Core Construction System Presented By: Aaron Rutledge CorTek, Inc. 999 Van Buren Ave. Loveland, CO 80537 Phone: 970-663-22...
Service Cores <ul><li>2+ hour fire rated egress shaft required for buildings over 2 stories </li></ul><ul><li>Concrete a c...
Problematic for Construction <ul><li>Cores must be in place before surrounding framing can be installed </li></ul><ul><li>...
A better way… <ul><li>Free up site schedule and resources by modularizing core off site in a specialized factory set up fo...
The CorTek Core Construction System <ul><li>Stay-in-place modular form system for concrete core structures </li></ul><ul><...
 
Features: <ul><li>High tolerance, all-steel construction. </li></ul><ul><li>Modules are load-bearing before concrete. </li...
A Load Bearing Form <ul><li>Vertical and horizontal structural elements support construction loads and allow form to be mo...
Optional wall thickness Effective thickness: 8”  10” 12” Actual thickness: 10” 12” 14” Because of the much higher toleranc...
Pre-installed stairs
Railings shipped ready to bolt on
Optional Stair & Railing Designs Pan treads Checkered plate treads Grating treads Parallel tube rails Picket rails Wire me...
Beam Attachments and Ledger Angle Pre-installed
Benefits: <ul><li>Immediate presence of stairs allows trades early and safe access to structure </li></ul><ul><li>Eliminat...
Job Site Efficiency >Enabling Lean Construction <ul><li>Reduction in on site “Muda” (waste): Transportation, Inventory, Mo...
Safety—A Job Site’s Most Important Consideration Moving formwork to a controlled factory environment eliminates many dange...
 
 
Where’s the rest of the structure?
Concurrent Framing Framing does not wait for formwork—saving weeks to months on project schedule
Quality <ul><li>Parametric modeling essentially eliminates detailing mistakes. </li></ul><ul><li>Controlled manufacturing ...
Green Benefits <ul><li>No wood forms and resulting site waste </li></ul><ul><li>No form oil </li></ul><ul><li>Greatly mini...
Target Projects <ul><ul><li>MULTI-STORY BUILDINGS OF ALL TYPES . . . . . .   </li></ul></ul><ul><ul><li>Structural steel f...
Attachment can be made to all floor framing materials
 
 
 
 
 
 
 
Design <ul><li>Direct Replacement for Conventional Cast-In-Place—no extra work required for Architect or Structural Engine...
Complete Detailed  Shop Drawings <ul><li>Stair and Railing Layouts </li></ul><ul><li>Rebar details </li></ul><ul><li>Frami...
Competition <ul><li>Price for a typical stair core story with 2 flights of stairs, 8 embeds and ledger angle at floor peri...
Installation Sequence and Details
Foundation Weld Embeds Option
Foundation Mechanical Splice Option
Base Module
Core Leveling Detail
 
Install Vertical Reinforcement
Vertical Reinforcement In Place
Base Connection Weld
Going Vertical
Module Alignment Detail
Non-contact Vertical Rebar Splices
Non-contact Vertical Splice Bars
Vertical Bar Alignment Guides
Vertical steel attached to each module
Contractor drops in steel beam and bolts it together.
Concrete Placing Form designed for approximately 6 feet/hour of concrete Up to 18 foot lifts can be poured at a time.  Rem...
Interior and Exterior finishes <ul><li>Exterior </li></ul><ul><li>Exposed Metal </li></ul><ul><li>Drywall </li></ul><ul><l...
Optional pre-installed hat channel accommodates exceptionally thin finish face
Hat-channel can be field shot directly on to walls and finished conventionally
Optional pre-installed masonry tie backs accelerate masonry field work
Exposed metal interior is an aesthetic alternate to concrete
Electrical conduit can be routed through walls and JBs flush mounted
Difficult/slow/error-prone field work brought into a controlled factory environment set up for efficiency and quality. Com...
Conclusion <ul><li>Eliminates the need for scaffolding and forms  </li></ul><ul><li>Reduces Critical Path construction tim...
Questions & Comments
www.corteksystems.com
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CorTek General Overview - 6-2010

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CorTek General Overview - 6-2010

