COST COMPARISON DINCEL vs AAC WALLS

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1 COST COMPARISON DINCEL vs AAC WALLS DISCLAIMER The information contained in this document is intended for the use of suitably qualified and experienced building professionals. This information is not intended to replace design calculations or analysis normally associated with the design and specification of buildings and their components. Dincel Construction System Pty Ltd accepts no liability for any circumstances arising from the failure of a specifier or user of any part of Dincel Construction System to obtain appropriate professional advice about its use and installation or from failure to adhere to the requirements of appropriate Standards and Codes of Practice, and relevant Building Codes. 1

2 HOW DO YOU GET MAXIMUM BENEFIT FROM DINCEL WHEN USED IN APARTMENT CONSTRUCTION? 2

3 CURRENT MARKET POSITION FOR BUILDERS / DEVELOPERS Land purchase price same for all. Apartment selling price same for all. Apartment market selling prices about 10% down. WHERE DO YOU MAKE THE DIFFERENCE TO COMPENSATE 10% DISCOUNT AND BE COMPETITIVE AT THE SAME TIME? DINCEL MAKES A DIFFERENCE BY REDUCING CONSTRUCTION COST AND TIME 3

4 WHAT TO LOOK FOR IN COST AND TIME EFFICIENCY SPEED Installation speed workplace safety. Co-ordination of trades Not affected by wet weather conditions Faster than column-slab system having infill walls. MATERIAL COST SAVING Less cement/concrete and steel in typical floor slabs and transfer levels. Eliminates conventional footings and waterproofing costs. Reduced waste and cleaning costs. Reduced maintenance costs. 4

5 DID YOU KNOW THAT LOAD BEARING WALLS OFFER: Maximum STRENGTH for Earthquakes and Cyclones FASTER Construction Maximum ENERGY EFFICIENCY Maximum COST EFFICIENCY Up to 43% cost efficiency Concrete Structures Engineering Codes offer significant benefits to load bearing wall systems. 5

6 LOADBEARING DINCEL WALL 6

7 DINCEL WALL MAIN PROFILES Maximum Building Height 110mm DINCEL Up to 8 storey buildings 155mm DINCEL Up to 15 storey buildings 200mm DINCEL Up to 30 storey buildings 275mm DINCEL Up to 45 storey buildings Maximum Building Height With Sprinklers/Fire Rated Plasterboard 110mm DINCEL Up to 12 Storeys 155mm DINCEL Up to 22 Storeys 200mm DINCEL Up to 40 Storeys 275mm DINCEL Up to 60 Storeys 7

8 BUILDING WITH DINCEL CONSTRUCTION SYSTEM Results in Less Concrete / Steel and Time Dincel System No columns, loadbearing Dincel Wall and one-way floor system. Floor Systems Timber floors, in-situ concrete or precast flooring (Ultrafloor, precast planks). Bondek, Condeck, Kingfloor, etc. WALL FLOOR SLAB DETAIL AT DINCEL WALL The steel bars shown are Earthquake / Wind Engineering requirement. 8

9 CONVENTIONAL COLUMN-SLAB FRAME The only reason this most common construction system consisting of columnslab & infill wall system exist is because there was no cost and time efficient concrete wall system available like DINCEL to replace columns and infill walls used for acoustic and fire purposes. 9

10 MINIMUM 23%, UP TO 43 % COST SAVINGS 42% More Energy 75 Tonnes More CO 2 SLAB-COLUMN FRAME SYSTEM 42% Less Energy Concrete In Slab: 36% MORE 75 Tonnes Less CO 2 Concrete In Slab: 36% LESS Steel In Slab: 64% MORE Steel In Slab: 64% LESS Total Cost: 43% MORE DINCEL CONSTRUCTION SYSTEM Total Cost: 43% LESS FLOOR SLABS CARRIED BY LOAD BEARING DINCEL-WALLS WILL ALWAYS RESULT IN LESS CONCRETE AND STEEL 10

11 COLUMN-SLAB CONSTRUCTION SYSTEM WITH INFILL WALLS COST MORE THAN USING DINCEL LOADBEARING WALL SYSTEM Column-slab frame system when built with the following infill wall types Infill Wall = Stud & Plasterboard COST MORE 23% Infill Wall = AAC Wall System COST MORE 28% Infill Wall = Masonry / Brick Wall COST MORE 43% 11

12 IMPORTANT ADVICE FOR DESIGNERS SLAB-COLUMN FRAME SYSTEM DINCEL CONSTRUCTION SYSTEM MAJOR COST SAVING RULES IN MULTI-STOREY APARTMENT CONSTRUCTION Cross ventilation requirements mostly result in party walls being parallel to each other. The most cost effective construction results utilising load bearing party walls. All party walls and wet areas are located at the top of each other in multi-unit developments and is a key cost issue. Where possible it is highly recommended that party walls are orientated at right angle direction to car parking aisle ways. 12

13 CASE STUDY DINCEL vs AAC WALLS Dincel vs Stud & Plasterboard Walls can be considered similar as per this case study 13

