Concrete Rib House - Complete

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Concrete Rib House describes the mechanical and value engineering of using concrete, not just for the sides of a home, but also for the roof and, obviously, the foundation/floor. The innovative roof and supports are thin and the ability of the finished home (using low cost forms) not only to withstand difficult weather, but to satisfy green heating/cooling requirements is unparalleled.

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  • please send it for me: jiro_manba89@yahoo.com
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  • I have a short information with floor plans and renderings. I will send to anybody interested, must send me your e-mail to sent you the file attached.
    Free!!! no charge
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  • This SlideShare have being looked 5,174 time, but I have not received any comment or questions, meanwhile the news shows photos of the sea of 2x4 wood studs on the ground as the devastation of a tornado, why?: population grows and keeps the construction methods used when houses were built scattered; looking for safe building sites, then stick framing was not problematic. But presently people build in unsafe places: flat areas prone to strong winds, canyons where a small fire becomes devastating, lower land risk to flooding, etc. but the use of the traditional wood framing haven’t change. There is a solution Concrete Rib Construction System but, nobody comments or asks for more information. What is wrong? My exposure of the system is not clear, or people not care for lost of dwellings and lives. Can somebody tell me what can I do to improve my work?.
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  • With 4,997 views, I have not any questions.
    Don't hesitate to ask me.
    aburtoeugenioarch@hotmail.com
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  • צלעות בטון בנייה מערכת היא הדרך היעילה ביותר כדי לספק דיור באופן מסיבי.
    תראו את זה.
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Concrete Rib House - Complete

  1. 1. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10651 TABLE OF CONTENTS INTRODUCTION PG 2 CONCRETE RIB HOUSE A CASE STUDY PG 5 TALKING MONEY – COST STUDY OF BUILDING CONCRETE RIB HOUSES USING SPREAD SHEETS PG 23 • FONDATION COST PG 25 • IWALLS COST PG 30 • ROOF COST PG 45 • BEARING AND PARAPET BEAMS COST PG 58 CONCLUSION: SHELL COST PER SQUARE FOOT PG 63 ARCHITECTURAL SOLUTIONS FROM THE CASE STUDY CONCRETE RIB HOUSE PG 2 FLOOD HAZARD AREAS THE FLOATING MEZZANINE SOLUTION WITH CRH SYSTEM PG 80 LIVE AND WORK CONDOMINIUMS USING CRH SYSTEM, A SOLUTIONTO ENERGY CONSERVATION PG 96 POUTPOURRI OF SAMPLES PHOTOS OF MASONRY CONCRETE HOUSES PG 105 MASTER PLANS WHERE TO BUILD WITH CRH SYSTEM PG 112 RAMMED EARTH HOUSES HOW THE CRH SYSTEM WAS BORN PG 117 CIUDAD AZTECA – 7,500 HOUSES BUILT IN 15 MONTHS, 8 SCHOOLS, SHOPPING CENTER, OFFICES PG 129 COSTA BANDERAS AN INVESTMENT AND RETURNS FOR A PLANNED RETIREMENT DEVELOPMENT PG 137 ABOUT THE AUTHOR PG 151 GENERAL INFORMATION PG 155
  2. 2. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10652 The fast growing population is changing living conditions for people. Land cost are forcing people to live in zones of high risk. The news often is about dwellings destroyed by natural disasters such as: fire, hurricanes, tornados, flooding, or earthquakes. Such destruction can be possible because the traditional construction system used, wood framing, is out of date to protect structures subject to the conditions in the lower cost areas where land is being developed. After years of experience designing and building in harsh environments with strict budgets, and after living in the USA and reading the newspapers about the destruction of homes by nature, I decided to perform a case study to show a house capable of resisting the calamities described in the news. This book describes my Concrete Rib House (CRH) construction system. The CRH is durable, capable of resisting natural disasters with an affordable budget and in compliance with desired conditions of thermal performance. It uses regional materials. Construction with poured-in-place concrete minimizes the use of timber resources. Before talking about CRH, let me analyze the cause and effect of such natural disasters. • FIRE.- Traditional construction systems based on the use of flammable materials in the exterior envelope are vulnerable to attack by burning embers. Plaster on the walls is not enough protection; embers go through openings and find places to start new fires, especially with the help of strong winds generated by topography or by weather conditions. News photos frequently show only the fireplace or other masonry element remaining in a burned house. • HURRICANES and TORNADOS.- The tradition of building houses with wood framing produces light structures; the roofs are easily lifted off by strong winds. Eaves catch the wind and the horizontal wind pressure against the windward side of the structure pushes the roof; on the leeward side, where there is no pressure, a vacuum is created; these forces working together can lift the roof off the walls. Without the roof, there is no bracing for the walls; result: the total structure collapses. • FLOODING.- Strong precipitation by itself or accompanied by hurricanes is factor for devastation. The flooding affects the wood framing, warping and damaging the structure, and rusting nails and other metal fasteners. Additional problems during flooding, such as destruction of utilities, lack of drinking water and lack of power are subjects which will be discussed in detail in the section of this book showing design solutions. • EARTHQUAKES.- Nobody knows when or how strong an earthquake will be. The typical construction solution to earthquake danger in wood framing is to reinforce corners with plywood to take the shear stress. Plywood, as a material based on a natural resource, cannot guarantee consistent quality control. This leaves a wooden structure vulnerable to seismic events. • MOLD AND TERMITES.- Again tradition is stronger than logic, dwellings built with wood framing are good to attract this pest. INTRODUCTION
  3. 3. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10653 In this book I will talk about the building solutions to avoid the damage of natural disasters described above using CRH the construction system developed by me during many years of general experience in architecture and building. I have constructed several thousands of dwellings of one and two stories, schools, commercial buildings, hotels, and offices using this system. It is based on the Romans old technique - concrete poured in place. Such a technique was used more than 2,000 years ago, with many Roman structures still standing. Below is a condensed description of solutions to the devastating effects of natural disasters. Details, with text and graphics, are discussed later in this book. FIRE.- Foundation, walls and roof are all poured-in-place concrete. This structure has no exposed flammable materials. For additional protection window and door openings can have an automatic system of metal curtains. HURRICANES and TORNADOS.- The CRH system is designed to have all its elements supported by rigid pinned connections; together the foundation, walls and roof form a monolithic box structure of heavy weight. The house can have eaves and gable roofs and still keep its cohesion under strong wind forces. FLOODING.- Concrete and Styrofoam are not affected by moisture. In severe flood hazard zones the interior face of the walls will have stucco covering instead of the gypsum board used in CRH in other areas. The Design Solutions section in this book has further information. EARTHQUAKES.- An advantage of working with concrete is that there is advanced technology in structural calculations to determine the quality and stress resistance necessary for the structure to respond to specific seismic conditions. Additionally, the CRH structure uses the T-beam concept for walls and roof, arranged in such a way that the structure is braced in the “x” and “y” directions. MOLD and TERMITES.- Concrete has no organic composition for mold; and termites don’t eat concrete.
  4. 4. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10654 Besides being the solution for natural disasters, the CRH construction system has an economic benefit; the CRH can create jobs. CRH produces houses in a massive manner. The system is so simple that it uses many unskilled workers who with a little training become highly productive. The big volumes of construction materials make room for negotiated prices – massive construction is the key for lower construction cost and good profits. Payrolls and materials purchases make the money flow; low house prices increase sales; homeowners need new furniture and accessories; moving companies are busy; cities receive building permit and property tax revenues; offices, stores, factories, and many other businesses will need to hire more employees. People related to the development business using CRH have income and buying power. The economy goes rolling. This book will show how the CRH system can be used to build with crews of unskilled workers, in a fast mode. Concrete can be customized according to structural and budget needs; it can be molded to create any architectural decoration element to satisfy the demands of market trends. Builders can build fast, developers can sell fast, perhaps with small profits per unit but much more often. The case study was built in the Coachella Valley of Southern California (near Palm Springs), chosen considering its very high and low temperatures and its location close to the San Andreas Fault, to test power savings and earthquake structural advantages. After showing the construction process, a cost study based on the information logged during the construction process will be analyzed. Several examples of design based on the case study, samples of conceptual design of large and small dwellings, some solutions for flooding areas, and design proposal for live-and-work units will be shown. To complement, some site planning samples, one with investment and profit projections, are included from my professional work. Lastly the book includes an appendix with my experiences in search of a construction system for massive production, from prefabrication, rammed earth, masonry concrete houses, schools, and a multistory hotel.
  5. 5. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10655 CONCRETE RIB HOUSE A CASE STUDY The system is simple, similar to structures built by the Romans using puzzolanas (natural cement of volcanic origin) concrete. Their structures have stood for millennia and today are tourist attractions. The CRH system is similar to that of the Romans but has been updated with today’s technology, new materials, and structural engineering. The Romans used brick walls as formwork. I used plywood panels for the case study and blocks of rigid foam as formwork and insulation. Plywood could be replaced by metal or fiberglass panels to achieve a more sustainable and longer lasting formwork, avoiding use of trees to support the green building movement.
  6. 6. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10656 THE CONCRETE RIB HOUSE Why concrete, why ribs…? Because the concrete structure resisting loads and stress in this house is similar in function to the ribs protecting the main organs of some living creatures, including humans. The concrete ribs produce a building structure highly resistant to natural calamities such as earthquake, fire, hurricane, cyclones and flooding. Concrete is not attacked by termites or mold. In both walls and roof, the spaces between the ribs are filled with rigid foam insulation. 13 inches of this material provides an R value of 54.21. There are no leaks because the insulation is embedded in the concrete. Foundation. This is similar to a customary foundation in conventionally framed houses. The difference is that steel dowels are set in the footings to anchor the walls. These dowels function to receive the reinforcement of vertical ribs. Note the reinforcement of the stems attached to the dowels and preparation to hold roof T-beams upper and lower re-bars, as well.
