Assumptions & Disclaimers
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.
Shell Construction Comparison
This is a step-by-step comparison of the am‑cor Ferrocement Construction System and standard Stick-Built Wood Framing 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 Wood Construction 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 Wood Construction 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 messstep 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 & make 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 6 set sill plate anchors embedded threaded rods/bolts 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 waterproof subgrade wall standard foundation waterproofing 11 interior partitions & furring treated wood - Floor: Slab on Grade/Basement Floor Slab
am‑cor System Wood Construction Labor Savings: approximately 20%
Material Savings: approximately 10%
Notes: no formwork construction & material; no wastestep 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 - Floor: Upper Level Decking
am‑cor System Wood Construction Labor Savings: approximately 20%
Material Savings: approximately 15%
Notes: all openings preframed in the factory; all design & engineering preapproved; floor ready for services, insulation & interior surfaces; no scraps, waste, nor messstep 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 step task material 1 consult drawings architectural or standard plan 2 consult code spans and stair opening header 3 measure & cut floor joists wooden framing material 4 measure & cut header & band wooden framing material 5 frame & fasten material wood, fasteners 6 measure & cut plywood approved, rated plywood 7 apply & fasten floor deck fasteners - Walls: Ground Floor Exterior Walls
am‑cor System Wood Construction Labor Savings: approximately 80%
Material Savings: approximately 75%
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 finishingstep task material 1 flash openings flashing material 2 insert windows & doors exterior doors & windows 3 apply amcorite structural ferrocement coat amcorite, sand & cement 4 seal around openings modulus & caulking step task material 1 consult drawings architectural or standard plan 2 consult code opening headers 3 measure & cut headers & sills for framing wooden material 4 measure & cut studs, corner bracing wooden material 5 frame & fasten material fasteners 6 measure & cut sheathing OSB or plywood 7 apply & fasten sheathing fasteners 8 flash openings flashing material 9 insert windows & doors exterior openings 10 flash exterior of openings flashing & weatherproofing 11 seal around openings modulus & caulking 12 apply weather seal house wrap or black paper - Walls: Upper Floors Exterior Walls
am‑cor System Wood Construction Labor Savings: approximately 45%
Material Savings: approximately 35%
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 finishingstep 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 & cut headers & sills for framing wooden material 4 measure & cut studs, corner bracing wooden material 5 frame & fasten material fasteners 6 measure & cut sheathing OSB or plywood 7 apply & fasten sheathing fasteners 8 flash openings flashing material 9 insert windows & doors exterior doors & windows 10 flash exterior of openings flashing & weatherproofing 11 seal around openings modulus & caulking 12 apply weather seal house wrap or black paper - Walls: Partitions
am‑cor System Wood Construction 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 messstep 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 3 measure & cut studs & plates for framing wooden material 4 measure & cut studs, corner bracing wooden material 5 frame & fasten material fasteners - Roof: Framing & Decking
am‑cor System Wood Construction 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 messstep 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 5 apply & fasten fascia, rake & soffit wood fascia, fasteners 6 cover with black paper asphalt paper, fasteners 7 apply roofing shingles/waterproofing - Services: Plumbing, Electrical, HVAC, AV, etc.
am‑cor System Wood Construction Labor Savings: approximately 30%
Material Savings: approximately 5%step task material 1 install grommets in pre- punched studs am‑cor Kit includes grommets step task material 1 consult drawings/ codebooks: limited hole size & location architectural or standard plan/ codebooks 2 drill/chip for service runs drilling equipment - Balconies & Porches: Covered & Uncovered
am‑cor System Wood Construction Labor Savings: approximately 35%
Material Savings: approximately 25%
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 requiredstep 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 measure & cut posts & beams pressure treated wood 4 measure & cut floor joists wooden material 5 measure & cut decking wooden material 6 frame & fasten joists, decking, posts, beams bolts, hangers & fasteners 7 apply cladding AZTEK/fiberglass- wood 8 flash & seal at wall/roof edges flashing & sealant
| Total Labor Savings: approximately 55% Total Material Savings: approximately 40% Total Time Savings: approximately 30% |
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| ™ Prefab Kit | Standard Construction Wood Stick-Built Framing |
|---|---|
| Steps to Complete: approximately 39 | Steps to Complete: approximately 76 |
| am‑cor System™ Ferrocement Prefab Kit | Standard Construction Wood Stick-Built Framing |
|---|---|
am‑cor Kit Specifications
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Platform Framing Specifications
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Overview
The is a structural building system:- unibody exterior stress-skin
- (earthquake, hurricane, tornado, fire, flood, etc.)
- durable & (low carbon footprint)
- minimal-maintenance
- True Sustainability: am‑cor Ferrocement building shells require minimal upkeep and maintenance and have an exceptionally long lifespan; meaning you never have to worry about fire, mold, mildew, termites, insects, vermin, or natural disasters
- Lower Carbon Footprint: prefabricated & preengineered = a (less shipping, less transportation, less waste, etc.)
- 8x 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 6 times the unit strength of standard wood members.
- 2x 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 composite
- Services & Insulation: am‑cor's hollow wall system allows for quick & easy placement of services and insulation, and does not require drilling or chipping for conduit, etc.
Conclusion
The is lighter, stronger, and faster and than Stick-Built Wood Framing construction, and is of superior 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.
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