Ft. Campbell Deconstruction Analysis

Transcription

1 Ft. Campbell Deconstruction Analysis Prepared by The University of Florida Powell Center for Construction and Environment Brad Guy Tim Williams Ryan Courson December 2002

2 Table of Contents I. Introduction 3 II. Building Reports a i. General Description ii. Material Description and Inventory iii. Deconstruction Narrative iv. Labor Rates v. Summary b and i. General Description ii. Material Description and Inventory iii. Deconstruction Narrative iv. Labor Rates v. Summary c i. General Description ii. Material Description and Inventory iii. Deconstruction Narrative iv. Labor Rates v. Summary d i. General Description ii. Material Description and Inventory iii. Deconstruction Narrative iv. Labor Rates v. Summary III. Building Comparisons 44 IV. Conclusions/ Lessons Learned/ Further Research 48 V. Appendix 52 2

3 Introduction Over 50 million square feet of surplus World War II buildings must be removed from Army installations. When demolished, a typical two-story barracks building becomes about 160 tons of debris that occupies diminishing landfill space on Army installations. The same barracks building, however, could also be deconstructed to produce approximately 12,000 board-feet of lumber, as well as windows, doors, plumbing fixtures, and mechanical and electrical components. The pilot project Optimizing Building Deconstruction Techniques for Army Buildings at Ft. Campbell, KY was initiated to develop deconstruction strategies for wood frame buildings, evaluate the strategies in terms of cost, time, and material recovery rates, and to develop criteria to optimize deconstruction strategies within project-specific cost and time limitations. During May, June, and July of 2002, Fort Campbell, KY made 20,000 to 25,000 square feet of surplus World War II wood-framed buildings available for this pilot deconstruction project. The Austin, Texas Habitat for Humanity affiliate, with labor provided by teams of Americorps volunteers, deconstructed 5 buildings at Ft. Campbell. The University of Florida s Powell Center for Construction and Environment (PCCE) was onsite to provide supervision and guidance and to collect and evaluate data describing deconstruction duration, deconstruction cost, and quantities of recovered materials. PCCE was also to provide lessons learned and recommended revisions to each deconstruction plan, as well as conclusions about safety, efficiency, management, and other project performance parameters. This document contains descriptions of the deconstructed buildings, narratives detailing the process and methods of each deconstruction, and analysis of the duration of each deconstruction task culminating in documentation of deconstruction labor rates for the various materials and assemblies encountered in the course of the pilot project. This report also discusses the lessons learned during the course of the project, suggestions for future research, and a general discussion on deconstruction safety and project management. 3

4 General Description 2748 Size Height Construction Type Foundation 120 x s.f. One-story Light wood frame Pier and wood beam Building 2748 was the first of the World War II-era buildings to be deconstructed for this project. This building was also removed from the rest of the buildings on the 2700 block and was therefore deconstructed by itself before the crew mobilized to the other end of the 2700 block, where three of the other buildings were grouped together. A crew of 12 laborers (nine Americorps volunteers and three professionals) dismantled the majority of the building over 9 working days. A raised pier and beam wood floor system supported the entire building. Approximately one-half of the building (the northern end) had a 3-4 concrete floor topping over the wood sub-structure. Given the effort required to hand demolish this concrete floor topping compared to the amount of recoverable underlying wood beams and joists, it was decided to only deconstruct the portion of the building that did not have the concrete floor. Severe fire damage in the roof in the northern end of the building facilitated this decision. The northern end of the building was left for mechanical demolition. For the purposes of this study, only the hours spent on hand deconstruction of the southern onhalf of building have been reported. Thus, all labor times and rates are based on the complete top-to-bottom deconstruction of a building measuring 60 by 25 6 equivalent to 1530 square feet. Building 2748 Floor Plan - Deconstructed areas are shaded. 4

5 Material Description and Inventory The materials and assemblies found in this building are as follows: Exterior Doors and Windows: The standard windows in this building were single-glaze aluminum windows typically 3 4 W. x 5 4 H.. Interior Finishes: All of the interior wall surfaces were covered with painted interior drywall. The ceiling drywall was nailed directly to the bottom chord of the roof structure. A suspended acoustic ceiling tile (ACT) ceiling was added at a height of 8 0. The finish floor was comprised of up to two layers of vinyl composition tile (VCT) over 1x4 T&G and wood subfloor. A four foot high ¼ plywood paneling wainscoting was added on all interior wall surfaces. Roof: The roof structure of this building was manufactured 2x6 trusses with a layer of ¾ plywood sheathing. A single layer of asphalt shingles covered the sheathing. Exterior Walls: The exterior walls were 2x6 studs at 24 on center resting on top of the wood sub-floor. Exterior grade drywall was fastened to the outside of the studs, followed by a layer of 1x6 lap siding, and vinyl siding. Interior Walls: Light 2x4 wood-frame construction. Wood Floor and Floor Structure: The original floor of the building was tongue and groove 1x4. The tongue and groove sat on a layer of diagonal 1x8 sub-floor. The floor structure was 2x10 joists at 24 on center supported by longitudinal beams running the length of the building. The longitudinal beams were made of triple gang-nailed 2x10 s and rested directly on the pier foundation. The piers were not removed, but all of the wood floor structure was salvaged. 5