  7. 7. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10657 WALLS The structural concept of the Concrete Rib Houses is based on the T-beam shape used to handle large spans with a minimum of concrete and steel reinforcement. The T-beam name is because its shape is a sort of capital T. The stem of the “T” would be the rib, and the crossbar of the “T” would be the flange. I use T-beams in the vertical position to create walls. For the sake of simplicity, I have not shown the steel reinforcement in the illustration at left. Two T-beams in the same line and touching creates an alcove where the insulation is embedded. The flanges in a wall create a diaphragm to resist shear stress. The insulation functions as formwork for the sides of the ribs and at the back of the flange. T-BEAM T-BEAMS ALCOVE
  8. 8. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10658 The sketch at the left shows one ribbed wall supporting and connected to the roof T-beam. This connection creates bracing between walls and improves the structural capacity to resist forces such as wind pressure or earthquakes. The architectural design is done to have T-beams of walls and roof in “x” and “y” directions to have bracing in all walls, keeping the “concrete box” concept unique in CRH system. Finally this sketch shows two vertical contiguous beams which create the alcove where the rigid foam insulation can be seen. The diagram shows the poured concrete walls with the embedded insulation. This system makes the insulation more effective because there are no leaks or voids, such as typically occur with insulation material installed between wood or metal framing. This concept is applicable to walls and roof. ROOF T-BEAM STEM ROOF T-BEAM FLANGE. ROOF SLAB T-BEAM IN VERTICAL POSITION CREATES THE WALL EXTENSION OF WALL FLANGE POURED WITH THE ROOF RIGID INSULATION
  9. 9. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 10659 The construction process is shown in the photo at right. Note the dowels and the preparation for plumbing and electrical which are set in trenches under and through the footings and floor slab. The photo at left shows the vertical reinforcement of the ribs being attached to the dowels, for a T-beam wall with embedded insulation. The 3 types of walls used en this system are described on the next page. FOUNDATION ELECTRICAL PLUMBING DOWEL RIB REINFORCEMENT ATTACHED TO DOWEL
  10. 10. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106510 WELDED WIRE MESH USED AS REINFORCEMENT FOR THE DIAPHRAGM RESISTING SHEAR STRESS WALL CONSTRUCTION The CRH uses three types of walls: • Type 1.- Exterior T-beam walls with embedded insulation, width per design depending of R value desired. Can be bearing or no bearing. • Type 2.- Exterior or interior walls. 6” thickness for bearing, 4” thickness for non-bearing. • Type 3.- Partition walls: steel framing, studs size per design. A picture of the welded wire reinforcement, and the wood forming behind. ROOF STEM REINFORCEMENT WALL RIB REINFORCEMENT
  11. 11. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106511 At right is shown the electrical preparation on the wood forming. Above: forming of several walls in progress. Above is the rigid foam insulation in place. Note the ties in place ready to receive the forming of the opposite side of the wall. The efficiency of the thermal insulation is the result of having not leaks or voids in between the construction elements. WALLS – continued
  12. 12. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106512 Insulation in all required walls following the building plans as lines drawn on the slab by the forming crew. After placement of insulation, reinforcement and forms, the concrete is poured to the top of the walls. WALLS – continued The next step is placing the rigid insulation following the previously marked location of the walls, as shown below (top left). The other sketches show the sequence of setting insulation and pouring walls.
  13. 13. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106513 At left exterior view of rigid insulation showing electrical ducts which will be embedded in concrete. Above interior view insulation covered by interior forming. Note the reinforcement for the roof stems . At left is a detail of dobies serving to hold the insulation as well keep the diaphragm at the thickness required by the structural calculations. Photo sequence of setting insulation
  14. 14. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106514 At left: Once the forming has been finished, the next step is pouring the walls with premix concrete delivered by pumping. This picture shows the pouring of the walls all the way to the top. Note the steel reinforcement to be used for the parapet walls, which will be poured later at the same time as the roof structure. At the lower left of the picture a window is shown set in place. When the walls are poured, the window will be held by concrete. The efficiency of the thermal insulation lies in eliminating leaks or voids in between the construction elements. The picture at right shows the removal of the forms and the surface on the face of the wall. This wall is an interior bearing wall 6” thick, which will carry T- beams in the direction of the re-bars. The T-beams on top of the area behind the opening will be north-to-south. These will combine with east- west axis beams to provide the greatest earthquake resistance. Pouring walls
  15. 15. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106515 Roof - diagrams of placing insulation and pouring concrete Note that supports holding the blocks of rigid insulation and the reinforcement of the ribs (flanges) are not shown. These can be seen in the first photo on page 16. Fast setting pre-mix concrete is placed by pump, as shown in the photo on page 17. Fast setting concrete is used to enable the roof forms to be removed quickly, to expedite further phases of the construction such as applying the gypboard and building the partition walls.
  16. 16. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106516 The forming to pour the roof is special because it is not necessary to form the entire bottom of the roof area. It is only necessary to support the bottom of the stems of the T beams which also serve to support the rigid insulation. These supports are lumber strips which are held up by vertical adjustable-height steel posts. At left the worker is adjusting a piece of insulation to be set. Above right is a photo of an opening for a skylight. Note the reinforcement and the metal nailers that will hold the ceiling gypsum board. Also note the T-beams set at right angle directions to work bracing each other.
  17. 17. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106517 Pouring the roof using pre-mix concrete set by pump. The roof pouring was done by a crew of 4 men on the roof plus one on the ground controlling the pump. They poured 2,200 square feet of roof in one day. Forming posts and beams were previously placed, and the rigid insulation and the stems steel rebar reinforcement done. Note that these T-beams are meant to work as bracing in one direction (east to west in this case). The T-beams on top of the area behind the opening will work as bracing at a right angle (north to south). This design gives the most resistance to earthquakes and wind pressure.
  18. 18. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106518 The savings in labor makes the Concrete Rib House system very competitive, and the strictly controlled quality delivers a great product. In the photo above a stem is visible at the edge of an opening for a sky dome, as well as the bottoms of stems between the rigid insulation. The centers of the stems have a steel stud embedded which will be used to attach the gypsum board for the ceiling. A similar solution is used in the center of the ribs in the walls for attaching the gypsum board wall finish. This enables the builder to meet the expectations of the market regarding the appearance and use of walls. The difference between this and a stick-built house will become apparent only during a fire when the CRH does not burn, or during a tornado when the roof does not blow away.
  19. 19. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106519 Living room Master bedroom Interior final appearance
  20. 20. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106520 kitchen Granite counter
  21. 21. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106521 1. Access path to the main entry. 2. Side yard entry court; note the corner window. 3. The casita separate entry. Patio with special fabric shaded trellis creates a relaxed atmosphere to enjoy the landscape and entertain friends. To increase fire resistance the columns and trellis can be built with vinyl elements, which will melt but will not create flames. No exterior surface of the house is flammable; contents such as memorabilia and furniture will be safe. 1 32 Exterior appearance
  22. 22. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106522 Concrete Rib House at night At night the house is vibrant in the dark. The owners of this house will sleep with no worries of earthquakes, fires, hurricanes, tornados, or other natural disasters. They are protected by the rib structure built with concrete as used around 2,000 years ago by the Romans whose structures still stand today as tourist attractions. Concrete is a material which allows strict quality control since the technology permits calculation of the strength required according to function, environmental circumstances and budget. Wood, as a natural product, does not offer the same control. The case study shows a house in the Desert Modern style, but this construction system easily accommodates any architectural style. Refer to the potpourri of samples section.
  23. 23. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106523 TALKING MONEY: A cost study of building Concrete Rib Houses $The greatest economic success in building houses using the Concrete Rib House method occurs when multiple units are produced with the same set of formwork. This cost study assumes 40 uses of one set of formwork, and will show a great competitive value, considering the high quality of the building structure. The prices used in this study are actual cost in California in the year 2007, the construction year of the CRH case study. Costs are generated using the logged prices for materials and labor. The labor costs unique for the CRH were established by observation of the time required for each task and using the workers’ hourly rates. In the case of processes common to conventional construction (for example foundation and stucco finish) the cost was negotiated at local market rates. The cost shown in the study are not marked up and do not include profit, taxes, worker insurance, travel expenses.
  24. 24. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106524 PROCESS TO OBTAIN UNITARY COSTS On the following pages you will find spread sheets for the basic elements to build a structure with the CRH method. The studies by experience by building the case study have green headers. The ones related to conventional construction: yellow and light blue headers. When referring to structural conditions, you will find structural drawings with floor plans, details, sections, as required for information. The cost studies are only for basic elements to build by CRH method, finishing materials (flooring, stucco. paint, as a sample), plumbing including kitchen and bath fixtures, electrical, air conditioned and other special materials or installations will be per market values. The basic costs for the CRH shown are: •FOUNDATION - The foundation of the CRH is done as in conventional construction, except for the use of dowels to receive the structural reinforcement for the exterior walls. •WALLS - This phase of the construction is one of the basic elements of CRH method. •ROOF - This phase is also a basic element of CRH method. Foundation, walls and roof are the core which makes the CRH method capable of resisting natural disasters. Finishing, equipment and appliances are as required by specifications, market costs.
  25. 25. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106525 FOUNDATION • The cost study is based on the experience when building the CRH case study. • Page 26 shows the construction foundation floor plan of the CRH case study. • Page 27 has the structural construction details depicting dimensions and reinforcement obtained by structural calculations in compliance with the governing codes and regulations of the City of Cathedral City. • Page 28 and 29 show spread sheets template using the information contained in pages 26 and 27. • The labor was provided by a concrete contractor working at a flat fee using his own equipment. • The material was bought as a separate item.
  26. 26. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106526 FOUNDATION FLOOR PLAN
  27. 27. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106527 FOUNDATION STRUCTURAL DETAILS
  28. 28. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106528 Table headers, yellow fill, calculations to find volume of concrete required: axis – Letters correspond to labels of the axes on the floor plan on page 26. between – Axis segment is located between the axes at right angles. See floor plan on page 26 type - Detail of foundation with dimensions and reinforcement required by details shown in sheet S3 on page 27. base in - Dimension of the base from sheet S3 on page 27 by detail type. height in - Dimension of the height from bottom to finish floor as shown sheet S3 page 27. by detail type. area in2 - Area of the foundation section in square inches (the product of Base by Height). length ft - The length dimension in feet and inches, per sheet S2 page 26. length in - The translation of the length from feet and inches to inches. volume in3 - The volume in cubic inches as the product of Area square inches by Length inches. volume CY - The volume in cubic inches divided by 45,656 (cubic inches in a cubic yard) to convert the cubic inches to cubic yards as used to order premix concrete Table headers, blue fill, calculations to find the re- bars for reinforcement, as noted in details sheet S3: rebar - Specifications of the re-bar type per diameter, and number of re-bars called in the details on S3 for reinforcement. length in – Total length in inches of re-bars reinforcement. pc of 20ft – Quantity of 20-foot re-bars, as commercially available in the market. The length in divided by 240 (12*20). FOUNDATION COST
  29. 29. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106529 •Table above left: dowels as shown in details on S3 – page 92. •Table above right, shows area calculations of the areas shown in sheet S2 on page 91. •Table lower right is the total of materials and labor required to build the foundation footings and floor slab for a house such as the Concrete Rib House depicted in this book. The unitary costs are as California Market in 2007. For updating use current costs in the location of the construction site being studied. FOUNDATION COST
  30. 30. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106530 WALLS In the case study of the Concrete Rib House different wall types were used, according with their function. For locations of each type, refer to floor plan S4 on page 31 and structural details on page 32. •T-WALL TYPE A (see detail 1 on Sheet S5 on page 32) – This wall has a shape of a T-beam but in vertical position, the stem of the T is named in here “Rib” because its protective function and its use define the why the Method is named Concrete Rib House. The Ribs and the diaphragm slab encased the rigid insulation, used by blocks in the dimensions required by design. The Rib end hold metal nailers which let attach drywalls panels. These walls are used at exterior perimeter locations for living areas. This cost study is for 16 inches wall thickness. Exterior walls can be any thickness weather conditions and or budget will be decision factors. •UNRIBBED WALL TYPE B (see detail 2 on page 32) – This walls have a rectangular foot print. Are used to enclose no living areas, or in locations not exposed to the exterior at living areas. Normally are used for bearing load walls, but can be partition walls. The face to have gypsum board panels will be have encased metal nailers. This cost study is for 6 inches thickness. •WOOD OR METAL FRAMED WALL TYPE C (see detail 3 on page 32) – Partition walls at market cost. The cost study will analyze the formwork used for A and B wall types. Items to hold wallers can be use over 40 times, but in the cost 40 times is the factor. The snap ties type are specific for the wall thickness. Cost of stucco, nailers, gypsum board, insulation, concrete, pumping and labor included in wall type A. Wall type B includes the same except insulation, gypsum board and or stucco only when specified. The costs have different values for such variances.
