purchase standard plan or hire architect & engineer to provide permit and working drawing set
foundation/stem walls of reinforced concrete/masonry
exterior walls of reinforced concrete/masonry
intermediate floors of reinforced poured concrete
interior wood/light gauge steel framing
furring to interior face of outside walls for services & insulation
shingled wood truss roof
exterior stucco finish
Shell Construction Comparison
This is a step-by-step comparison of the and standard Reinforced Concrete & Masonry construction.
As a reference, we use : a 1 story, 1650 sq.ft. plan, with the goal of creating a Dried-In Building Shell, complying with the IBC (International Building Code).
Foundation: Reinforced Concrete Strip Footing
am‑cor System
Concrete / Masonry
Labor Savings: approximately 25% Material Savings: approximately 15%
step
task
material
1
line out
string & batter boards
2
prepare & set reinforcing
reinforcing bars & tie wire
3
cast footings
poured concrete (smooth & level)
step
task
material
1
line out
string & batter boards
2
prepare & set reinforcing
reinforcing bars & tie wire
3
prepare & bend hooked bars
reinforcing bars
4
set hooked bars
tie wire
5
cast footings
poured concrete (smooth & level)
Foundation: Stem/Basement Wall of (a) Reinforced Concrete, or (b) Masonry
am‑cor System
Concrete / Masonry
Labor Savings: approximately 50% Material Savings: approximately 40% Notes: all openings preframed in the factory; all design & engineering preapproved; walls ready for services, insulation & interior surfaces; no scraps, waste, or mess
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor wall panels
fasteners included
3
apply amcorite structural ferrocement coat
amcorite, Portland cement, sand, water
4
waterproof subgrade wall
standard foundation waterproofing
step
task
material
1
consult drawings
architectural or standard plan
2
measure & form openings
treated jambs, heads & sills
3
custom build formwork
treated wood & plywood
4
set concrete forms
forms, spacers, ties
5
prepare & set reinforcing
reinforcing bars & tie wire
6a
cast concrete
poured concrete
6b
lay masonry
unit masonry
7a
remove formwork
labor & time
7b
grout masonry
masonry grout mix
8a
rub concrete
cement & water
8b
parge blockwork
cement & sand parging mix
9
waterproof subgrade wall
standard foundation waterproofing
10
interior partitions & furring
treated wood
Floor: Slab on Grade/Basement Floor Slab
am‑cor System
Concrete / Masonry
Labor Savings: approximately 20% Material Savings: approximately 10% Notes: no formwork construction & material; no waste
step
task
material
1
prepare slab base
gravel, slab insulation
2
groundworks (plumbing)
plumbing supplies
3
prepare & set reinforcing
reinforcing bars & tie wire
4
place vapor seal
plastic sheeting
5
cast floor slab
poured concrete
step
task
material
1
prepare slab base
gravel, slab insulation
2
groundworks (plumbing)
plumbing supplies
3
prepare & place formwork
wooden forms, spacers, ties
4
prepare & set reinforcing
reinforcing bars & tie wire
5
place vapor seal
plastic sheeting
6
cast floor slab
poured concrete
7
remove & discard formwork
labor & time
Floor: Upper Level Decking
am‑cor System
Concrete / Masonry
Labor Savings: approximately 50% Material Savings: approximately 65% Notes: all openings preframed in the factory; all design & engineering preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor floor panels
am‑cor Kit includes fasteners
3
apply amcorite ferrocement subfloor
amcorite, sand & cement, approx. 1" (2.5cm)
step
task
material
1
consult drawings
architectural or standard plan
2
set shoring
wood supports
3
custom build formwork
treated wood & plywood
4
set concrete slab forms
forms, hardware
5
measure & form slab openings
wooden framing material
6
prepare & set reinforcing
reinforcing bars & tie wire, high chairs & mesh
7
slab pour
concrete, min. 6" (15cm)
8
remove formwork
labor & time
Walls: Ground Floor Exterior Walls of (a) Reinforced Concrete, or (b) Masonry
am‑cor System
Concrete / Masonry
Labor Savings: approximately 85% Material Savings: approximately 80% Notes: wall panels already placed in previous step: "Foundation: Stem Wall" or "Floor: Slab on Grade"; all openings preframed in the factory; all design & engineering already preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess; exterior surfaces ready for finishing
step
task
material
1
flash openings
flashing material
2
insert windows & doors
exterior doors & windows
3
apply amcorite structural ferrocement coat
amcorite, sand & cement, approx. 1" (2cm)
4
seal around openings
modulus & caulking
step
task
material
1
consult drawings
architectural or standard plan
2
consult code
opening headers
3
measure & form openings
treated jambs, heads & sills
4
custom build formwork
treated wood & plywood
5
set concrete forms
forms, spacers, ties
6
prepare reinforcing
reinforcing bars & tie wire
7
set reinforcing
reinforcing bars & tie wire
8a
cast concrete
poured concrete
8b
lay masonry
unit masonry
9a
remove formwork
labor & time
9b
grout masonry
masonry grout mix