6 Material Inventory and Labor Distribution Table Component 1 Material 2 Quantity 3 Labor Time 4 Exterior Windows MEP Casework Interior Finishes Interior Walls Roof Exterior Walls Floor Aluminum Windows 14 ea Total Exterior Windows hr 3.98 % Total MEP hr 2.87 % Total Casework 9.00 hr 1.38 % Distribution of Labor 5 Plywood Paneling 672 sf 4.75 Sheetrock - Wall 1950 sf Sheetrock - Ceiling 1530 sf 7.25 Vinyl Tile - Floor 1530 sf Total Interior Finishes hr % 6 Framing Wood 2x4 255 sf 7.65 Insulation 255 sf 9.64 Total Interior Walls hr 2.64 % 7 Asphalt Shingles 1775 sf Sheathing Plywood 1775 sf Structure Wood 2x6, 2x sf Total Roof hr % Vinyl Siding 1898 sf Wood Siding 1898 sf Framing Wood 2x sf Total Exterior Walls hr % Tongue and Groove 1x sf Sub-floor Wood 1x sf Floor Structure 2x sf Total Floor hr % Total Building 1530 sf hr % General Notes: 1. The Component column refers to the large scale assemblies or general groups of items which comprise the building. MEP includes all mechanical, electrical, and plumbing equipment including ducts, electric wire and conduits, fire suppression systems, and all plumbing fixtures and piping. Casework includes all interior trim items such as baseboards and window and door trim, as well as built-in cabinets or shelves. Interior Finishes includes materials such as sheetrock, acoustic ceiling tiles, plywood wainscoting, and any floor finishes with the exception of the original tongue and groove flooring applied directly to the sub-floor. 2. The Material column describes the constituent materials or elements which are assembled or grouped to form a larger component to the level of detail that was recorded accurately during the deconstruction process. 3. The Quantity column is generally an inventory of how much of a particular material was deconstructed and the unit by which Labor Rates will be calculated. A description of how quantities were measured for each material will be covered in the Labor Rates table for each building. Abbreviations are as follows: ea for each, sf for square feet, and lf for linear feet and hr for hours 4. Labor Time is measured in hours. 6

7 5. Distribution of Labor gives a quick impression of where time was spent during the deconstruction as well as a means of comparing the relative complexity or difficulty of deconstructing the different components. Specific Notes: 6. As compared to the other one-story buildings, a much larger percentage of overall time was spent in this building removing interior finishes. The difference is attributable to the large amount of time required for the removal of the vinyl composition floor tile (VCT) in this building. There were two layers of VCT with an intermediate layer of particleboard. Each layer of VCT was glued and nailed to the floor making removal exceedingly strenuous. 7. Deconstruction of the Interior Walls occupied a relatively low percentage of time for this building. But, as noted in the general description of 2748, only the portion of the building without the concrete floor topping was completely deconstructed and only time spent deconstructing this portion of the building was included in the analysis. This portion of the building had only one interior wall that divided two large spaces. 7

8 Deconstruction Narrative May 3, 2002 Hours: 12:00-4:00 Number of Workers: 12 May 7, 2002 Hours: 7:30 4:15 Number of Workers: 11 May 8, 2002 Hours: 7:30 4:00 Number of Workers: 11 May 9, 2002 Hours: 7:30 3:30 Number of Workers: 11 May 10, 2002 Hours: 7:30 3:45 Number of Workers: 12 8 The first day of deconstruction began with the removal of interior finishes and exterior vinyl siding. On the interior, workers deconstructed wood trim around the windows and baseboards around the perimeter of the rooms. On the exterior, vinyl siding was removed from the east wall of the building. In the morning, caution tape was laid out and a review of the use of fall protection was given in preparation for roof work. Workers on the ground removed the rest of the vinyl siding on the north, south, and west sides. Inside, removal of vinyl floor tiles began. Mid-morning, removal of asphalt shingles on the eastern half of the roof began. After lunch, the shingle removal on the eastern half was completed. Exterior windows were salvaged. Workers removed the asphalt shingles from the western half of the roof. Inside, demolition of the vinyl floor tiles continued. Demolition and disposal of vinyl floor tiles continued. Tiles were glued and nailed to the sub-floor making removal difficult. Room 4 had vinyl tiles on a layer of plywood backing. Room 5 had two layers of vinyl tiles separated by a layer of particleboard. The first part of the day was devoted to demolishing and disposing of the ceiling drywall and attic insulation over room 5. Workers removed plywood sheathing from the roof and began deconstructing the exposed trusses.

9 May 14, 2002 Hours: 7:30 4:15 Number of Workers: 12 Workers completed the deconstruction of the plywood roof sheathing and trusses. The deconstruction of the roof structure began on the south and progressed to the north. As the structure above was cleared away, workers on the south side of the floor were able to begin lifting the tongue and groove flooring. The flooring was denailed and stacked as it was removed. May 15, 2002 Hours: 8:00 4:00 Number of Workers: 12 Deconstruction of exterior walls began. Painted wood siding and rigid board Styrofoam insulation was removed. Exterior framing was deconstructed. Removal of the tongue and groove flooring continued, as did denailing and stacking of the flooring. May 16, 2002 Hours: 7:30 3:15 Number of Workers: 12 Deconstruction of the wood sub-floor began. Workers continued denailing and stacking the tongue and groove flooring, 2x4 framing, and wood siding. Towards the end of the day, 2x10 floor joists were deconstructed as they were exposed by the removal of the subfloor. May 18, 2002 Hours: 7:30 4:15 Number of Workers: 22 A second crew of Americorps workers arrived to help complete the deconstruction of Building The original crew finished deconstructing the last of the floor joists. The new crew began by continuing the work of processing deconstructed flooring, framing, sub-floor, and floor joists. 9

10 Labor Rates Table Material Quantity 1 Deconstruction Hours 2 Deconstruction Hours/unit 3 Campbell Avg. Dec Hrs/unit 4 Gainesville Hours/unit 5 Burdened Hours 6 Burdened Hours/unit Supervisory Hours/unit 7 Total Hours/unit 8 Campbell Avg. Total Hrs/unit Component/ Material Windows and Doors Windows 14 ea Total Doors and Windows Total Hours/sf of building MEP 1530 sf N/a N/a N/a Total MEP Casework 1530 sf N/a N/a N/a Total Casework Interior Finishes Plywood - Wall 672 sf Sheetrock Wall 1950 sf Sheetrock - Ceiling 1530 sf Vinyl Tile - Floor 3060 sf Total Interior Finishes Interior Walls and Ceilings Framing 255 sf Insulation 255 sf Total Wall Assembly Roof Asphalt Shingles 1775 sf Sheathing Plywood 1775 sf N/a N/a Structure 1530 sf N/a Structure 1650 lf Total Roof Assembly Exterior Walls Vinyl siding 1898 sf Wood 1x sf Framing 1725 sf N/a N/a Total Exterior Walls Floor T&G 1x sf Subfloor 1530 sf Joists 1530 sf N/a Joists 791 lf Total Floor Total Building 1530 sf