  31. 31. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106531 FLOOR PLAN SHOWING WALL TYPES
  32. 32. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106532 STRUCTURAL DETAILS 1, 2, 3 FOR WALLS
  33. 33. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106533 The formwork material and labor cost is the same for any thickness of wall. What defines the wall thickness are the dimensions of the ties used. In this study 6” and 16” ties will be considered. $ 1.40 Cost per use when used 40 times, lineal foot of wall 8 feet height $ 28.10Cost per use when used 40 times, 20 ft wall $ 1,123.9520 ft FORM WORK TOTAL COST 16.0016.00hours helper, assisting carpenter1 20.0020.00hours carpenter making formwork1 4.862.43stakes from 2x4x8'2 1.400.143' washer pin-100 in a box10 2.000.10red shot20 12.123.03bracing 2x4x10'4 14.582.43footing plates 2x4x8'6 72.723.03walers 2x4x12'24 204.004.25Jahan "C" bracket buy48 212.402.95Jahan "A" bracket buy72 53.12sales tax 6.75fuel subcharge $ 504.0050.403/4" bb plyform 4x8 shts HUB price10 TOTAL UNITAR Y PRICE DESCRIPTIONQ STUDY TO SET COST OF FORMING PER LINEAL FOOT $ 1.40 Cost per use when used 40 times, lineal foot of wall 8 feet height $ 28.10Cost per use when used 40 times, 20 ft wall $ 1,123.9520 ft FORM WORK TOTAL COST 16.0016.00hours helper, assisting carpenter1 20.0020.00hours carpenter making formwork1 4.862.43stakes from 2x4x8'2 1.400.143' washer pin-100 in a box10 2.000.10red shot20 12.123.03bracing 2x4x10'4 14.582.43footing plates 2x4x8'6 72.723.03walers 2x4x12'24 204.004.25Jahan "C" bracket buy48 212.402.95Jahan "A" bracket buy72 53.12sales tax 6.75fuel subcharge $ 504.0050.403/4" bb plyform 4x8 shts HUB price10 TOTAL UNITAR Y PRICE DESCRIPTIONQ STUDY TO SET COST OF FORMING PER LINEAL FOOT FORMWORK COST
  34. 34. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106534 There is an additional cost of forming material used to hold the formwork to the concrete floor slab such material is per use. $ 0.48Cost lineal foot of wall 8 feet height $ 9.6520 ft FORM WORK TOTAL COST 4.862.43stakes from 2x4x8'2 1.400.143' washer pin-100 in a box10 2.000.10red shot20 TOTAL UNITAR Y PRICE DESCRIPTIONQ COST OF FORMING ACCESSORIES PER LINEAL FOOT $ 0.48Cost lineal foot of wall 8 feet height $ 9.6520 ft FORM WORK TOTAL COST 4.862.43stakes from 2x4x8'2 1.400.143' washer pin-100 in a box10 2.000.10red shot20 TOTAL UNITAR Y PRICE DESCRIPTIONQ COST OF FORMING ACCESSORIES PER LINEAL FOOT $ 1.26 Cost per lineal foot snap ties of wall 8 ft height 25.20Total cost of 20 ft wall 25.200.423m short 6" snapties60 TOTAL UNITAR Y PRICE DESCRIPTIONQ SNAP TIES FOR 6" WALL $ 1.26 Cost per lineal foot snap ties of wall 8 ft height 25.20Total cost of 20 ft wall 25.200.423m short 6" snapties60 TOTAL UNITAR Y PRICE DESCRIPTIONQ SNAP TIES FOR 6" WALL ACCESSORIES SNAP TIES $ 3.00 Cost per lineal foot snap ties of wall 8 ft height 60.00Total cost of 20 ft wall 60.001.003m short 16" snapties60 TOTAL UNITAR Y PRICE DESCRIPTIONQ SNAP TIES FOR 16" WALL $ 3.00 Cost per lineal foot snap ties of wall 8 ft height 60.00Total cost of 20 ft wall 60.001.003m short 16" snapties60 TOTAL UNITAR Y PRICE DESCRIPTIONQ SNAP TIES FOR 16" WALL Snap ties holding the two panels of the formwork are per use. Cost to be added.
  35. 35. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106535 STUCCO COST Dimensions correspond to the floor plan on page 31. The length of the wall segment of each axis was multiplied by the height, which includes the wall and the parapet. These segment areas were added to obtain a total (A). The flat fee contracted for the case study house, which included labor and material, was divided by the total square feet. The cost gives the average cost per square foot of stucco. Note that the price for stucco on a “standard” 8-foot high wall would be $ 8.72 per linear foot. $ 1.09average cost per sf $ 2,800.00flat fee labor and material negotiated: 2,572.4019510.019.5kitchen/familyD-F9 16010.016.0master bedroom west9-12F 22510.022.5master bedroom/bathF-J12 52510.052.53 bedrroms/master2-12J 22010.022.0bath/bedrrom 1F-J2 7010.07.0bath3-2F 3510.03.5living east3-3'C' 16010.016.0living northC-C'3 6010.06.0casita east1-3C 15510.015.5casita northB-C1 15010.015.0casita west1-4B 63.99.07.1garage east9-11D 2169.024.0garage southA-D11 49.59.05.5garage northA-B4 2889.032.0garage entry4-11A total Aareaheightlengthdescriptionbetweenaxes STUCCO AT FACADES - $ 1.09average cost per sf $ 2,800.00flat fee labor and material negotiated: 2,572.4019510.019.5kitchen/familyD-F9 16010.016.0master bedroom west9-12F 22510.022.5master bedroom/bathF-J12 52510.052.53 bedrroms/master2-12J 22010.022.0bath/bedrrom 1F-J2 7010.07.0bath3-2F 3510.03.5living east3-3'C' 16010.016.0living northC-C'3 6010.06.0casita east1-3C 15510.015.5casita northB-C1 15010.015.0casita west1-4B 63.99.07.1garage east9-11D 2169.024.0garage southA-D11 49.59.05.5garage northA-B4 2889.032.0garage entry4-11A total Aareaheightlengthdescriptionbetweenaxes STUCCO AT FACADES -
  36. 36. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106536 NAILERS $ 1.32 Cost per lineal foot nailers to hold gypsum board 16" wall 8 ft height 26.30Total cost of 20 ft wall 0.500.50lote nails to hold metal 1.5/81 2.600.26styrofoam backing 1n 1.5/8" studs10 23.202.321.5/8" 25ga stud 8'10 TOTAL UNITAR Y PRICE DESCRIPTIONQ NAILERS ON 16" WALL $ 1.32 Cost per lineal foot nailers to hold gypsum board 16" wall 8 ft height 26.30Total cost of 20 ft wall 0.500.50lote nails to hold metal 1.5/81 2.600.26styrofoam backing 1n 1.5/8" studs10 23.202.321.5/8" 25ga stud 8'10 TOTAL UNITAR Y PRICE DESCRIPTIONQ NAILERS ON 16" WALL $ 1.32 Cost per lineal foot gypsum nailers one face of wall 8 ft height 26.30Total cost of 20 ft wall 0.500.50lote nails to hold metal 1.5/81 2.600.26styrofoam backing 1n 1.5/8" studs10 23.202.321.5/8" 25ga stud 8'10 TOTAL UNITAR Y PRICE DESCRIPTIONQ GYP. BD. NAILERS FOR 6" WALL $ 1.32 Cost per lineal foot gypsum nailers one face of wall 8 ft height 26.30Total cost of 20 ft wall 0.500.50lote nails to hold metal 1.5/81 2.600.26styrofoam backing 1n 1.5/8" studs10 23.202.321.5/8" 25ga stud 8'10 TOTAL UNITAR Y PRICE DESCRIPTIONQ GYP. BD. NAILERS FOR 6" WALL Gypsum board (drywall) panels are used to face the interior of the walls because this is what consumers expect. In order to have an effective nailing surface (other than concrete) to hold the gyp board, the CRH method uses nailers of 1.5/8” metal studs with a backing of Styrofoam set into the formwork to be embedded in concrete during pouring. Patent Pending. One nailer along the stem of each rib. Ribs are 24 in on center. When the face of a wall 6 in thick will be covered with drywall, nailers are used. The cost analyzed is per linear foot of wall.