  1. 1. Core Construction System Presented By: Aaron Rutledge CorTek, Inc. 999 Van Buren Ave. Loveland, CO 80537 Phone: 970-663-2222 Fax: 970-663-9969 [email_address] www.corteksystems.com
  2. 2. Service Cores <ul><li>2+ hour fire rated egress shaft required for buildings over 2 stories </li></ul><ul><li>Concrete a cost effective material to create this fire separation and resulting vertical structure </li></ul><ul><li>Monolithic concrete structure naturally becomes integral part of buildings lateral system </li></ul>
  3. 3. Problematic for Construction <ul><li>Cores must be in place before surrounding framing can be installed </li></ul><ul><li>Slow to construct with highly unpredictable schedules </li></ul><ul><li>Quality issues frequently arise </li></ul><ul><li>Dangerous </li></ul>“ Like rolling the dice on every project”
  4. 4. A better way… <ul><li>Free up site schedule and resources by modularizing core off site in a specialized factory set up for quality and efficiency </li></ul>
  5. 5. The CorTek Core Construction System <ul><li>Stay-in-place modular form system for concrete core structures </li></ul><ul><li>Factory built modules stack like building blocks. </li></ul><ul><li>Custom-built to the specific requirements of each project. </li></ul>
  6. 7. Features: <ul><li>High tolerance, all-steel construction. </li></ul><ul><li>Modules are load-bearing before concrete. </li></ul><ul><li>Pre-installed: </li></ul><ul><ul><li>Horizontal Rebar </li></ul></ul><ul><ul><li>Stairs </li></ul></ul><ul><ul><li>Embed Plates and Shear Tabs </li></ul></ul><ul><ul><li>Ledger Angle </li></ul></ul><ul><ul><li>Elevator Divider Beams </li></ul></ul><ul><ul><li>Optional Finishing Connectors (hat channel, masonry ties) </li></ul></ul>
  7. 8. A Load Bearing Form <ul><li>Vertical and horizontal structural elements support construction loads and allow form to be modularized. </li></ul><ul><li>Structural skeleton allows for support of stairs, landings, structural framing, scaffolding, personnel, and other construction loads </li></ul><ul><li>Form does not require stripping </li></ul><ul><li>Finished wall structurally equal to a conventional 8”-12” CIP concrete wall </li></ul>
  8. 9. Optional wall thickness Effective thickness: 8” 10” 12” Actual thickness: 10” 12” 14” Because of the much higher tolerances of the CorTek System, the resulting finished wall assembly can be thinner than conventional methods for many applications.
  9. 10. Pre-installed stairs
  10. 11. Railings shipped ready to bolt on
  11. 12. Optional Stair & Railing Designs Pan treads Checkered plate treads Grating treads Parallel tube rails Picket rails Wire mesh rails
  12. 13. Beam Attachments and Ledger Angle Pre-installed
  13. 14. Benefits: <ul><li>Immediate presence of stairs allows trades early and safe access to structure </li></ul><ul><li>Elimination of many dangerous field operations </li></ul><ul><li>Can eliminate the need for scaffolding </li></ul><ul><li>Reduction of poor fit-up and coordination problems among trades </li></ul><ul><li>Cores generally part of the critical path—the CorTek system cannot be beat for speed--reducing overall schedule by weeks or months on most projects. </li></ul>
  14. 15. Job Site Efficiency >Enabling Lean Construction <ul><li>Reduction in on site “Muda” (waste): Transportation, Inventory, Motion, Waiting, Overproduction, Over Processing, Defects </li></ul><ul><li>Drastic reduction of field labor. </li></ul><ul><li>Just In Time Delivery minimizes site congestion. </li></ul><ul><li>Re-work from misplaced embeds, doors, bulging concrete and leaning or twisted towers eliminated </li></ul><ul><li>Several cores can be constructed simultaneously </li></ul><ul><li>Job site freed from extensive lay down requirements of CIP form boards , lumber, and rebar </li></ul>
  15. 16. Safety—A Job Site’s Most Important Consideration Moving formwork to a controlled factory environment eliminates many dangerous field operations
  16. 19. Where’s the rest of the structure?
  17. 20. Concurrent Framing Framing does not wait for formwork—saving weeks to months on project schedule
  18. 21. Quality <ul><li>Parametric modeling essentially eliminates detailing mistakes. </li></ul><ul><li>Controlled manufacturing environment. </li></ul><ul><li>Multiple fail safing operations. </li></ul><ul><li>Rigid Quality Assurance Program </li></ul><ul><li>Jigs, Fixtures and Design provide extraordinarily tight tolerances </li></ul>