11 General Notes: 1. Abbreviations are as follows: ea for each, sf for square feet, and lf for linear feet. The Quantity of Doors and Windows was measured by an exact count of doors or windows removed. For MEP and Casework, deconstruction activity was not recorded in sufficient detail to calculate rates based upon an exact count of fixtures or inventory of materials. Instead, the Quantity is understood to be the square footage of the entire building and labor rates are calculated on a per square foot of building basis. This actually provides labor rates that allow for simplified time/cost estimation based upon area of building without requiring detailed inventories of MEP or Casework materials. For Interior Finishes, all Quantities are measured in square feet of material. For materials that are applied to both sides of an interior wall, the areas of materials on both sides of the wall are added into the total. For Roof materials, the actual surface area of asphalt shingles or sheathing is calculated and is therefore larger than the footprint of the building since the total area of these materials allows for the slope of the roof. The Quantity of the roof structure is given using two different methods of measurement. The first measurement listed is the area of the building. Rates based upon this Quantity are useful for quick estimating when the spacing and/or construction of the roof structure have not been precisely measured. The second measurement is the total linear feet of structural members. Only the rafters and bottom chord are measured. Diagonal bracing and blocking is not part of this total as these short pieces are generally of little salvage value and are more cumbersome to inventory. For Floors, the structural floor joists are measured in two ways, just as the roof structure; one quantity based upon the overall area of the floor and one actual count of the linear feet of structural members, again not accounting for short sections of blocking. 2. Deconstruction hours include all of the time spent actually removing materials from the building. This includes deconstruction or demolition and clean up or disposal of waste. 3. Deconstruction Hours/Unit is the rate at which the material was deconstructed or demolished measured in whichever unit was used to show the Material Quantity. For example: Doors are measured by exact count, so the Door Deconstruction Rate is given in hours per door; Tongue and Groove Flooring is measured in square feet of area, so the T&G Flooring Deconstruction Rate is given in hours per square foot of T&G Flooring. 4. Campbell Average Deconstruction hours show the average rate from all five Ft. Campbell buildings. An average is not given for one-of-a-kind components such as the heavy doors from 834 or the plywood roof sheathing of For components that vary significantly from one building to another either in content or accuracy of data recording, such as MEP or Casework, no average is given. Only components or materials which are basically similar across several buildings are averaged. For instance, roof and floor structure are basically similar in all buildings except for 834. The values from 834 are therefore not included in the average rate shown and the table on 834 shows no Campbell average value for comparison since the roof and floor structure of this building are unique within the study. 5. Gainesville Hours/Unit are the average deconstruction rates (not including non-productive or processing time) from several deconstruction case studies performed by the CCE and are included as a baseline for comparison and discussion. 6. Burdened Hours are those that are part of any deconstruction work day that are not directly involved with the removal of materials. These hours include non-productive time such as setting up for the day, worker rest and water breaks, preparation of safety equipment, and tool clean-up at the end of the day. Burdened Hours also include time spent processing materials and preparing them for reuse or resale such as cleaning, denailing, and loading of the materials for removal from the site. 7. Supervisory Hours/Unit is a small factor that represents the time spent by a trained professional directing or instructing laborers. 8. Total Hours/Unit is the sum of Deconstruction, Burdened, and Supervisory time measured per unit (each, per square foot, or per linear foot). This rate would be useful for developing a time/cost estimate of a building for which a detailed inventory has been done and exact quantities of materials are known. 9. Total Hours/Sf of Building is calculated by dividing the total hours (deconstruction, burdened, and supervisory) spent on each component by the square footage of the building without considering the actual quantity of each material. This provides a rate that can be used to generate quick time/cost estimates without actually conducting a detailed inventory of a building. 11

12 Labor Rate Commentary For the most part, the labor time and rates involved in the deconstruction of this building are comparable to the other buildings at Ft. Campbell. Some notable differences are in the times related to removing vinyl composition floor tile and fiberglass insulation. The removal of VCT was particularly time consuming in this building. There were two layers of VCT separated by particleboard underlayment. Each layer was glued and brad-nailed to the surfaces below. Whereas VCT can typically be removed using a roofing shovel and a small amount of effort, the tiles in this building required strenuous effort to pry them up. The total hours/square foot for Interior Finish removal for 2748 (0.099 hrs/sf) is much higher than in other Ft. Campbell buildings (0.024 for 2736 and for 2738, and for 2717). This is almost entirely due to the large amount of time devoted to removing VCT. Removal of the fiberglass insulation was also more time consuming than in other buildings. Unlike the other buildings where the insulation was removed for disposal, workers tried to save this insulation for resale and so took more care in removing it from the attics. The insulation was subsequently rained on and ruined and so required additional labor to pick it up a second time and throw it away. Another difficulty for this building that occurred throughout the entire project was the size, timing and location of roll-off particularly for asphalt shingle removal. Larger 40 C.Y. roll-offs were used which meant they were not moved as often as 20 C.Y. roll-offs and therefore could not be positioned to capture asphalt shingles more readily directly from the roof. Time was spent collecting shingles from the ground after removal. The height of the 40 C.Y. relative to the height of first floor windows, also make it more difficult to remove waste materials from the interior at a level either equal to or higher than the edge of the roll-off, which in turn facilitates the use of plywood slides. 12