  37. 37. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106537 INSULATION Work of hanging drywall on the walls was negotiated at a flat fee, including labor, materials, taping and texturing. The table on age 56 contains detail used to establish cost of walls. GYPSUM BOARD CONCRETE $ 0.58 SF $ 22.85 Cost per lineal foot blocks of insulation 16" wall 8 ft height 457.00Total cost of 20 ft wall 54.002.701.5x1.5 angle 25 ga 10'20 403.0040.30styrofoam 20x14x9610 TOTAL UNITAR Y PRICE DESCRIPTIONQ RIGID INSULATION 16" WALL $ 22.85 Cost per lineal foot blocks of insulation 16" wall 8 ft height 457.00Total cost of 20 ft wall 54.002.701.5x1.5 angle 25 ga 10'20 403.0040.30styrofoam 20x14x9610 TOTAL UNITAR Y PRICE DESCRIPTIONQ RIGID INSULATION 16" WALL $ 14.28 Cost per LF concrete 6" wall 8 ft height 285.52Total cost of 20 ft wall 285.5296.46Volume 0.5x8x20/27 in CY2.96 TOTAL UNITAR Y PRICE DESCRIPTIONQ CONCRETE IN 6" WALL $ 14.28 Cost per LF concrete 6" wall 8 ft height 285.52Total cost of 20 ft wall 285.5296.46Volume 0.5x8x20/27 in CY2.96 TOTAL UNITAR Y PRICE DESCRIPTIONQ CONCRETE IN 6" WALL $ 5.47 Cost per LF concrete 16" wall 8 ft height 109.48Total cost of 20 ft wall 14.2896.46volume 9 ribs= 0.33x1.55x8/27 in CY0.148 95.2196.46Volume diaphram 0.17x20x8/27 in CY0.987 TOTAL UNITAR Y PRICE DESCRIPTIONQ CONCRETE IN 16" WALL $ 5.47 Cost per LF concrete 16" wall 8 ft height 109.48Total cost of 20 ft wall 14.2896.46volume 9 ribs= 0.33x1.55x8/27 in CY0.148 95.2196.46Volume diaphram 0.17x20x8/27 in CY0.987 TOTAL UNITAR Y PRICE DESCRIPTIONQ CONCRETE IN 16" WALL
  38. 38. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106538 These costs include labor and materials such as rebar, pencil rods, wire mats, and wire ties per structural calculations. REINFORCEMENT $ 5.95119.09reinforcement 16in wall 48.0016.00hours steel reinforcement3 3.593.5916 ga wire tie1 10.102.021/4 pencil rod 20'5 15.103.02#3 rebar 20 feet5 23.280.292x2 dobie w/wire80 19.0215.856x6 10x10 wire mats 7'x20'1.2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'steel reinforcement and labor $ 5.95119.09reinforcement 16in wall 48.0016.00hours steel reinforcement3 3.593.5916 ga wire tie1 10.102.021/4 pencil rod 20'5 15.103.02#3 rebar 20 feet5 23.280.292x2 dobie w/wire80 19.0215.856x6 10x10 wire mats 7'x20'1.2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'steel reinforcement and labor $ 6.99139.86reinforcement 6in wall 32.0016.00hours steel reinforcement labor2 7.183.5916 ga wire tie2 4.042.021/4 pencil rod 20'2 96.643.02#3 rebar 20 feet32 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'steel reinforcement and labor $ 6.99139.86reinforcement 6in wall 32.0016.00hours steel reinforcement labor2 7.183.5916 ga wire tie2 4.042.021/4 pencil rod 20'2 96.643.02#3 rebar 20 feet32 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'steel reinforcement and labor
  39. 39. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106539 PLACING FORMWORK $ 4.7695.20formwork in place 16in wall 16.0016.00hours helper carpenter placing styrofoam1 35.2016.00hours helper carpenter2.2 44.0020.00hours carpenter, trace, align, plumb, brace2.2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'setting form work $ 4.7695.20formwork in place 16in wall 16.0016.00hours helper carpenter placing styrofoam1 35.2016.00hours helper carpenter2.2 44.0020.00hours carpenter, trace, align, plumb, brace2.2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'setting form work Placing formwork for 6- inch walls and 16-inch walls are similar. 16in walls have the rigid insulation placed using metal angles and dobies in coordination with the reinforcement steel. $ 3.6072.00formwork in place 6in wall 32.0016.00hours helper carpenter2 40.0020.00hours carpenter, trace, align, plumb, brace2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'setting form work $ 3.6072.00formwork in place 6in wall 32.0016.00hours helper carpenter2 40.0020.00hours carpenter, trace, align, plumb, brace2 6"wall 8' height $/ft TOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'setting form work
  40. 40. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106540 CONCRETE POURING This phase of the construction uses a team of concrete workers using a concrete pump and vibrator. The pump is rented. The vibrator and scaffolds are included in the concrete sub- contractor fee. $ 11.30226.08pouring concrete 16in wall 190.7689.98CUY concrete pouring2.12 35.3216.66CUY concrete pumping2.12 $ F/8'htTOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'concrete pouring by pump. $ 15.78315.65pouring concrete 6in wall 266.3489.98CUY concrete pouring2.96 49.3116.66CUY concrete pumping2.96 $ F/8'htTOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'concrete pouring by pump. $ 11.30226.08pouring concrete 16in wall 190.7689.98CUY concrete pouring2.12 35.3216.66CUY concrete pumping2.12 $ F/8'htTOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 16"x20'x8'concrete pouring by pump. $ 15.78315.65pouring concrete 6in wall 266.3489.98CUY concrete pouring2.96 49.3116.66CUY concrete pumping2.96 $ F/8'htTOTAL UNITARY PRICE DESCRIPTIONQ STUDY COST OF WALL 6"x20'x8'concrete pouring by pump.
  41. 41. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106541 TOTAL CONSTRUCTION COST OF WALLS Using the values obtained in the cost studies in the page noted from the table at right, the different cost for each one of the walls used in the CRH Case Study will be shown on the following pages. 11.30LF/8' ht105Concrete pouring 16in wall 15.78LF/8' ht105Concrete pouring 6in wall 4.76LF/8' ht104Placing formwork for 16in wall 3.60LF/8' ht103Placing formwork for 6in wall 5.96LF/8' ht103Steel reinforcement 16in wall 6.99LF/8' ht102Steel reinforcement 6in wall 5.47LF/8' ht102Concrete 16in wall 14.28LF/8' ht102Concrete 6in wall 22.85LF/8' ht102Insulation 0.80SF102Gypsum board 1.32LF/8' ht101Nailers 16in wall 1.32LF/8' ht101Nailers 6in wall 1.09SF100Stucco 3.00LF/8' ht99Snap ties 16in wall 1.26LF/8' ht99Snap ties 6in wall 0.48LF/8' ht99Formwork accessories 1.40LF/8' ht98Formwork $UNITpageDESCRIPTION 11.30LF/8' ht40Concrete pouring 16in wall 15.78LF/8' ht40Concrete pouring 6in wall 4.76LF/8' ht39Placing formwork for 16in wall 3.60LF/8' ht38Placing formwork for 6in wall 5.96LF/8' ht38Steel reinforcement 16in wall 6.99LF/8' ht37Steel reinforcement 6in wall 5.47LF/8' ht37Concrete 16in wall 14.28LF/8' ht37Concrete 6in wall 22.85LF/8' ht37Insulation 0..58SF37Gypsum board 1.32LF/8' ht36Nailers 16in wall 1.32LF/8' ht36Nailers 6in wall 1.09SF35Stucco 3.00LF/8' ht34Snap ties 16in wall 1.26LF/8' ht34Snap ties 6in wall 0.48LF/8' ht34Formwork accessories 1.40LF/8' ht33Formwork $UNITpageDESCRIPTION
  42. 42. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106542 TYPE A – RIBBED WALL WITH INSULATION 69.79LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 8.721.09SFdrywall8 11.3011.30LF/8' htConcrete pouring 6 in wall1 5.475.47LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 22.8522.85LF/8' htInsulation1 3.603.60LF/8' htPlacing formwork for 16 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 16" drywall/stucco 65.71LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 4.640.58SFdrywall8 11.3011.30LF/8' htConcrete pouring 6 in wall1 5.475.47LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 22.8522.85LF/8' htInsulation1 3.603.60LF/8' htPlacing formwork for 16 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 16" drywall/stucco
  43. 43. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106543 TYPE B – UNRIBBED WALL UNRIBBED WALL TYPE B (see detail 2 on page 32) There are different costs regarding the material used to cover the faces. 51.51LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" exposed/stucco 51.51LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" exposed/stucco 60.23LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 8.721.09SFdrywall8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" drywall/stucco 56.15LF/8' ht TOTAL 6"wall 8' height 6.400.80SFStucco8 4.640.58SFdrywall8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" drywall/stucco
  44. 44. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106544 TYPE B – UNRIBBED WALL 62.55LF/8' ht TOTAL 6"wall 8' height 17.441.09SFdrywall16 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" drywall/drywall 54.39LF/8' ht TOTAL 6"wall 8' height 9.280.58SFdrywall16 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" drywall/drywall 53.83LF/8' ht TOTAL 6"wall 8' height 8.721.09SFdrywall8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" exposed/drywall 49.75LF/8' ht TOTAL 6"wall 8' height 4.640.58SFdrywall8 15.7815.78LF/8' htConcrete pouring 6 in wall1 14.2814.28LF/8' htConcrete 6x12x96 inches1 6.996.99LF/8' htSteel reinforcement 6 in wall1 1.321.32LF/8' htNailers 6 in wall1 1.261.26LF/8' htSnap ties 6 in wall1 3.603.60LF/8' htPlacing formwork for 6 in wall1 0.480.48LF/8' htFormwork accessories1 1.401.40LF/8' htFormwork1 TOTAL UNITAR Y PRICE UNITDESCRIPTIONQ STUDY COST OF WALL 6" exposed/drywall
  45. 45. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106545 ROOF .. The Microsoft Office Excel generated tables analyze labor and materials per square foot of roof of the CRH structure in the study: • Formwork and pipes used for shoring are rented. Beams and boards cost to be prorated by 40 uses, are in page 48. • Labor and accessories for formwork on page 49. • Labor for stems and flange reinforcement and placing block insulation on page 52. • Rebar, mesh and metal nailers material on page 53. • The rigid insulation blocks and mesh to reinforce the top slab (T-beam’s flange) on page 54. • Fast set concrete used in roof to reduce the construction time on page 54. • Drywall used in ceilings and walls are discussed on page 56. • Roofing labor and materials on page 57. The cost study uses direct costs of the elements used for the roof structure as shown in the list below.The cost study uses direct costs of the elements used for the roof structure as shown in the list below. Refer to the plan and structural detailsRefer to the plan and structural details on pages 46 and 47.
  46. 46. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106546 ROOF PLAN SHOWING POSTS AND BEAMS FOR FORMWORK
  47. 47. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106547 ROOF STRUCTURAL DETAILS
  48. 48. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106548 $ 0.02Cost per SF of lumber per use to pour a roof 69.28Cost per use 2,771.34Total cost lumber for Case Study 1,302.0037.204x8x14 wood beams35 1,469.349.072x8x8 boards used162 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - wood beams and boards 40 uses $ 0.02Cost per SF of lumber per use to pour a roof 69.28Cost per use 2,771.34Total cost lumber for Case Study 1,302.0037.204x8x14 wood beams35 1,469.349.072x8x8 boards used162 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - wood beams and boards 40 uses The rental of shoring pipe is cost effective because it includes the delivery and return to the renting company. The pipes do not need to be stored or maintained. Minimal investment is necessary. In the case study 129 shoring pipes were used for the roof of 2850 SF. Cost is shown at the Table at left. Beams and boards are supported by the shoring pipe. These serves to hold the concrete in the ribs as well as the rigid insulation between the ribs. Beams and boards need to be purchased. The cost study assumes 40 uses of a set of beams and boards, averaging the cost, as shown here. $ 0.17Cost per SF pipe shore used 496.48Cost per 7 days rent 2,127.77Total cost 80 pipes a month 902.270.74tax of pipe shore per month 1,225.509.50pipe shore w/head rent per month129 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - pipe shore 10 days use $ 0.17Cost per SF pipe shore used 496.48Cost per 7 days rent 2,127.77Total cost 80 pipes a month 902.270.74tax of pipe shore per month 1,225.509.50pipe shore w/head rent per month129 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - pipe shore 10 days use
  49. 49. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106549 $ 0.43Cost per SF labor and accesories to set formwork 1,242.35 Cost per 2,800 SF of roof at Case Study 1,242.35Total cost lumber for Case Study 30.0030.00lote nails nails and red shot1 8.100.05lote nails to hold metal 1.5/8162 5.270.03styrofoam backing 1n 1.5/8" studs162 46.980.291.5/8" 25ga stud 8'162 1,152.0012.00hours used by 8 laborer in day and half96 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - labor and related materials $ 0.43Cost per SF labor and accesories to set formwork 1,242.35 Cost per 2,800 SF of roof at Case Study 1,242.35Total cost lumber for Case Study 30.0030.00lote nails nails and red shot1 8.100.05lote nails to hold metal 1.5/8162 5.270.03styrofoam backing 1n 1.5/8" studs162 46.980.291.5/8" 25ga stud 8'162 1,152.0012.00hours used by 8 laborer in day and half96 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF FORMWORK - labor and related materials Labor involves placing the shoring pipes and putting the 4x8 wood beams on the pipe heads to receive the 2x8 boards. The boards are nailed to the beams, and serve to brace the formwork, facilitating the placing of nailers which will serve to hold the drywall ceiling. These tasks are simple and do not require special skills; entry level construction laborers can do this with no problem. 31184Total to be used by cost study w/15% add for splicing 27.18160.1Total 18.63T-beams both sides supported on 16" walls 68.11T-beams one side 6" wall other side 16" wall 27.1873.32T-beams supported on 6" walls 20FT rebar #4 TOTAL 20FT rebar #3 TOTALTotal per case study of beams noted ROOF T-BEAMS STEEL REINFORCEMENT resume 31184Total to be used by cost study w/15% add for splicing 27.18160.1Total 18.63T-beams both sides supported on 16" walls 68.11T-beams one side 6" wall other side 16" wall 27.1873.32T-beams supported on 6" walls 20FT rebar #4 TOTAL 20FT rebar #3 TOTALTotal per case study of beams noted ROOF T-BEAMS STEEL REINFORCEMENT resume The table at the right shows the total rebar numbers used to build the case study following the structural calculations reflected on pages 112 and 113. The following pages detail the process of obtaining these totals. Costs for additional components of the roof will be shown in the following pages.