10a
rub concrete
cement & water
10b
parge blockwork
cement & sand parging mix
11
flash openings
flashing material
12
insert windows & doors
exterior openings
13
flash exterior of openings
flashing & weatherproofing
14
seal around openings
modulus & caulking
15
interior partitions & furring
treated wood / steel framing
Walls: Upper Floors Exterior Walls
am‑cor System
Concrete / Masonry
Labor Savings: approximately 85% Material Savings: approximately 80% Notes: all openings preframed in the factory; all design & engineering already preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor mess; exterior surfaces ready for finishing
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor wall panels
am‑cor Kit includes fasteners
3
flash openings
flashing & weatherproofing
4
insert windows & doors
exterior doors & windows
5
apply amcorite structural ferrocement coat
amcorite, sand & cement
6
seal around openings
modulus & caulking
step
task
material
1
consult drawings
architectural or standard plan
2
consult code
opening headers
3
measure & form openings
treated wood rough grounds
4
custom build formwork
treated wood & plywood
5
set concrete forms
forms, spacers, ties
6
prepare & set reinforcing
reinforcing bars & tie wire
7a
cast concrete
poured concrete
7b
lay masonry
unit masonry
8a
remove formwork
labor & time
8b
grout masonry
masonry grout mix
9a
rub concrete
cement & water
9b
parge blockwork
cement & sand parging mix
10
flash openings
flashing material
11
insert windows & doors
exterior openings
12
flash exterior of openings
flashing & weatherproofing
13
seal around openings
modulus & caulking
14
interior partitions & furring
treated wood/steel framing
Walls: Partitions
am‑cor System
Concrete / Masonry
Labor Savings: approximately 50% Material Savings: approximately 25% Notes: all openings preframed in the factory; all design & engineering already preapproved; walls ready for services, insulation & interior surfaces; no scraps, waste, nor mess
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor partition panels
am‑cor Kit includes fasteners
step
task
material
1
consult drawings
architectural or standard plan
2
measure & cut door headers for framing
wood framing material/steel framing
3
measure & cut studs & plates for framing
wooden material/steel framing
4
measure & cut studs, corner bracing
wooden material/steel framing
5
frame & fasten material
fasteners
Roof: Framing & Decking
am‑cor System
Concrete / Masonry
Labor Savings: approximately 10% Material Savings: approximately 10% Notes: all openings preframed in the factory; all design & engineering already preapproved; roof ready for services, insulation & interior surfaces; no scraps, waste, nor mess
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor roof panels
am‑cor Kit includes fasteners
3
apply roof decking: rated plywood or amcorite ferrocement
plywood or amcorite, sand, and cement; am‑cor Kit includes fasteners
4
apply & fasten metal fascia, rake & soffit
included in am‑cor Kit
5
cover with black paper or amcorite ferrocement
asphalt paper or concrete sealer
6
apply roofing
shingles or waterproofing, fasteners
step
task
material
1
consult drawings
architectural or standard plan
2
set wood trusses
engineered wooden roof trusses
3
install truss anchors
truss anchors, fasteners
4
apply rated plywood decking
rated plywood, fasteners, H-clips
5
apply & fasten fascia, rake & soffit
wood, vinyl or metal fascia, fasteners
6
cover with black paper
asphalt paper, fasteners
7
apply roofing
shingles/waterproof
Services: Plumbing, Electrical, HVAC, AV, etc.
am‑cor System
Concrete / Masonry
Labor Savings: approximately 30% Material Savings: approximately 5%
Labor Savings: approximately 50% Material Savings: approximately 65% Notes: all columns, posts, floors, and railings preframed in the factory; all design & engineering already preapproved; no scraps, waste, nor mess, exterior surfaces ready for finish coat; amcorite unibody structural ferrocement skin acts as flashing and back flashing: no complicated waterproofing details required
step
task
material
1
consult drawings
am‑cor Field Manual
2
set labeled am‑cor balcony/porch panels (includes posts, railings)
am‑cor Kit includes fasteners
3
enamel or coat with amcorite
enamel/amcorite, sand, cement
4
apply waterproofing
waterproofing
5
flash & seal at wall/roof edges
flashing & sealant
step
task
material
1
consult drawings
architectural or standard plan
2
consult code
posts, beams, joist spans
3
set shoring
treated wood & plywood
4
custom build formwork
wooden material
5
set concrete forms
forms, hardware
6
measure & cut slab openings
wooden framing material
7
prepare & set reinforcing
reinforcing bars & tie wire, high chairs & mesh
8
slab pour
concrete, min. 6" (15cm)
9
remove formwork
labor & time
10
apply waterproofing
waterproofing
11
flash & seal at wall/roof edges
flashing & sealant
Building Components
The following pictures show cutaway sections of a standard reinforced concrete block masonry wall compared with a standard am‑cor System wall panel.