13 General Description 2736 & 2738 Size Height Construction Type Foundation 106 x s.f. Single Story Light wood frame Pier and beam Slab on grade Buildings 2736 and 2738 were originally Recreation and Storehouse Buildings built during the mobilization for World War II. They were deconstructed in 11 days between May 13 and June 1, West Elevation Vinyl siding remove Buildings 2736 and 2738 were similar buildings located side by side in the 2700 block of Ft. Campbell. These two buildings were deconstructed simultaneously and provided an opportunity to compare labor rate data from one to the other. Each building was light wood-frame construction, with roughly 60% supported on a raised wood floor on piers and the remainder on a concrete slab-on-grade. Only the raised portion (shaded in the plans below) was completely deconstructed. The slab-on-grade, concrete piers and chimney were mechanically removed after the deconstruction was completed. These mechanical rates are not included in this report. The roof, interior finishes, and interior walls were entirely removed from each of the buildings, but labor times were only calculated for the completely deconstructed portions. Building 2736 Floor Plan - Deconstructed areas are shaded. Building 2738 Floor Plan - Deconstructed areas are shaded. 13

14 Material Description and Inventory The materials and assemblies found in these buildings are as follows: Exterior Doors and Windows: The windows single-glaze aluminum frame. The standard dimension was 3 4 W x 5 4 H. The windows were removed as an entire assembly for resale. Interior Finishes: All of the interior wall surfaces were covered with painted drywall. The ceiling drywall was nailed directly to the bottom chord of the roof structure. Suspended acoustic ceiling tiles were in several rooms below the drywall. Four foot high ¼ Plywood paneling wainscoting was added in most rooms. Roof: The roof structure was composed of built-up trusses at 24 on center. Top and bottom cords are 2x6, with intermediate pieces of 2x6 s and 2x4 s nailed diagonally on either side of the main cords. The roof structure was in excellent condition and so completely deconstructed for salvage and resale. The roof sheathing was 1x6 nailed to the trusses. It was damaged extensively by water and years of temperature change, resulting in a very low value material that broke apart easily during removal. The roof sheathing was demolished by hand and disposed. A layer of roofing felt and worn asphalt shingles was nailed on top of the sheathing. This was removed for disposal as well Roof Structure Exterior Walls: The exterior walls were painted 2x4 studs at 24 on center resting on top of the sub-floor. Exterior grade drywall was fastened to the outside of the studs, followed by a layer of 1x6 lap siding, and finally vinyl siding. The vinyl siding was deconstructed for reuse, but the wooden siding and exterior drywall had to be discarded. It was interesting to note that the wood siding was actually damaged extensively by the vinyl siding rather than protected. While the vinyl served well to protect the building from rain and snow, it trapped water vapor within the walls of the building, which eventually rotted most of the siding. Interior Walls: Light 2x4 construction. Wood Floor and Floor Structure: The finish floor on the entire portion of the building on the raised wood floor was tongue and groove 1x4. The tongue and groove sat on a layer of 1x8 sub-floor. Floor structure was 2x10 joists at 24 on center supported by longitudinal beams running the length of the raised floor area. The longitudinal beams were made of triple gang-nailed 2736 Exterior Wall 14

15 2x10 s and rested directly on the pier foundation. The piers were not removed, but all of the wood floor structure was salvaged. Material Inventory and Labor Distribution Table Component 1 Material 2 Quantity 3 Labor Time 4 Distribution of Labor 5 Exterior Windows and Doors Aluminum Windows MEP Casework Interior Finishes Interior Walls Roof Exterior Walls Wood Floor and Floor Structure Wood Doors Total Exterior Windows and Doors % Total MEP % Total Casework % Plywood Paneling 1048 sf 5.57 Sheetrock 3172 sf ACT - Ceiling 1463 sf Sheetrock - Ceiling 1463 sf 5.97 Total Interior Finishes % Framing Wood 2x sf Insulation 1330 sf 4.03 Total Interior Walls % Aluminum Gutters 142 lf 4.30 Asphalt Shingles 1988 sf Sheathing Wood 1x sf Structure Wood 2x6, 2x sf Total Roof % Vinyl Siding 1682 sf Wood Siding 1682 sf Total Exterior Walls % Tongue and Groove 1x sf Sub Floor and Floor Structure 1785 sf Total Floor % Total Building 1785 sf % 15

16 Material Inventory and Labor Distribution Table Component 1 Material 2 Quantity 3 Labor Time 4 Exterior Windows and Doors MEP Interior Finishes Interior Walls Roof Exterior Walls Wood Floor and Floor Structure Distribution of Labor 5 Aluminum Windows Wood Doors Total Exterior Windows and Doors % Total MEP % Plywood Paneling 656 sf Sheetrock 4474 sf Sheetrock - Ceiling 1785 sf 5.44 Total Interior Finishes % Framing Wood 2x sf Insulation 1455 sf Total Interior Walls % Asphalt Shingles 1988 sf Sheathing Wood 1x sf Structure Wood 2x6, 2x sf Total Roof % Vinyl Siding 1682 sf 3.16 Wood Siding 1682 sf Total Exterior Walls % Tongue and Groove 1x sf Sub Floor 1785 sf Floor Structure 1785 sf Total Floor % Total Building % General Notes: General Note are the same as those listed in the chapter on 2748 Specific Notes: The distribution of time spent on each component was fairly similar between these two buildings. Differences could stem from a number of factors including: varying skill levels and/or enthusiasm between the work teams assigned to each building, variations in deconstruction techniques between buildings, confusion during the recording of data while assigning labor time to the correct building since work on both was carried out simultaneously and some individual workers moved between buildings or worked in the shared space between the adjacent buildings. 16