  50. 50. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106550 27.1873.32rebars of 20 feet length 543.581,466.42rebars in LF 031.087.502.8636.507.5010A 12062.8524.0012.57523.0024.009A 116.25178.0523.2523.2512.36522.2523.258A 43.567.3621.7521.7511.93220.7521.756A 202.5318.9020.2520.2511.641019.7520.255A 40.5197.6420.2535.6827.46216.8317.834sim 20.8332.5020.8320.8311.67119.8320.834A 0153.6833.1610.52215.8316.583A 0288.5631.0010.14414.5015.502A 0135.8029.009.90213.6614.501A #4 TOTAL #3 TOTAL positive reinf. 1#4 positive reinf. 2#3 positive reinf. 1#3 pinned support #3 negative reinf. bea ms Qspan LF beam length includin g wall support s LFtype ROOF T-BEAMS STEEL REINFORCEMENT supported on 6" walls 27.1873.32rebars of 20 feet length 543.581,466.42rebars in LF 031.087.502.8636.507.5010A 12062.8524.0012.57523.0024.009A 116.25178.0523.2523.2512.36522.2523.258A 43.567.3621.7521.7511.93220.7521.756A 202.5318.9020.2520.2511.641019.7520.255A 40.5197.6420.2535.6827.46216.8317.834sim 20.8332.5020.8320.8311.67119.8320.834A 0153.6833.1610.52215.8316.583A 0288.5631.0010.14414.5015.502A 0135.8029.009.90213.6614.501A #4 TOTAL #3 TOTAL positive reinf. 1#4 positive reinf. 2#3 positive reinf. 1#3 pinned support #3 negative reinf. bea ms Qspan LF beam length includin g wall support s LFtype ROOF T-BEAMS STEEL REINFORCEMENT supported on 6" walls 68.11rebars of 20 feet length 1,362.17rebars in LF 387.5235.6812.76820.0021.006B 61.5012.30519.0020.004 464.9033.1613.331015.8316.833 174.0031.0012.50413.7514.752 274.2529.0013.7512.10512.7513.751 #3 TOTAL positive reinf. 2#3 positive reinf. 1#3 pinned support #3 negative reinf. beams Qspan LF beam length includin g wall supports LFtype ROOF T-BEAMS one on 6" the other 16" walls. 68.11rebars of 20 feet length 1,362.17rebars in LF 387.5235.6812.76820.0021.006B 61.5012.30519.0020.004 464.9033.1613.331015.8316.833 174.0031.0012.50413.7514.752 274.2529.0013.7512.10512.7513.751 #3 TOTAL positive reinf. 2#3 positive reinf. 1#3 pinned support #3 negative reinf. beams Qspan LF beam length includin g wall supports LFtype ROOF T-BEAMS one on 6" the other 16" walls. Different design conditions make the supporting walls of the roof different. At left we have the study of a roof supported on 6” walls at both ends. The table at right shows the roof T-beams to be supported by a 6” wall in one side and a 16” wall on the opposite side.
  51. 51. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106551 18.63rebars of 20 feet length 372.60rebars in LF 76.2045.0031.20121.5022.508 296.4043.5030.60420.7521.757 #3 TOTAL positive reinf. 2#3 positiv e reinf. 1#3 pinned support #3 negative reinf. beams Qspan LF beam length includin g wall support s LFtype ROOF T-BEAMS both supports on 16" walls. 18.63rebars of 20 feet length 372.60rebars in LF 76.2045.0031.20121.5022.508 296.4043.5030.60420.7521.757 #3 TOTAL positive reinf. 2#3 positiv e reinf. 1#3 pinned support #3 negative reinf. beams Qspan LF beam length includin g wall support s LFtype ROOF T-BEAMS both supports on 16" walls. 84.253,261.482,717.90 1.4054.0045.00122.508 5.39208.80174.00421.757 10.42403.20336.00821.006B 6.20240.00200.00520.004 10.43403.92336.601016.833 3.66141.60118.00414.752 4.26165.00137.50513.751 1.4054.0045.0037.5010A 7.44288.00240.00524.009A 7.21279.00232.50523.258A 2.70104.4087.00221.756A 12.56486.00405.001020.255A 2.2185.5871.32217.834sim 1.2949.9941.66120.834A 2.0679.5866.32216.583A 3.84148.80124.00415.502A 1.8069.6058.00214.501A CY concret e at flanges, stems factor 0.062 SF of wire mesh in flange SF of wire mesh as stirrups beams Q beam length includin g wall support s LFtype ROOF: mesh 6x6-w2.5xw2.5-concrete 84.253,261.482,717.90 1.4054.0045.00122.508 5.39208.80174.00421.757 10.42403.20336.00821.006B 6.20240.00200.00520.004 10.43403.92336.601016.833 3.66141.60118.00414.752 4.26165.00137.50513.751 1.4054.0045.0037.5010A 7.44288.00240.00524.009A 7.21279.00232.50523.258A 2.70104.4087.00221.756A 12.56486.00405.001020.255A 2.2185.5871.32217.834sim 1.2949.9941.66120.834A 2.0679.5866.32216.583A 3.84148.80124.00415.502A 1.8069.6058.00214.501A CY concret e at flanges, stems factor 0.062 SF of wire mesh in flange SF of wire mesh as stirrups beams Q beam length includin g wall support s LFtype ROOF: mesh 6x6-w2.5xw2.5-concrete The tables on page 50 and 51refered to T-beam types are as structural details in page 47, as well mesh reinforcement. Note than the structural documents use the word joist for the T-beams. The table at right shows the welded wire mesh 6x6 – w2.5xw2.5 used for beam stem as stirrups and steel reinforcement of the beam flange. The table also shows the amount of concrete in cubic yards used to build the roof of the Case Study Concrete Rib House,
  52. 52. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106552 $ 0.56Cost per lineal foot 13.50Total cost of 24 FT rib and insulation 6.0012.00 half hour 1 laborer set insulation for 24 FT beam0.5 1.5012.00 quarter hour 1 laborer set reinforcement on place a 24 FT beam0.25 6.0012.00 half hour 1 laborer prepare material and assemble reinforcement for 24 FT beam0.5 TOTAL UNITARY PRICE DESCRIPTIONQ STEEL REINFORCEMENT and placing insulation $ 0.56Cost per lineal foot 13.50Total cost of 24 FT rib and insulation 6.0012.00 half hour 1 laborer set insulation for 24 FT beam0.5 1.5012.00 quarter hour 1 laborer set reinforcement on place a 24 FT beam0.25 6.0012.00 half hour 1 laborer prepare material and assemble reinforcement for 24 FT beam0.5 TOTAL UNITARY PRICE DESCRIPTIONQ STEEL REINFORCEMENT and placing insulation $ 0.05 Cost per square foot deducting overlaping 6.0012.00 half hour 1 laborer place a math of 7x20 FT on roof with 2x2 dobies0.5 TOTAL UNITARY PRICE DESCRIPTIONQ REINFORCEMENT placing wire mesh $ 0.05 Cost per square foot deducting overlaping 6.0012.00 half hour 1 laborer place a math of 7x20 FT on roof with 2x2 dobies0.5 TOTAL UNITARY PRICE DESCRIPTIONQ REINFORCEMENT placing wire mesh The table at left shows time used to cut and assemble rebar, wire mesh, stirrups and pencil rod. Another laborer places the reinforcement in the formwork after setting the nailers in place, and another worker places the block insulation and puts wires and 2x2 metal angles to hold the blocks in place. The times are averages obtained by observation of 3 laborers during 8 hours work. Once the reinforcement of the ribs (stems) and insulation, is in place, a worker lays wire mesh on top overlapping 12 inches and tying the mesh with wire; special 2x2-inch dobies are used to keep the mesh reinforcement centered in the two inches slab thickness. The time was averaged by observation of crew doing the job.
