contact Vertical Rebar Splices

Vertical steel attached to each module

Vertical Bar Alignment Guides

Contractor drops in steel beam and bolts it together.

Concrete Placing Form designed for approximately 6 feet/hour of concrete Up to 18 foot lifts can be poured at a time. Removable weep hole plugs aid placing concrete to correct pour heights Web bar spacing allows for easy penetration of pumper tip hose and vibrator

Interior and Exterior finishes Exterior Exposed Metal Drywall Masonry Stucco Thin set brick Interior Exposed Metal Drywall Hardboard Panel Tile

Exterior

Exposed Metal

Drywall

Masonry

Stucco

Thin set brick

Interior

Exposed Metal

Drywall

Hardboard Panel

Tile

Optional pre-installed hat channel accommodates exceptionally thin finish face

Hat-channel can be field shot directly on to walls and finished conventionally

Optional pre-installed masonry tie backs accelerate masonry field work

Exposed metal interior is an aesthetic alternate to concrete

Difficult/slow/error-prone field work brought into a controlled factory environment set up for efficiency and quality. Computer aided parametric design used for rapid parametric structural and architectural design. Decreased site congestion increases project flow. Freeing site schedule from concrete core schedule increases “battle plan” options. An Advanced Building System

Conclusion Eliminates the need for scaffolding and forms Reduces Critical Path construction time associated with building cores Pre-installed stairs Pre-installed floor and beam connections Modules do not require stripping. CorTek cores are individually designed for each job in a controlled environment Simultaneous construction with floor framing Structurally equivalent to 8”-12” CIP concrete shear wall. Cost effective

Eliminates the need for scaffolding and forms

Reduces Critical Path construction time associated with building cores

Pre-installed stairs

Pre-installed floor and beam connections

Modules do not require stripping.

CorTek cores are individually designed for each job in a controlled environment

Simultaneous construction with floor framing

Structurally equivalent to 8”-12” CIP concrete shear wall.

Cost effective

Questions & Comments

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