The CorTek Core Construction System


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The CorTek Core Construction System is revolutionizing the way stair and elevator cores are being built.

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The CorTek Core Construction System

  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]
  2. 2. Product Overview <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>
  3. 3. Features: <ul><li>Unequalled speed of construction </li></ul><ul><li>High tolerance, all-steel construction. </li></ul><ul><li>Minimal field work. </li></ul><ul><li>Modules are load-bearing before concrete. </li></ul><ul><li>Cost Competitive. </li></ul>
  4. 4. 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
  5. 5. 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>
  6. 6. 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>
  7. 9. Competition <ul><li>Price for a typical stair core story with 2 flights of stairs, 6 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: $33,192/Story* </li></ul></ul><ul><ul><li>Pre-Cast: $44,529/Story* </li></ul></ul><ul><ul><li>Masonry: $30,754* </li></ul></ul><ul><li>CorTek: $33,514 @ $14,380/Mod </li></ul><ul><li>*Based on independent estimate provided by Will Hopkins of the Icon Group </li></ul>
  8. 14. 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. 15. Pre-installed stairs
  10. 16. Railings shipped ready to bolt on
  11. 17. Optional Stair & Railing Designs Pan treads Checkered plate treads Grating treads Parallel tube rails Picket rails Wire mesh rails
  12. 18. Parallel Tube Railing
  13. 19. Mesh Railing
  14. 20. Picket Railing
  15. 21. Elevator Core
  16. 22. Safety—A Job Site’s Most Important Consideration Moving formwork to a controlled factory environment eliminates many dangerous field operations
  17. 26. Where’s the rest of the structure?
  18. 27. Concurrent Framing Framing does not wait for formwork—saving weeks to months on project schedule
  19. 28. 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><ul><li>* </li></ul><ul><li>Based on independent estimate provided by the Icon Group September 2008 </li></ul>
  20. 29. 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>
  21. 30. 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>
  22. 31. 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>
  23. 32. Quality <ul><li>Parametric modeling essentially eliminates detailing mistakes. </li></ul><ul><li>Controlled manufacturing environment. </li></ul><ul><li>Multiple failsafing operations. </li></ul><ul><li>Rigid Quality Assurance Program </li></ul><ul><li>Jigs, Fixtures and Design provide extraordinarily tight tolerances </li></ul>
  24. 33. Job Site Efficiency >Enabling Lean Construction <ul><li>Drastic reduction of field labor. </li></ul><ul><li>Just In Time Delivery minimizes site congestion. </li></ul><ul><li>Core construction can be concurrent with frame construction. </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>
  25. 34. Installation Sequence and Details
  26. 35. Foundation Embeds
  27. 36. Base Module
  28. 37. Core Leveling Detail
  29. 39. Install Vertical Reinforcement
  30. 40. Vertical Reinforcement In Place
  31. 41. Base Connection Weld
  32. 42. Going Vertical
  33. 43. Module Alignment Detail
  34. 44. Non-contact Vertical Rebar Splices
  35. 45. Vertical steel attached to each module
  36. 46. Vertical Bar Alignment Guides
  37. 47. Beam Attachments and Ledger Angle Pre-installed
  38. 48. Contractor drops in steel beam and bolts it together.
  39. 49. 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>
  40. 50. Optional pre-installed hat channel accommodates exceptionally thin finish face
  41. 51. Hat-channel can be field shot directly on to walls and finished conventionally
  42. 52. Optional pre-installed masonry tie backs accelerate masonry field work
  43. 53. Exposed metal interior is an aesthetic alternate to concrete
  44. 54. 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>
  45. 55. 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>
  46. 56. Questions & Comments
  47. 57.