  53. 53. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106553 161.47 2x4x8 boards & 8' nailersrequired 1,291.77 21.50121.508 83.00420.757 160.00820.006B 95.00519.004 158.301015.833 55.00413.752 63.75512.751 19.5036.5010A 115.00523.009A 111.25522.258A 41.50220.756A 197.501019.755A 33.66216.834sim 19.83119.834A 31.66215.833A 58.00414.502A 27.32213.661A Total length bottom ribs LF beams QLF spantype ROOF T-beam bottom stems 161.47 2x4x8 boards & 8' nailersrequired 1,291.77 21.50121.508 83.00420.757 160.00820.006B 95.00519.004 158.301015.833 55.00413.752 63.75512.751 19.5036.5010A 115.00523.009A 111.25522.258A 41.50220.756A 197.501019.755A 33.66216.834sim 19.83119.834A 31.66215.833A 58.00414.502A 27.32213.661A Total length bottom ribs LF beams QLF spantype ROOF T-beam bottom stems The table above shows cost calculations of steel reinforcement for ribs (stem) of the T-beams including the nailers which are set by the laborers during the same phase of placing the stem reinforcement. The table at right shows calculations for bottom of ribs. Table on next page calculations of total length of ribs – refer to floor plan in page 46 for information. $ 0.50Cost per SF roof T-beams stem $ 1,432.17Total cost of T-beam stem in 2080 SF roof 10.773.5916 ga wire tie - roll3 40.402.02pencil rod 20' - pg 10320 417.962.581.3/8" stud 8' and styrofoam backing - pg 101162 317.0015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 103*20 57.383.02Rebar #3 T-beams on 16"-16" walls - pg 11619 208.383.02Rebar #3 T-beams on 6"-16" walls - pg 11569 156.805.60Rebar #4 in T-beams on 6" walls - pg 11528 223.483.02Rebar #3 in T-beams on 6" walls - pg 11574 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS Rib (stem) reinforcement and nailer $ 0.50Cost per SF roof T-beams stem $ 1,432.17Total cost of T-beam stem in 2080 SF roof 10.773.5916 ga wire tie - roll3 40.402.02pencil rod 20' - pg 10320 417.962.581.3/8" stud 8' and styrofoam backing - pg 101162 317.0015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 103*20 57.383.02Rebar #3 T-beams on 16"-16" walls - pg 11619 208.383.02Rebar #3 T-beams on 6"-16" walls - pg 11569 156.805.60Rebar #4 in T-beams on 6" walls - pg 11528 223.483.02Rebar #3 in T-beams on 6" walls - pg 11574 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS Rib (stem) reinforcement and nailer
  54. 54. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106554 1,358.95 22.50122.508 87.00421.757 168.00821.006B 100.00520.004 168.301016.833 59.00414.752 68.75513.751 22.5037.5010A 120.00524.009A 116.25523.258A 43.50221.756A 202.501020.255A 35.66217.834sim 20.83120.834A 33.16216.583A 62.00415.502A 29.00214.501A Total length reinf. beams Q beam length including wall supports LFtype T-BEAMS total by LF 1,358.95 22.50122.508 87.00421.757 168.00821.006B 100.00520.004 168.301016.833 59.00414.752 68.75513.751 22.5037.5010A 120.00524.009A 116.25523.258A 43.50221.756A 202.501020.255A 35.66217.834sim 20.83120.834A 33.16216.583A 62.00415.502A 29.00214.501A Total length reinf. beams Q beam length including wall supports LFtype T-BEAMS total by LF The T-beam flange once poured becomes the top of the roof as a continuous slab. The T-beams have supports at the heights which can provide slopes of a minimum of ¼” per foot. Crickets can be built to direct water on a flat roof toward the gargoyles. Parapet walls and concrete beams will be the complement of the roof structure, being studied as a separate section. $ 5.04Cost per SF roof insulation 40.3040.30styrofoam 20x14x961 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS rigid insulation $ 5.04Cost per SF roof insulation 40.3040.30styrofoam 20x14x961 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS rigid insulation $ 0.96Cost per SF roof concrete flange $ 2,746.56 Total cost of T-beam flange in 2080 SF roof 37.700.292x2 dobies w/wire - pg 103130 14.363.5916 ga wire tie - roll - pg 1034 2,694.5015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 116170 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS flange reinforcement $ 0.96Cost per SF roof concrete flange $ 2,746.56 Total cost of T-beam flange in 2080 SF roof 37.700.292x2 dobies w/wire - pg 103130 14.363.5916 ga wire tie - roll - pg 1034 2,694.5015.85wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 116170 TOTAL UNITARY PRICE DESCRIPTIONQ ROOF T-BEAMS flange reinforcement
  55. 55. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106555 Construction speed is important to minimize cost of construction loans. The CRH, as a system to produce buildings in large numbers, uses fast set concrete to reduce the setting time of concrete from the standard 28 days to only 3 days. Using fast set concrete, the formwork for the roof is soon moved to the next building, allowing the next phase of construction to continue. For competitive quality and price the concrete used to build the roof had fiber glass mesh in the mix. The cost was recorded from pouring of 40 CY during the construction of the case study CRH. $ 5.09Cost per SF concrete $ 174.04Cost per lineal CY concrete at roof 6,961.63Total cost of 40 CY at roof 60.0020.00days 2 hours water curing3 1,170.001,170.0040 CY labor for roof concrete pouring1 398.009.95pumping first 9 $150 - next $8 each40 21.700.54tax0.0775 280.007.00CY fiber mesh (blue box)40 361.939.05tax to concrete0.0775 4,670.00116.75CY 8.5 sack & M.R. 3/8"40 TOTAL UNITARY PRICE DESCRIPTIONQ FAST SET CONCRETE $ 5.09Cost per SF concrete $ 174.04Cost per lineal CY concrete at roof 6,961.63Total cost of 40 CY at roof 60.0020.00days 2 hours water curing3 1,170.001,170.0040 CY labor for roof concrete pouring1 398.009.95pumping first 9 $150 - next $8 each40 21.700.54tax0.0775 280.007.00CY fiber mesh (blue box)40 361.939.05tax to concrete0.0775 4,670.00116.75CY 8.5 sack & M.R. 3/8"40 TOTAL UNITARY PRICE DESCRIPTIONQ FAST SET CONCRETE
  56. 56. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106556 This page shows the detail of the walls and ceiling faced with drywall. The difference in cost between wall and ceiling were obtained by observation of the process.
  57. 57. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106557 $ 3.01Cost per SF roofing 8,650.008,650.00 2780 SF roof covered area, flat fee including 3" cant strip, metal cap, skylight bases sealed. Labor and materials1 TOTAL UNITARY PRICE DESCRIPTIONQ ROOFING - flat roof cold application fiber glass base #75 $ 3.01Cost per SF roofing 8,650.008,650.00 2780 SF roof covered area, flat fee including 3" cant strip, metal cap, skylight bases sealed. Labor and materials1 TOTAL UNITARY PRICE DESCRIPTIONQ ROOFING - flat roof cold application fiber glass base #75The roof waterproofing job was a flat cost negotiated for a high quality including the parapet walls, the skylights bases, cold to primer roof holding single fiberglass base #75. Torch down polyglass modified, corners sealed with roof cement and granules. ROOF CRH DIRECT COST $ 16.70 / SFROOF CRH DIRECT COST $ 16.70 / SF 16.70Direct Cost of Roof CRH method per SF . 1223.01SFLabor and material - roofing 1210.87SFLabor and material - drywall on ceiling 1205.09SFFast set concrete: material, labor setting, pumping 1190.96SFMaterial reinforcement for T - beam flange (slab cover) 1195.04SFRigid insulation blocks 1180.50SFMaterial reinforcement for T -beam stem includes nailers. 1170.05SFlabor reinforcement flange T -beam Rib (stem) 1170.56SFLabor stems reinforcement and placing insulation 1140.43SFCost per SF labor and accessories to set formwork 1130.02SFBeams and boards roof formwork (40 uses) 1130.17SFCost per rental pipe shore See PAGE $UNITDESCRIPTION 16.70Direct Cost of Roof CRH method per SF . 573.01SFLabor and material - roofing 560.87SFLabor and material - drywall on ceiling 555.09SFFast set concrete: material, labor setting, pumping 540.96SFMaterial reinforcement for T - beam flange (slab cover) 545.04SFRigid insulation blocks 530.50SFMaterial reinforcement for T -beam stem includes nailers. 520.05SFlabor reinforcement flange T -beam Rib (stem) 520.56SFLabor stems reinforcement and placing insulation 490.43SFCost per SF labor and to set formwork 480.02SFBeams and boards roof formwork (40 uses) 480.17SFCost per rental pipe shore See PAGE $UNITDESCRIPTION
  58. 58. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106558 BEARING & PARAPET BEAMS Bearing beams are shown on page 59 as types A, B1, B2, C, and D. Details of section dimensions and reinforcement are on page 60. Bill of materials and labor is shown in the tables on the same page. Beams forming part of the parapet walls are shown in the plan on page 61. Spans of parapet walls that receive a load greater than the acceptable by the standard section and reinforcement are also detailed on page 61. Price established on page 62. A summary of bearing and parapet beams is on page 62, table at lower right.
  59. 59. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106559 BEARING BEAMS PLAN AND DETAILS
  60. 60. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106560 $ 2.46Cost per LF beam reinforcement 1.2012.00labor assembling0.1 0.363.5916 ga wire tie - roll - pg 1030.1 0.150.15#3 rebar LF stirrup1 0.760.15#3 rebar LF reinforcement5 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - reinforcement $ 2.46Cost per LF beam reinforcement 1.2012.00labor assembling0.1 0.363.5916 ga wire tie - roll - pg 1030.1 0.150.15#3 rebar LF stirrup1 0.760.15#3 rebar LF reinforcement5 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - reinforcement The cost study was calculated using reinforcement per LF and a layer of concrete one inch deep by 6” wide x one LF. With the above criteria the cost of each beam type required by structural calculations is shown in the table at right. $ 0.27Cost inch layer by one LF by 6" 0.267516.45 inch layer by one LF by 6" concrete 8.5 sack, pumped, pouring, and tax0.0415 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - concrete $ 0.27Cost inch layer by one LF by 6" 0.267516.45 inch layer by one LF by 6" concrete 8.5 sack, pumped, pouring, and tax0.0415 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - concrete $ 36.27Cost beam C 6X32X36 28.899.63Type D- 6"x36" - concrete3.00 7.382.46Type D - 6"x36" - reinforcement3.00 $ 44.08Cost beam C 6X32X36 34.248.56Type C- 6"x32" - concrete4.00 9.842.46Type C - 6"x32" - reinforcement4.00 $ 52.86Cost beam B1 or B2 - 6x46x43 44.0512.31Type B1 or B2 - 6"x46" - concrete3.58 8.812.46Type B1 or B2 - 6"x46" - reinforcement3.58 $ 95.97Cost beam A - 6x46x78 79.9812.31Type A - 6"x46" - concrete6.5 15.992.46Type A - 6"x46" - reinforcement6.5 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - reinforcement & concrete per type $ 36.27Cost beam C 6X32X36 28.899.63Type D- 6"x36" - concrete3.00 7.382.46Type D - 6"x36" - reinforcement3.00 $ 44.08Cost beam C 6X32X36 34.248.56Type C- 6"x32" - concrete4.00 9.842.46Type C - 6"x32" - reinforcement4.00 $ 52.86Cost beam B1 or B2 - 6x46x43 44.0512.31Type B1 or B2 - 6"x46" - concrete3.58 8.812.46Type B1 or B2 - 6"x46" - reinforcement3.58 $ 95.97Cost beam A - 6x46x78 79.9812.31Type A - 6"x46" - concrete6.5 15.992.46Type A - 6"x46" - reinforcement6.5 TOTAL UNITARY PRICE DESCRIPTIONQ BEARING BEAMS - reinforcement & concrete per type
  61. 61. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106561 PARAPET BEAMS PLAN AND DETAILS