17 Deconstruction Narrative *The work on 2736 and 2738 was carried out at the same time. This deconstruction narrative describes work done on both buildings. May 13, 2002 Hours: 8:30-4:00 Number of Workers: 9 May 20, 2002 Hours: 8:30-4:00 Number of Workers: 25 May 21, 2002 Hours: 7:45 4:00 Number of Workers: 23 May 22, 2002 Hours: 7:30 4:00 Number of Workers: 23 Rain today made work on 2748 impossible, so the crew moved inside these buildings to begin the first stages of deconstruction. They salvaged wood trim, acoustic ceiling panels, and plywood wall panelling. Once the salvageable materials were removed from the ceiling and walls, the sheetrock was demolished from many interior surfaces. Deconstruction of non-load bearing interior walls began. Further initial deconstruction work was carried out on both buildings. Activities included: demolition of acoustic ceilings, sheetrock ceilings and walls, and vinyl floors. Removal of exterior vinyl siding began. Demolition of asphalt shingles began on both buildings. Deconstruction of the exterior windows of both buildings began. The removal of the vinyl siding continued. Workers on finished removing the asphalt shingles and began deconstructing the roof sheathing. Shingle removal continued on Shingle removal continued on Building and finished by late afternoon. Roof sheathing removal continued on Workers began processing vinyl siding for resale. 17

18 May 23, 2002 Hours: 8:00 4:15 Number of Workers: 23 May 24, 2002 Hours: 7:30 3:00 Number of Workers: 23 Demolition of roof sheathing began on Deconstruction teams on Building were able to begin taking down trusses using ladders and ropes. A clean-up crew spent several hours removing wood debris and shingles from around the site. On 02738, truss removal continued. Ceiling insulation was also being disposed. The remaining windows in were deconstructed and oak plywood panelling was removed and processed. May 28, 2002 Hours: 7:30 4:00 Number of Workers: 22 May 29, 2002 Hours: 8:00 3:15 Number of Workers: 24 More roof sheathing was demolished on The roof trusses were disconnected and lowered by rope as they were uncovered. Truss removal on continued. Walls no longer supporting the roof were deconstructed. A few workers began trying to demolish the concrete floor slab with sledgehammers. Truss deconstruction continued on both buildings. In the areas of where walls had been removed, crews began deconstructing the subfloor and floor joists. May 30, 2002 Hours: 8:30 3:45 Number of Workers: The last floor joists from the area to be deconstructed on were removed. Workers cleaned up insulation, sheetrock, and wood debris from the building

19 footprint. On 02736, the last pieces of roof sheathing and all trusses were removed. Sheetrock was removed from selected walls. These walls were then deconstructed. Deconstructed wood was taken to the warehouse for processing. May 31, 2002 Hours: 7:45 3:45 Number of Workers: 27 Workers deconstructed flooring, subflooring, and floor joists in the area of that was to be removed. June 1, 2002 Hours: 7:45 3:45 Number of Workers: 27 The last floor joists from were removed by mid-morning. The rest of the day was spent transporting deconstructed lumber to the warehouse for processing and cleaning up around the building site. 19

20 Labor Rates Table Material Quantity 1 Deconstruction Hours 2 Deconstruction Hours/unit 3 Campbell Avg. Dec Hrs/unit 4 Gainesville Hours/unit 5 Burdened Hours 6 Burdened Hours/unit Supervisory Hours/unit 7 Total Hours/unit 8 Campbell Avg. Total Hrs/unit Total Hours/sf of building 9 Component/Material Windows and Doors Doors 4 ea Windows 13 ea Total Doors and Windows MEP 1785 sf N/a N/a Total MEP Interior Finishes Plywood - Wall 1048 sf Sheetrock Wall 3172 sf ACT - Ceiling 1463 sf Sheetrock - Ceiling 1463 sf Total Interior Finishes Interior Walls and Ceilings Framing 1330 sf Insulation 1330 sf Total Wall Assembly Roof Gutter - Aluminum 142 lf Asphalt Shingles 1988 sf Sheathing Wood 1x sf Structure 1785 sf N/a Structure 1916 lf Total Roof Assembly Exterior Walls Vinyl siding 1682 sf Wood 1x sf Total Exterior Walls Floor T&G Oak 1x sf Joists 1785 sf N/a Joists 918 lf Total Floor Total Building 1785 sf

21 Labor Rates Table Material Quantity 1 Deconstruction Hours 2 Deconstruction Hours/unit 3 Campbell Avg. Dec Hrs/unit 4 Gainesville Hours/unit 5 Burdened Hours 6 Burdened Hours/unit Supervisory Hours/unit 7 Total Hours/unit 8 Campbell Avg. Total Hrs/unit Total Hours/sf of building 9 Component/Material Windows and Doors Doors 4 ea Windows 12 ea Total Doors and Windows MEP 1785 sf N/a N/a N/a Total MEP Interior Finishes Plywood - Wall 656 sf Sheetrock Wall 4474 sf Sheetrock - Ceiling 1785 sf Total Interior Finishes Interior Walls and Ceilings Framing 1455 sf Insulation 1455 sf Total Wall Assembly Roof Asphalt Shingles 1988 sf Sheathing Wood 1x sf Structure 1785 sf N/a Structure 1916 lf Total Roof Assembly Exterior Walls Vinyl siding 1682 sf Wood 1x sf Total Exterior Walls Floor T&G Oak 1x sf Subfloor 1785 sf Joists 1785 sf N/a Joists 918 lf Total Floor Total Building 1785 sf