  19. 22. Green Benefits <ul><li>No wood forms and resulting site waste </li></ul><ul><li>No form oil </li></ul><ul><li>Greatly minimizes site labor installation </li></ul><ul><li>Recycled and recyclable steel used in construction. </li></ul><ul><li>Perfect delivery method for high volume fly ash concrete </li></ul>
  20. 23. Target Projects <ul><ul><li>MULTI-STORY BUILDINGS OF ALL TYPES . . . . . . </li></ul></ul><ul><ul><li>Structural steel framed buildings. </li></ul></ul><ul><ul><li>Wood framed buildings. </li></ul></ul><ul><ul><li>Concrete framed buildings. </li></ul></ul><ul><ul><li>Industrial Structures. </li></ul></ul><ul><ul><li>Current production equipment tooled for 8” - 12” thick walls to target 3-12 story buildings. </li></ul></ul>
  21. 24. Attachment can be made to all floor framing materials
  22. 32. Design <ul><li>Direct Replacement for Conventional Cast-In-Place—no extra work required for Architect or Structural Engineer. </li></ul><ul><li>Conventional concrete rebar configurations. </li></ul><ul><li>No proprietary design methods or material strengths. </li></ul><ul><li>No requirement for special code approvals. </li></ul>
  23. 33. Complete Detailed Shop Drawings <ul><li>Stair and Railing Layouts </li></ul><ul><li>Rebar details </li></ul><ul><li>Framing and Floor Connections </li></ul><ul><li>3D Revit model available for each project. </li></ul>
  24. 34. Competition <ul><li>Price for a typical stair core story with 2 flights of stairs, 8 embeds and ledger angle at floor perimeter. Price includes placed concrete and all installation costs </li></ul><ul><li>Conventional Methods </li></ul><ul><ul><li>Cast-In-Place: $38,574/Story* </li></ul></ul><ul><ul><li>Pre-Cast: $49,219/Story* </li></ul></ul><ul><ul><li>Masonry: $34,346/Story* </li></ul></ul><ul><li>CorTek: $36,786 </li></ul>
  25. 35. Installation Sequence and Details
  26. 36. Foundation Weld Embeds Option
  27. 37. Foundation Mechanical Splice Option
  28. 38. Base Module
  29. 39. Core Leveling Detail
  30. 41. Install Vertical Reinforcement
  31. 42. Vertical Reinforcement In Place
  32. 43. Base Connection Weld
  33. 44. Going Vertical
  34. 45. Module Alignment Detail
  35. 46. Non-contact Vertical Rebar Splices
  36. 47. Non-contact Vertical Splice Bars
  37. 48. Vertical Bar Alignment Guides
  38. 49. Vertical steel attached to each module
  39. 50. Contractor drops in steel beam and bolts it together.
  40. 51. Concrete Placing Form designed for approximately 6 feet/hour of concrete Up to 18 foot lifts can be poured at a time. Removable weep hole plugs aid placing concrete to correct pour heights Web bar spacing allows for easy penetration of pumper tip hose and vibrator
  41. 52. Interior and Exterior finishes <ul><li>Exterior </li></ul><ul><li>Exposed Metal </li></ul><ul><li>Drywall </li></ul><ul><li>Masonry </li></ul><ul><li>Stucco </li></ul><ul><li>Thin set brick </li></ul><ul><li>Interior </li></ul><ul><li>Exposed Metal </li></ul><ul><li>Drywall </li></ul><ul><li>Hardboard Panel </li></ul><ul><li>Tile </li></ul>
  42. 53. Optional pre-installed hat channel accommodates exceptionally thin finish face
  43. 54. Hat-channel can be field shot directly on to walls and finished conventionally
  44. 55. Optional pre-installed masonry tie backs accelerate masonry field work
  45. 56. Exposed metal interior is an aesthetic alternate to concrete
  46. 57. Electrical conduit can be routed through walls and JBs flush mounted
  47. 58. Difficult/slow/error-prone field work brought into a controlled factory environment set up for efficiency and quality. Computer aided parametric design used for rapid parametric structural and architectural design. Decreased site congestion increases project flow. Freeing site schedule from concrete core schedule increases “battle plan” options. An Advanced Building System
  48. 59. Conclusion <ul><li>Eliminates the need for scaffolding and forms </li></ul><ul><li>Reduces Critical Path construction time associated with building cores </li></ul><ul><li>Pre-installed stairs </li></ul><ul><li>Pre-installed floor and beam connections </li></ul><ul><li>Modules do not require stripping. </li></ul><ul><li>CorTek cores are individually designed for each job in a controlled environment </li></ul><ul><li>Simultaneous construction with floor framing </li></ul><ul><li>Structurally equivalent to 8”-12” CIP concrete shear wall. </li></ul><ul><li>Cost effective </li></ul>
  49. 60. Questions & Comments
  50. 61. www.corteksystems.com

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