  62. 62. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106562 BEARING AND PARAPET BEAMS PER LFBEARING AND PARAPET BEAMS PER LF $ 14.58Cost per LF beam E or E1 11.7711.77LF concrete 6x44 - material and labor1 1.4412.00labor assembling0.12 0.433.5916 ga wire tie - roll - pg 1030.12 0.340.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1163 0.600.15#3 rebar LF reinforcement4 TOTAL UNITARY PRICE DESCRIPTIONQ PARAPET BEAMS TYPE E, E1- per LF $ 14.58Cost per LF beam E or E1 11.7711.77LF concrete 6x44 - material and labor1 1.4412.00labor assembling0.12 0.433.5916 ga wire tie - roll - pg 1030.12 0.340.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1163 0.600.15#3 rebar LF reinforcement4 TOTAL UNITARY PRICE DESCRIPTIONQ PARAPET BEAMS TYPE E, E1- per LF $ 9.54Cost per LF beam as the title 6.966.96LF concrete 6x26 - material and labor1 1.4412.00labor assembling0.12 0.433.5916 ga wire tie - roll - pg 1030.12 0.260.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1162.33 0.450.15#3 rebar LF reinforcement3 TOTAL UNITARY PRICE DESCRIPTIONQ PARAPET BEAMS TYPE F to F4, G, H, J, K to K2, L & M - per LF $ 9.54Cost per LF beam as the title 6.966.96LF concrete 6x26 - material and labor1 1.4412.00labor assembling0.12 0.433.5916 ga wire tie - roll - pg 1030.12 0.260.11SF wire mesh 6x6 w2.5xw2.5 - 20'x7' - pg 1162.33 0.450.15#3 rebar LF reinforcement3 TOTAL UNITARY PRICE DESCRIPTIONQ PARAPET BEAMS TYPE F to F4, G, H, J, K to K2, L & M - per LF Above studies of parapet beams as shown in floor plan and details in page 126. The differences in reinforcement and dimensions were per loading conditions. For example, parapet Beams E and E1 are supporting the garage roof at the span of garage doors. 1279.54LFCost per parapet beam F to F4, G, H, J, K to K2, L & M 12714.58LFCost per parapet beam E 12536.27PcCost per beam type D material & labor 12544.08PcCost per beam type C material & labor 12552.86PcCost per beam type B1, B2 material & labor 12595.97PcCost per beam type A material & labor See PAGE $UNITDESCRIPTION 629.54LFCost per parapet beam F to F4, G, H, J, K to K2, L & M 6214.58LFCost per parapet beam E 6036.27PcCost per beam type D material & labor 6044.08PcCost per beam type C material & labor 6052.86PcCost per beam type B1, B2 material & labor 6095.97PcCost per beam type A material & labor See PAGE $UNITDESCRIPTION
  63. 63. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106563 Using the information from pages 90 to 127 a cost of the Case Study shell is shown below. Remember this cost is an average assuming construction of 40 units. More or fewer units will affect the results; generally the cost will be lower if more than 40 units are built, and will be greater when fewer than 40 units are built. The cost is DIRECT COST with no contractor’s mark up, workers compensation, overhead, taxes, or whatever can be added for the working conditions, location, weather, etc. COST OF SHELL of the Case Study CRH Phase Q Unit DESCRIPTION UNITARY PRICE Page TOTAL FOUNDATION 2,870.00 SF Average cost 3.68 29 10,561.60 WALLS 131.00 LF Type A - 16" drywall/stucco 65.71 42 8,608.01 42.50 LF Type B - 6" exposed/stucco 51.51 43 2,189.18 24.00 LF Type B - 6" exposed/drywall 49.75 44 1,194.00 6.00 LF Type B - 6" stucco/drywall 56.15 43 336.90 55.00 LF Type B - 6" drywall/drywall 54.39 44 2,991.45 ROOF 2,870.00 SF Concrete, insulation, roofing and drywall 16.70 57 47,929.00 BEAMS 1.00 piece Type A - 6"x46" 95.97 60 95.97 1.00 piece Type B1 - 6"x46" 52.86 60 52.86 1.00 piece Type B1 - 6"x46" 52.86 60 52.86 1.00 piece Type C - 6"x32" 44.08 60 44.08 3.00 piece Type D - 6"x36" 36.27 60 108.81 32.50 LF Type E, E1 - parapet 6"x32" 14.58 62 473.85 250.50 LF Type F to M = parapet 6"x26" 9.54 62 2,389.77 Probable cost of the shell of the Case Study CRH if 40 units are build 77,028.34$ The Direct Cost of a CRH shell per Square Foot 19.90$ To work in a budget use the square foot cost of the sell by the build area and add the elements as windows, plumbing, electrical, finishing, etc. also add contractor mark up and building permit, and play with such numbers to reach the desired budget amount.
  64. 64. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106564 SAMPLES BASED ON THE CASE STUDY The following pages illustrate how using the set of forms from one house, Model 1, it is possible to reuse the set in different configurations to produce many different designs, Models 2, 3, to Model x. This flexibility is a plus for developers.
  65. 65. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106565 FLOOR PLAN OF THE CASE STUDY HOUSE
  66. 66. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106566 FLOOR PLAN MODIFIED # 1 3 car garage, laundry, mechanical, foyer, 3 bedrooms, bath, master bedroom, master bath, walk-in closet, kitchen, dining, living, and terrace.
  67. 67. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106567 MAIN ENTRY DETAIL From floor plan modified # 1
  68. 68. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106568 FROM FLOOR PLAN MODIFIED #1 Entry, foyer, living, dining, kitchen terrace.
  69. 69. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106569 BREAKFAST COUNTER, DINING Floor plan modified # 1.
  70. 70. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106570 FLOOR PLAN MODIFIED #1 Terrace , note the corner window and the receded windows and doors. Also the precast sill and headers, features for the CRH innovative construction system.
  71. 71. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106571 FROM FLOOR PLAN MODIFIED #1 Master bedroom, master bath, walk-in closet, the thickness of the exterior walls result of the rigid insulation embedded: characteristic of the Concrete Rib House Construction System.
  72. 72. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106572 FLOOR PLAN MODIFIED #1 Bathroom detail
  73. 73. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106573 FLOOR PLAN MODIFIED # 2 Shows the living area similar to the Modified 1, but with 2 car garage and the main entry facing the street, details of Modified 1 applied to this, plus the three following sketches.
  74. 74. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106574 Kitchen detail at modified 1 and 2, showing the pantry area and the serving the breakfast counter.
  75. 75. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106575 Kitchen detail view #2 at modified 1 and 2, showing the pantry area and the serving the breakfast counter.
  76. 76. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106576 Laundry room detail at modified 1 and 2, also shows the tub at bath and the guest closet at Foyer.
  77. 77. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106577 MODIFIED 3. 4 bedrooms, 2 car, with loggia facing the street the living area is similar as Modified 1 and 2. Details of living area applied to all of them.
  78. 78. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106578 OPTION 4 – 3 bedrooms 2 car garage Dimensions similar at the previous shown, only one bedroom less and garage shorter by three feet, has a nice loggia facing the street.
  79. 79. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106579 FLEXIBILITY The reuse of formwork, generally up to 40 uses for plywood, can change the arrangement of the spaces providing many different models of houses to give many options to buyers. The design is not limited to one story. The reuse of the formwork can be applied to two or more stories. Formwork can be done to create any texture or detail as moldings, trims or any gingerbread as desired or required by architectural style or innovation in design, fiberglass or similar materials can achieve the negative shape to mold the concrete. This process can produce very elaborated forms by the time of pouring the concrete with not expensive labor involved. Design by modules can make the reuse of the formwork with out having to build 40 units to make effective the system.
  80. 80. FLOOD HAZARD AREAS The floating mezzanine solution This design, for people living in flood hazard zones, enables them to stay safely in their homes, retaining belongings, pets, etc., and avoiding the need to be evacuated. The key is a floating upper floor, with all the basics for living, including drinking water from a built-in reservoir collecting rain water with a purifier device, will be provided to survive the days of isolation. Note: water lines contamination is probable under flooding conditions.
  81. 81. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106581 A water reservoir is the core providing service to the fixtures directly by straight connections in the first floor and collapsible connections to the floating area. In normal conditions services are provided by the local utilities. In emergency conditions water can be obtained by rain, and purified for drinking, bathing and cooking Foundation built by conventional methods. Tank reinforced concrete poured in place.
  82. 82. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106582 The ground level has laundry room, guest closet, powder room, full kitchen with breakfast counter, and spacious area for living dining and family activities. The sketch is shown with partial walls for clarity.
  83. 83. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106583 This image shows the core reservoir and the mezzanine with exterior walls before installing the drywall to show the rigid insulation embedded in concrete. Walls in the first level omitted.
  84. 84. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106584 This sketch shows the 3 basic elements: foundation, reservoir tank and the floating mezzanine.
  85. 85. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106585 Here the mezzanine is shown floating per Archimedes principle. The volume of the rigid foam is calculated to carry the loads of the mezzanine deck.
  86. 86. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106586 Ground level showing the foyer with the stairs and at rear the 2 car garage. The beams on columns support the mezzanine, which remains in place by gravity.
  87. 87. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106587 Detail of the powder room with access to the laundry room, no doors shown for clarity, no drywall in place to show the rigid insulation in the walls.
  88. 88. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106588 This image shows the full kitchen in the ground floor. Note all fixtures requiring water are against the reservoir tank wall, this saving on plumbing tubing costs.
  89. 89. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106589 Foyer detail showing stairs
  90. 90. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106590 Mezzanine floor plan showing the emergency kitchen. The wall nearest the reservoir is framed to allow space for free movement of the collapsible hoses when flooding occurs. This keeps the water running in the faucets of the fixtures with no interruption. Roofs of the garage and foyer shown. Drywall panels are not shown to give idea of how exterior walls are insulated. Master bedroom plus two standard bedrooms shown.
  91. 91. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106591 Emergency food storage is contained in the refrigerator attached to the wall of the floating Mezzanine by a mechanism which allows movement to be reach under flooding conditions.
  92. 92. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106592 Detail of bathroom on mezzanine, note the separation between framed wall and concrete tank wall of the reservoir. This allows movement of the hoses connecting to the water supply during flooding conditions.
  93. 93. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106593 The illustration at right shows the construction of the mezzanine deck, using metallic trusses holding rigid foam blocks and supporting the flooring plus the partition walls, furniture and live loads. The volume of the foam is calculated to float with all the loads in the flooding. The corners of the mezzanine have rolling devices to allow the vertical movement. At left a detail of one connection by collapsible hoses in between the reservoir tank and a faucet, the collapsible hose lets free vertical movement keeping the service uninterrupted. Water in normal conditions services are provided by the local utilities. In emergency conditions water can be obtained by rain, and purified for drinking, bathing and cooking.
  94. 94. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106594 . The use of solar panels is another feature to allow the people in the house to have power for the light and kitchen fixtures in emergency situations.
  95. 95. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106595 Street view of the proposal for a Concrete Rib House with floating mezzanine. Using this design concept can produce infinite solutions, even one story houses with the flooring on a structure like the mezzanine shown on page 94.
  96. 96. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106596 LIVE and WORK The dependence on oil has created the need to seek other sources of energy. Meanwhile it is wiser to reduce our use of petroleum products such as gasoline. Driving to work is eliminated when all you have to do is go downstairs to be at the work place. Live and Work condo units can be easily produced because the CRH system is ideal for the mass production required by such developments. Photovoltaic elements will serve besides to “fill the tank” of the automobiles likely to be soon in available in the market for owning one.