22 General Notes: General Notes are the same as those in the chapter on 2748 Labor Rate Commentary Deconstruction was going on at both of these adjacent buildings at the same time. The very busy worksite coupled with certain workers moving from one building to another during the day made data recording challenging at times. At times when workers were clearly separated, such as when working on the roof or on the interior, the recorded data is likely to be very reliable. During times when similar work was being done on both buildings at the same times and work teams switched from building to building during the day, such as during the removal of the exterior wood siding and framing, the subfloor and the floor structure, it becomes more difficult to trust that those gathering the data properly recorded which workers were working on which buildings. For these situations, the average values across all buildings at Ft. Campbell probably will provide better estimating tools than the values from 2736 and The Deconstruction Rates for the removal of interior framing and insulation vary between 2736 and 2738, but it is valuable to note that taken as an assembly, the Deconstruction Rate for the interior walls works out to be the same (0.019 hrs/sf). This suggests that while the data recorded in this case may not be accurate to the level of exactly what each worker was doing at each 15-minute interval while deconstructing interior walls, the overall length of time spent on the wall assembly is still reliable. Rates for the removal of the roof shingles, sheathing, and structure are consistent between these two buildings and are comparable to the experiences at the other Ft. Campbell structures. 22

23 General Description Size 91 x29 6 Height Two Story Construction Type Light wood frame Foundation Pier and beam 2717 Building 2717 was originally a Barrack built during the mobilization for World War II. A large crew of Americorp volunteers deconstructed it in 14 working days. Building 2717 was entirely deconstructed by hand except for the concrete piers that supported the floor structure and several concrete exterior stairs. These were subsequently mechanically demolished and removed from the site Floor Plans - Deconstructed areas are shaded. 23

24 Material Description and Inventory The materials and assemblies found in this building are as follows: Exterior Doors and Windows: The windows were single-glaze aluminum frame. The standard dimension was 3 4 W x 5 4 H. The windows were removed as an entire assembly for resale. Interior Finishes: All of the interior wall surfaces were covered with painted interior drywall. The ceiling drywall was nailed directly to roof joist or second floor structure. Suspended acoustic ceiling tiles were added in the outer structural bays with the main AC duct ceiling mounted in the middle bay. Roof: The roof structure was composed of 2x8 rafters and 2x6 joists at 24 o.c. The rafters rested on upper longitudinal beams in line with the intermediate columns. Longitudinal X bracing ran the length of the building. The roof structure was in excellent condition and so completely deconstructed for salvage and resale. The roof sheathing was 1x8 nailed to the trusses. The roof sheathing was demolished by hand and disposed. A layer of roofing felt and worn asphalt shingles was nailed on top of the sheathing. This was removed for disposal as well. Exterior Walls: The exterior walls were balloon-frame 2x4 at 24 o.c. resting on top of the first floor sub-floor. Exterior grade drywall was fastened to the outside of the studs, followed by a layer of 1x6 lap siding, and finally vinyl siding. The vinyl siding was deconstructed for reuse, and the wood lead-base painted siding was salvaged for re-milling by the US FPL. Interior Walls: Light 2x4 construction with drywall both sides Exterior Wall Wood Floor and Floor Structure: The finish floor was vinyl floor tile over underlayment in the main room on both floors - over 1x4 T&G wood flooring over 1x 8subfloor. The bathrooms had a concrete topping over the subfloor. The second floor structure was 2x8 joists at 24 o.c. nailed to the exterior wall studs and supported by longitudinal beams of 2 boxed 2x8s nailed to either side of 6x6 columns. The first floor structure was 2 boxed 2x12 longitudinal beams and 2x8 joists at 24 o.c. The first floor sub-floor was diagonal 1x10s. The first floor was raised on 14 diameter round concrete piers. 24

25 Material Inventory and Labor Distribution Table Component 1 Material 2 Quantity 3 Labor Time 4 Exterior Windows MEP Casework Interior Finishes Interior Walls Roof Exterior Walls Wood Floor and Floor Structure Columns Wood 6x6 Aluminum Windows Total Exterior Windows % Total MEP % Total Casework % Sheetrock sf ACT - Ceiling 666 sf Vinyl Tile - Floor 5150 sf Total Interior Finishes % Framing Wood 2x sf Insulation 1717 sf Total Interior Walls % Aluminum Gutters 182 lf 4.50 Asphalt Shingles 3108 sf Sheathing Wood 1x sf Structure Wood 2x6, 2x sf Total Roof % Fascia and Soffit lf Framing Wood 2x sf Vinyl Siding 4610 sf Wood Siding 4610 sf Total Exterior Walls % Tongue and Groove 1x sf Sub Floor 5150 sf Floor Structure 5150 sf Poured Concrete Floor 508 sf Total Floor % Total Columns 220 lf % Distribution of Labor 5 Total Building 5310 sf % General Notes: General Notes are the same as those listed in the chapter on 2748 Specific Notes: Proportionally more time was spent deconstructing the Wood Floor and Floor Structure of this building than in the other buildings. This is to be expected given that this is the only two-story building that was removed. It had twice the amount of floor material in relation to the total other materials than any of the other buildings. 25

26 Deconstruction Narrative June 3, 2002 Hours: 7:30 3:45 Number of Workers: 39 June 4, 2002 Hours: 7:30 3:30 Number of Workers: 40 The first day of deconstruction began with the removal of windows and exterior vinyl siding. On the interior, workers deconstructed wood trim around the windows and baseboards around the perimeter of the rooms, removed gypsum board from interior walls, and began removing floor and ceiling tiles. There were four crews working on the building. In the morning, workers continued to remove vinyl siding. On the interior first floor, crews removed gypsum board, interior wall framing, and floor tiles. In the afternoon, they began removing tongue and groove flooring. One of the crews worked on the site processing interior wall framing and tongue and groove flooring. June 5, 2002 Hours: 7:30 3:30 Number of Workers: 45 On the exterior, workers removed exterior sheathing and asphalt roof shingles. On the interior, workers continued removing tongue and groove flooring and interior wall framing members. 26