am‑cor Wall & Masonry Wall Cutaways
am‑cor Wall & Masonry Wall Cutaways
While standard reinforced concrete & masonry construction requires separate assemblies and methods for roof, wall, and floor construction, the am‑cor System provides a solution for all aspects of building construction, using the same Ferrocement methods and materials to construct:
am‑cor System floor assembly
am‑cor System floor assembly
walls
floors
roofs
beams, arches
columns/posts
opening headers
balconies, overhangs
railings, knee walls
verandas, patios
stairs
Material
Thanks to the patented FerroStress panel designs and advanced, modern, unibody Ferrocement engineering, the am‑cor System uses considerably less material than standard reinforced concrete & masonry construction, thus saving money on raw material, transportation & shipping, and more.
When building a typical wall of the same height, width, depth, and comparable structural specifications, the am‑cor System uses approximately 20% of the concrete and 85% of the steel required by standard reinforced concrete & masonry construction.
am‑cor vs. Concrete Material Use
am‑cor vs. Concrete Material Use
Use of the am‑cor System as a structural shell helps lower project costs and considerably decrease the carbon footprint of new construction. Savings include design, material, transportation, labor, and management costs.
Time & Labor
The am‑cor System uses considerably less construction time than standard reinforced concrete block construction, thus saving money on labor and management costs. These time savings are due to a number of engineering advances, including the unibody FerroStress structural skin, which replaces disparate materials, complicated assemblies, and outdated building practices.
When building a typical wall of the same height, width, depth, and comparable structural specifications, the am‑cor System takes approximately 20% of the construction time of standard reinforced concrete block construction. Further, it does not require the complicated practices of formwork for concrete posts & beams.
am‑cor vs. Concrete Time Use
am‑cor vs. Concrete Time Use
Use of the am‑cor System as a structural shell helps lower project costs by lowering labor costs, total time on site, and reducing time required for cleanup and installation of services. The am‑cor System affords further savings in project management, construction management, and general overheads. Because of reduced construction time, am-cor projects can increase ROI faster and more efficiently.
Overview
am‑cor FerroStress wall assembly
am‑cor FerroStress wall assembly
The am‑cor System is a structural building system:
The patented am-cor Ferrocement Construction System compares favorably with Standard Reinforced Concrete & Masonry construction. There are a number of benefits to using the am-cor System, including strength, and labor and material savings. In its standard configuration the am-cor System is generally:
40% Lighter: The am-cor System uses 60% less concrete than reinforced concrete & masonry, saving money and time on foundations, shipping, and labor.
Lower Carbon Footprint: 60% less material = an exceptionally low carbon footprint (less manufacturing, less shipping, less transportation, less energy use, etc.)
Double The Strength: The am‑cor System's patented FerroStress™ technology & high strength-to-weight ration creates a continuous, unibody Ferrocement stress skin using amcorite™ structural gel, providing 2-3 times the unit strength of reinforced concrete block masonry.
5x Faster: The am‑cor System is panelized and pre-engineered; walls are erected and set in minutes.
Unibody Integration: The am‑cor System integrates all structural elements (walls, beams, columns, headers, floors, etc.) into high strength panels, which are joined together into a single unified Ferrocement composite
Services & Insulation: am‑cor's hollow wall system allows for quick & easy placement of services and insulation, and does not require furring out to create interior surfaces, or drilling or chipping for conduit, etc.
Conclusion
The am‑cor Ferrocement Construction System is lighter, stronger, faster and cheaper than Standard Reinforced Concrete & Masonry construction, while being of commensurate durability and strength. Moreover, the am‑cor System’s overall integration allows for considerably faster & simpler construction, thereby lowering overheads and management costs.
Use of the am‑cor System provides a higher level of construction (fire, disaster, vermin resistance; greater security; ease of insulation and service installation) for a lower price.
All figures are good-faith reasonable estimates under standard site & marketplace conditions and are calculated in US monetary, labor, and material units for common industry scenarios. All figures are estimates for the specified task or material only, and exclude supporting labor, materials, equipment and tools. Also excluded are taxes, cost of land, siteworks & utilities, construction management costs, fuel, electricity, transportation, etc. Figures assume no unusual site conditions, standard construction practices, generic building plan, etc. Overheads or standard costs of doing business are not included. Architect fees, Contractor fees, and siteworks costs are not included. Actual buildings may vary significantly per project and may not necessarily fall within the range of generic savings as calculated. Please note all figures are time & project sensitive and not binding in any way. Estimates of labor & material are time & project sensitive and will vary. Labor & material prices, fuel, utilities, & business overheads vary with each region, and vary with kit size and design. All content in this document is for general informational purposes only. Opinions expressed herein are solely those of am‑cor inc.
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