  97. 97. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106597 The units are similar the differences are only in the walls types 6 in thick walls shared by two contiguous units. In the rendered ground floor shows an end unit, the shared wall is labeled, as well the use of the areas/ This sample shows a possible musical store 6 in common wall Garage, storing and laundry Stairs to mezzanine 2 double doors entries to the store Store front windows
  98. 98. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106598 Detail corner showing one entry double door, the cahier station, merchandise for sale, the top of the stair. The interior face of the walls are ready to be gyp board walled, except one in the garage/store area to show the appearance after dry wall applied – the CRH system looks like the traditional framed walls - Top of door to the powder room for clients convenience.
  99. 99. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 106599 This is an areal view of the ground floor with the concrete slab mezzanine in place and shows the stair in its stairs well
  100. 100. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065100 For clarity first the rendering shows the two bedrooms, the two closets and the bathroom with doors to each bedroom also the stair going to the roof garden is shown At right a detail of the shared bathroom of the bedrooms with the door of bedroom one shown., some walls removed for clarity.
  101. 101. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065101 At right detail of the living room, the kitchen area with hard floor for the service work, also in the bottom right of the sketch partial of dining area in the foreground the stair going to the roof garden are shown. The low walls and windows to complete the façade are shown with no drywall board applied to show the encased rigid insulation characteristic of the CRH system. This two views are showing the dining area, the one at left has the door of bedroom one and the start of the stair, the view at right shows the guardrail wall facing the store area. The opening of the living and dining areas to the store makes convenient for the store owner to rest pleasantly when are not costumers in the store.
  102. 102. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065102 At left an overview of the slanting roof covered with solar panels to provide for electric power for the condo needs and to “fill the tank” of the future electric car. Also the green area for landscaping or growing vegetables to have a fresh salad when wished. A concrete build in spa to enjoy the sky view in a relaxing worm water. A terrace area to have table and sitting to have snacks and a cup of coffee. At left a detail of the comfort area terrace and spa, the door to the stairs well is shown at right of the picture
  103. 103. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065103 Some additions such as stair lifts, grab bars and wider doors, can be used to accommodate handicapped persons to occupy Live and Work units.
  104. 104. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065104 Some shots of the vending area to convey information how an unit can display for business, which can be any use: ice cream stores, artist galleries, bicycle shop, beauty saloon, law or dentist, real estate or any other office. You name what you need is. Live up, work down and relax at the top….
  105. 105. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065105 Potpourri of samples The design freedom of the CRH system is illustrated on the following pages. Architectural styles using arches, protruding elements such as moldings, brick walls, half timbered, gable roofs, mansard style, frieze, architrave, or other decorative elements --you name them. All can be incorporated at reasonable cost simultaneously with the pouring of concrete because decorative elements are in the formwork preparation.
  106. 106. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065106 A two story dwelling of a modified Moroccan style. The protruding decorative elements are produced thanks to special accessories added to the forms. This house was built in Cancun where hurricanes are frequent and strong . The house shown at the right was built in the City of Mexico, where earthquakes are the main concern. There were 100 units built with 2 sets of forms. At left a detail of the balcony. The project included two other architectural styles for a total of 300 units as shown on the next page.
  107. 107. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065107 In the same development of the house on the previous page, another 100 units built using 2 sets of forms at a pace of 2 daily. In Mexico the French style is highly appreciated. Eugenio Aburto was able to provide it, even though these houses were meant for an affordable market. By using the accessories in the forms the moldings, the shutters, and the mansard roofing were all created at the time of pouring. This gave the homes the desired character and made them a good buy. Below is a detail of the balcony; the spindles are precast elements using a light weight concrete..
  108. 108. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065108 This is a romantic Spanish style, reminiscent of the balcony on the first floor where the Spanish used to flirt with the young lady living in the house. The sales of this style were terrific.
  109. 109. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065109 The poured-in-place concrete system developed by me has no limitations. Here a multistory building is shown: the Hotel Komvaser built in Cancun. The space under the left wing of rooms is a big cistern to serve the water needs for operation uninterrupted at any time. Hurricanes sometimes shut down the Cancun water lines, but with the cistern there was no water shortage. The picture at right shows a vaulted roof built with a combination of steel trusses and colored waterproof plaster. Note the use of arches and columns capitals, all done by the special forming design.
  110. 110. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065110 As previously stated, the use of specially designed forms is the way of obtaining complicated architectural elements with poured concrete. One of the many properties of concrete is taking the shape of the mold. For repetitive shapes, the way to build at low cost is by inserting liners or decorative elements in the forms. The vaulted cantilevered roof shown in the picture below was built using one fiberglass form for all the roof. An embossed pattern made the underside of the vault look like the traditional Spanish terracotta blocks called “ladrillos.” A final coat of color made the appearance real. The cost was minimal. The picture at left shows the character achieved by the use of special forming in the concrete work. FINISHED VAULTED ROOF IN RED: THE FIBER GLASS ROOF FORM
  111. 111. MASTER PLANS An important document to show the placement of the structures to be build with the CRH system is the Site Plan. My concern as an architect is to create an environment where the residents have access to commercial and professional facilities, entertainment and good restaurants. Land uses should be close enough to allow walking or bicycling. Analysis of the site and contour lines includes slope degree, orientation, natural drainage, and existing vegetation. This is the basis for locating structures and services such as waste management, water recycling and trash disposal. The goal is to keep the habitat natural and place the buildings to facilitate energy conservation for low maintenance and durability.
  112. 112. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065112
  113. 113. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065113
  114. 114. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065114
  115. 115. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065115
  116. 116. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065116 This page intentionally left blank
  117. 117. RAMMED EARTH HOUSES HOW THE CONCRETE RIB HOUSE WAS BORN In Calpulalpan, Tlaxcala Mexican Republic For Banco de Credito Ejidal Under Management of Professor Francisco Hernandez y Hernandez
  118. 118. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065118 Professor Francisco Hernandez y Hernandez, General Manager of the Banco de Credito Ejidal, give me a commission: build houses for the poorest people in Mexico, the farmers. It was a big challenge, with no budget for labor and little money for construction materials. I took the challenge and found the solution. • For labor, I used the future owners. • For construction material, I used dirt. THE CONSTRUCTION SITE AND CONSTRUCTION MATERIAL SOURCE
  119. 119. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065119 I made an agreement with the farmers who wanted to have a house: they needed to provide the labor from beginning to end of the houses. Nobody would know which house will belong to which family. At the end of construction a drawing would be used to assign each house to a family. Everybody in the family was involved in construction. Women were in charge of bringing the food at the site and cheerleading the men. GRADING, SEWER LINES, ROUGH PLUMBING, TO START. STOCK PILING DIRT TO USE LATER
  120. 120. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065120 After concrete foundation and slab, rocks were embedded in the concrete to serve as hold downs for the walls. The Farmers Bank (Banco Ejidal) sponsoring the project was paying for the cement, but sand, gravel, and rocks were collected by the farmers. They were lucky because a little creek with abundant rock was close. ROCK DOWELS DETAIL In the photo at right a stock of dirt is visible in the foreground. Behind the farmers a wall can be seen. A Bank truck is delivering cement. Farmers build a shade structure at the right to have “tacos” with the family. Even the children come to discuss the construction advance and dream of having their own bedroom and a bathroom with out going outside. It was very rewarding doing this project.
  121. 121. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065121 Panoramic view of metal forms strong enough to accept the impact of the compactor when earth is rammed. Behind the form are walls from which the forms were removed. A village cornfield is growing in the rear.
  122. 122. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065122 This is a detail showing at the rear some forms in place, and a portion of wall where is an opening for a window. Note the lower part of the wall which has masonry concrete to prevent damage from rain. While observing this process I started to think about using concrete poured in forms in a similar way. Thus, 40 years ago the ides for the Concrete Rib House began. This system of rammed earth construction give dwellings to 30 families in the rural area of Calpulalpan, a village in the State of Tlaxcala, Mexico. As a result of their experience in teamwork, after moving into the houses, the farmers pooled resources and bought agricultural machinery and quickly became prosperous.
  123. 123. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065123 ONE OF THE FINISHED HOUSES HAS THE OWNER ENJOYING LIFE. THE FINISHING WAS USING AN EMULSION OF WATER AND LIME SPRAYED AGAINST THE WALLS, VYNIL PAINT AS ACCENT (THE BANK PROVIDED FOR THE PAINT)
  124. 124. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065124 ANOTHER HOUSE, DIFFERENT FLOOR PLAN
  125. 125. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065125 The walls have 2 coats of lime as finish, the color accents done with vinyl paint. ONE BEDROOM OF THE THREE
  126. 126. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065126 Dining area with furniture designed by me and built by the farmers. The finish: crude oil dissolved in gasoline. Joists concrete and metal U shape exterior reinforcement roof expanded metal lath with cement plaster (see next pg)
  127. 127. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065127 I designed innovative joists built with the steel reinforcement in the exterior, like crabs. U-shaped bent steel has connectors welded in the interior bottom. I also used this design for a prefabricated school in Cuernavaca for the Committee to Build Schools. When filled with concrete it works as a beam; the tension stress is resisted by the exposed steel. It avoids the destruction of trees for lumber, and makes the house fire resistant, at a low cost. Some of the 30 houses built with Rammed Earth, shown during construction
  128. 128. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065128 After building all the houses with rammed earth, I could not stop thinking about taking a shot at building the walls with poured concrete. The results are shown at left, just after taking the metal forms off the walls. Note the header with exterior metal reinforcement, similar to the joists described on the previous page. The picture below shows the structure of a house built in the 1960s with poured-in-place concrete. A similar system was used by the Romans around 2,000 years ago. It is interesting to note that the Anasazi, builders of Chaco Canyon, New Mexico, used a similar system with stone walls as forming and mud as bonding for a sort of masonry. Their structures, built around 700 ago, stand to awe tourists today. Concrete walls experiment
  129. 129. CIUDAD AZTECA 7,500 houses built In 15 months 8 schools, shopping center, offices Ciudad Azteca was a development managed by an aggressive young business man: Mr. Norberto Kanner, who create a real city for workers. I had the opportunity of building with my system of poured-in-place concrete. My effective building system contributed to the success of Mr Kanner’s Norka development project.
  130. 130. CONCRETE RIB HOUSE - Eugenio Aburto, AIA - 760 610 1065130 This experience was managing the construction of 7,500 houses using my poured-in-place masonry system. The houses needed to be affordable, and the system accomplished this because I used the abundant local stone for 30% of the volume of the concrete walls. This resulted in huge savings on materials cost. The system is very effective if modified according to the conditions of materials and labor availability. In this job wood forms were used; 25 sets of forms delivered 25 houses every day to buyers. It was gratifying to me to see the expression of happiness on the faces of the buyers moving into their new homes, with the children choosing their bedrooms and placing their toys with care. Above, the photo shows the foundation process, with a finished house in the background. The photo at right shows several houses in process, some ready for the roof, other for the finishing touches. Ciudad Azteca mass produced housing for workers

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