27 June 7, 2002 Hours: 7:30 12:45 Number of Workers: 38 On the exterior, workers were processing tongue and groove flooring, wall framing members, and exterior vinyl siding. On the interior first floor, workers continued to remove flooring and non-structural wall framing members. Also, workers began deconstructing roof trusses and demolishing the concrete floor of the bathroom. June 8, 2002 Hours: 7:30 2:45 Number of Workers: 21 June 10, 2002 Hours: 7:30 4:00 Number of Workers: 33 The majority of workers were removing roof trusses. Other workers were demolishing the first floor bathroom concrete slab and removing exterior wood siding on the second floor. Deconstruction began on the second story exterior walls of the building by the end of the day. One group of workers was on site processing lumber throughout the day. Others were on the second floor removing all the interior and exterior walls before lunch, and lifting the sub-floor after. June 11, 2002 Hours: 8:00 4:00 Number of Workers: 24 Workers removed all of the second floor joists and columns. The exterior siding on the first floor was being removed at the same time. 27

28 June 12, 2002 Hours: 7:30 4:15 Number of Workers: 27 June 13, 2002 Hours: 7:30 4:00 Number of Workers: 12 The first floor walls were removed in large sections before lunch. After lunch, one group of workers disassembled and processed the wall sections while others began removing the sub-floor and then the floor joists. In the morning, the workers removed the final floor joists from the building. The rest of the day was spent cleaning up wood and insulation debris from the site and processing materials. June 17, 2002 Hours: 7:30 10:00 Number of Workers: 12 Workers completed cleanup of the site. 28

29 Labor Rates Table Material Quantity 1 Deconstruction Hours 2 Deconstruction Hours/unit 3 Campbell Avg. Dec Hrs/unit 4 Gainesville Hours/unit 5 Burdened Hours 6 Burdened Hours/unit Supervisory Hours/unit 7 Total Hours/unit 8 Campbell Avg. Total Hrs/unit Total Hours/sf of building 9 Component/Material Windows and Doors Windows 34 ea Total Doors and Windows MEP 5310 sf N/a N/a N/a Total MEP Interior Finishes Sheetrock Wall sf ACT - Ceiling 666 sf Vinyl Tile - Floor 5150 sf Total Interior Finishes Interior Walls and Ceilings Framing 1717 sf Insulation 1717 sf Total Wall Assembly Roof Aluminum Gutters 182 lf Asphalt Shingles 3108 sf Sheathing Wood 1x sf Structure 2655 sf N/a Structure 3373 lf Total Roof Assembly Exterior Walls Framing 4610 sf N/a N/a Fascia and Soffit 246 lf N/a N/a Vinyl Siding 4610 sf Wood 1x sf Total Exterior Walls Floor T&G Oak 1x sf Subfloor 5150 sf Joists 5150 sf N/a Joists 4915 lf Concrete Slab 508 sf N/a N/a Total Floor Columns Wood 6x6 220 lf N/a N/a Total Columns Total Building

30 General Notes: General Notes are the same as those in the chapter on 2748 Labor Rate Commentary Most of the Labor Rates from Building 2717 are comparable to the other Ft. Campbell buildings. Surprisingly at first, the second story height of the roof did not appreciably slow down the deconstruction rate. It might be expected that the added height would slow the movement of materials to the ground or force the workers to move more slowly. However, considering that the same fall protection measures and safety equipment were used on this building as on the lower one-story buildings, the workers methods of operation on the roof did not have to change for Building

31 General Description Size 152 x 60 Height Single Story Construction Type Wood frame Foundation Pier and beam 834 Building 834 was a warehouse during the mobilization for World War II. Except for 3 upfront preparations days, it was deconstructed in 35 days between June 11 and July 16, Building 834 may have been the most problematic building due to many complicating factors. As a large warehouse it had a heavier structure and greater heights over the floor. It was also used to store materials from the previous building deconstructions which posed challenges to the safe and effective deconstruction process. It was also the building with the least interior finishes and contained a very high proportion of salvageable lumber. 834 Floor Plan - Deconstructed areas are shaded. 31

32 Material Description and Inventory The materials and assemblies found in this building are as follows: Exterior Doors and Windows: There were minimal windows in this building and several sliding wood doors and large openings blocked with plywood. Window and door salvage was negligible. Interior Finishes: There was unpainted 1x6 T&G wood siding in the large main warehouse room and drywall finishes in the ancillary rooms. There was a crumbling fiberboard material attached to the underside of the roof rafters that came off very easily. The floor finish had areas of 1x4 T&G flooring where the circulation routes occurred. The principle flooring material overall was 2x6 T&G decking without a sub-floor. Roof: The roof structure was composed of 2x10 rafters at 24 o.c. supported by longitudinal double 2x10 beams. The beams and rafters and joists were predominantly bolted together with 2x6 bracing and 2x6 joists. Top and bottom chords were 2x6 lumber, with intermediate pieces of 2x6 s and 2x4 s nailed diagonally on either side of the main chords. The intermediate columns were 4-2x8 nailed together and were spaced about 10 o.c. running in the long direction and about 12 o.c. in the short direction - 4 bays across the short direction of the building. Longitudinal 2x6 bracing was between the columns in the center of the building. The roof finish was comprised of 1x8 boards with asphalt shingles that were all removed for disposal. Exterior Walls: The exterior walls were 2x6 at 24 o.c. resting on top of the 2x6 T&G decking with - vinyl siding over 1x8 lap siding over exterior drywall. These walls were supported laterally by the roof joists.. Interior Walls: Light 2x4 construction. 32

33 Wood Floor and Floor Structure: The finish floor over the entire building on the raised wood floor was 2x6 T&G. The floor structure was 2-2x12 joists at 16 on center supported by longitudinal concrete stem walls running the length of the building. The perimeter walls were also supported by a perimeter stem wall. All masonry and concrete was demolished mechanically after removal of the wood components. 33

34 Material Inventory and Labor Distribution Table Component 1 Material 2 Quantity 3 Labor Time 4 Exterior Windows and Doors MEP Casework Interior Finishes Interior Walls Roof Exterior Walls Wood Floor and Floor Structure Wood Door 7 x Large Metal Doors Aluminum Windows Total Exterior Windows and Doors % Total MEP % Total Casework % Plywood Paneling 444 sf 8.50 T&G 1x sf Sheetrock - Wall 2634 sf ACT - Ceiling 482 sf 0.75 Sheetrock - Ceiling 512 sf 4.75 Vinyl Tile - Floor 482 sf 3.25 Total Interior Finishes % Total Interior Walls 1174 sf % 6 Asphalt Shingles 9546 sf Sheathing Wood 1x sf Structure Wood 2x6, 2x8, 2x sf Total Roof % Framing Wood 2x sf Vinyl Siding 3770 sf Wood Siding 3770 sf Total Exterior Walls % Distribution of Labor 5 Tongue and Groove 3262 sf Oak1x3 Sub Floor T&G 2x sf Floor Structure 2x sf Total Floor % 7 Total Building % General Notes: General Notes are the same as those listed in the chapter on 2748 Specific Notes: 6. This warehouse had proportionally fewer interior walls than any of the other buildings except for The low percentage of time spent on this component is therefore expected. 7. The floor structure of this building was designed to support very large loads of stored materials and was heavily constructed. The tongue and groove 2x6 sub-floor proved to be very time consuming to deconstruct. The doubled 2x12 floor joists at 16 centers required more effort per square foot than the single joists on 24 centers found in all other buildings. 34

35 Deconstruction Narrative May 6, 2002 Hours: 7:30-4:00 Number of Workers: 12 May 17, 2002 Hours: 7:30 3:00 Number of Workers: 12 June 6, 2002 Hours: 8:15 4:00 Number of Workers: 42 June 11, 2002 Hours: 7:30 4:15 Number of Workers: 13 June 12, 2002 Hours: 7:30 4:30 Number of Workers: 13 Rain interrupted the day s work on Building 02748, so the workers moved to Building 834 where they were able to deconstruct oak tongue and groove flooring. Another rainy day. Work continued on deconstruction of the oak tongue and groove flooring. General clean up was done in preparation for future work. This was the first day of serious deconstruction of this building. A small team of workers removed the exterior vinyl siding. Inside, several teams were removing wood trim and panelling from the interior walls. Once the trim was cleared, tongue and groove 1x6 s were removed from the walls. Other workers were busy processing the tongue and groove flooring taken up in May as well as some of the tongue and groove wall material as it became available. Workers were divided between Building and 834. Some of those at 834 began demolishing the asphalt shingles on the east side of the roof. Others removed vinyl siding from the south side of the building and processed miscellaneous lumber that was being stored at this location. Demolition of asphalt shingles continued throughout the day. All shingles had been removed by late afternoon. Inside, workers continued removing tongue and groove flooring. 35

36 June 13, 2002 Hours: 7:30 4:15 Number of Workers: 17 June 14, 2002 Hours: 8:00 4:00 Number of Workers: 28 June 15, 2002 Hours: 8:15 3:30 Number of Workers: 29 June 16, 2002 Hours: 12:00 5:00 Number of Workers: 22 June 18, 2002 Hours: 8:00 3:00 Number of Workers: 27 Removal and processing of tongue and groove flooring inside the warehouse continued today, but had to be coordinated to stay clear of the work that was being done overhead removing 1x8 roof sheathing. Removal of the roof sheathing continued today. Workers on the ground began removing the exterior wood siding and sheathing in areas away from where overhead work was being performed. Processing of lumber from the warehouse as well as happened throughout the day. This day was much the same as the previous with removal of sheathing on the roof and exterior walls and processing of many types of lumber. A team was assigned to clean-up debris left behind during the removal of the sheathing inside the building and around its perimeter. Clean-up and disposal of debris continued as well as processing of lumber. A group of people removed air conditioning ducts and fire sprinkler pipes. Deconstruction of the roof structure began today. Workers used an existing wooden catwalk as a platform on which to stand while taking the trusses apart. Deconstruction of the fire sprinkler pipe continued in advance of the roof workers. On the ground, processing of the truss material began. 36

37 June 19, 2002 Hours: 7:30 4:00 Number of Workers: 30 June 20, 2002 Hours: 7:30 3:30 Number of Workers: 34 June 21, 2002 Hours: 7:30 11:45 Number of Workers: 35 June 24, 2002 Hours: 12:00 4:15 Number of Workers: 27 June 25-26, 2002 Hours: 7:30 4:30 Number of Workers: 16 June 27, 2002 Hours: 7:30 4:30 Number of Workers: 28 Deconstruction and processing of the roof structure continued. As the roof structure was removed, deconstruction of some walls began. A clean-up team moved throughout and around the building to keep work areas free of debris. Deconstruction and processing of the roof structure continued. Deconstruction and processing of the roof structure continued. Some work was done processing flooring and windows as well. Deconstruction and processing of the roof structure continued. Some work was done processing flooring as well. Deconstruction and processing of the roof structure continued. Some work was done processing flooring as well. Deconstruction and processing of the roof structure continued. The western exterior wall was pulled to the ground using ropes and the framing and siding processed. 37

38 June 28, 2002 Hours: 7:30 4:30 Number of Workers: 28 Deconstruction of the roof structure was completed. Processing of the roof structure continued. The remaining exterior walls were pulled down and deconstructed. July 1, 2002 Hours: 7:30 3:45 Number of Workers: 19 July 2, 2002 Hours: 7:30 1:45 Number of Workers: 19 July 3, 2002 Hours: 7:30 3:45 Number of Workers: 15 The morning was spent loading wood into the trailer for shipment to Austin, Texas. After lunch, deconstruction work began on the tongue and groove 2x6 sub-floor. Deconstruction of the subfloor continued. Large and frequent nails made the removal extremely difficult and time-consuming. More work on the sub-floor. July 5, 2002 Hours: 7:30 2:30 Number of Workers: 2 38 More work removing the subfloor. Deconstruction of the floor joists began.