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15 AAC WALL SYSTEM vs DINCEL CONSTRUCTION SYSTEM AAC SYSTEM DINCEL CONSTRUCTION SYSTEM AS CONCRETE STRUCTURES CODE REQUIRE AAC SYSTEM Minimum 200mm thick slab. No mesh reinforcement allowed. Steel reinforcement rate is 130kg/m 3 RESULT: Including Time Saving EVERY 3 RD FLOOR COMES FREE OF CHARGE DINCEL SYSTEM Minimum 150mm thick slab (for acoustic reasons) with SL92 mesh use allowed. Steel reinforcement rate is 77kg/m 3 15

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17 DINCEL LOADBEARING WALLS 17

18 BUILDING WITH AAC SYSTEM BUILDING CODES REQUIREMENT FOR THE DETAILS BETWEEN STRUCTURE AND AAC WALLS WALL-FLOOR DETAIL AT AAC WALL Buildings move and slabs deflect in time which can result in gaps at fire/acoustic sealants. WHO BECOMES RESPONSIBLE FOR NON- COMPLIANCE? Builder Developer Architect? WALL-COLUMN DETAIL AT AAC WALL 18

19 AS CONCRETE STRUCTURES CODE Mandatory from May 2011 Frame Structures with AS Minimum slab thickness is 200mm. Mesh reinforcement cannot be used. DINCEL load bearing system allows 150 mm thick slabs and mesh reinforcement. COLUMN-SLAB SYSTEM 19

20 BS EN : 2004 EUROCODE Flat Plates : a 90 minute fire requires 200mm thick slab (Table 5.9). One/two way slabs by beams or loadbearing Dincel Wall : a 90 minute fire requires 100mm thick slab (Table 5.8). COLUMN-SLAB SYSTEM 20

21 150mm THICK SLAB - ACOUSTIC QUESTION YOUR ACOUSTIC ENGINEER If a 150mm thick wall for airborne sound complies with the BCA s deemed to satisfy condition. Why a 150mm thick slab would not comply for airborne sound purposes? The following Day Design and SLR Acoustic Certificates are based on the Canadian s acoustic floor testing for 150mm slabs. There is no reason why your Acoustic Engineer would not agree with Day Design s and SLR s certifications. Acoustic improvements to Australian buildings were originally introduced because of inadequate wall construction (e.g. brick walls with excessive wall chasing); not necessarily the poor performance of minimum 125mm thick slabs used then. Why would you waste extra concrete and steel resulting in an increase in the structural cost by a minimum of 28% if there is evidence that a 150mm thick slab would comply. IF YOU DON T ASK YOU WILL NOT ACHIEVE MONEY AND TIME SAVING 21

22 Building Code of Australia allows Alternative Solution. BCA Volume 1 A0.4 and A0.5. SLR Certification complies with BCA A2.2 Certificate of Evidence. Therefore: CAN USE 150mm SLAB! 22

23 Building Code of Australia allows Alternative Solution. BCA Volume 1 A0.4 and A0.5. Day Design s Certification complies with BCA A2.2 Certificate of Evidence. Therefore: CAN USE 150mm SLAB! 23

24 WHY BUILDING WITH DINCEL LOADBEARING WALLS PROVIDES A FAST AND COST EFFICIENT SOLUTION AS 3600 allows thinner than 200mm slabs reinforcement. and use of mesh The use of mainly mesh reinforcement in the floor slabs achieves the FASTEST possible floor slab reinforcement installation time. The conventional column free vertical elements (mainly walls) with Dincel s Snap-On connecting panels achieves the fastest possible installation. 24

25 1 Concrete Supply CONVENTIONAL FRAME CONSTRUCTION WITH AAC WALLS WITH CONVENTIONAL FORMED SLABS TOTAL Slab (200mm) x 300 columns 3 off (32 MPa) 25m $200.00/m 3 $5, Concrete Laid (Slab 7 x x 1.8 = 116.9m2) + columns 3 off Slab laid including pump cost and surcharge = 116.9m 2 x $20.00/m 2 Columns Concrete to be poured prior to slab, minimum charge 1 man labour (1 x $300.00/day) + pump cost (4 hours $160.00/hour) $2, $ Steel Supply Slab and columns reinforcing bars (not mesh) $2,000.00/t $6, Steel Laid reinforcing bars (not mesh) $800.00/t $2, Formwork Slab 116.9m $70.00/m 2 Column 3 off x $ each $8, $2, mm AAC Panel supplied and installed Perimeter and party walls 74.5m 2 x $75.00/m 2 (includes restraints and caulking) $5, Cost difference between Fyrcheck & standard plasterboard 74.5m2 x $20.00/m 2 = $1,490 $1, TOTAL COST $34, Per Square Metre of Floor Area Cost $34, $296.60/m 2 Note: Floor finishes, internal partition walls, plasterboard, insulation, metal studs, finishes at party and façade walls are not included in the above cost analysis as they are common to both Dincel and AAC Wall systems. Cost of finishing at the junction of the AAC Wall System and column not included. 25

26 DINCEL CONSTRUCTION SYSTEM WITH CONVENTIONAL FORMED SLABS 1 Floor Slab (116.9m 2 ) Concrete supply (32MPa) = 17.5m $200.00/m 3 Concrete laid (including pump) = 116.9m $20.00/m 2 Reinforcement (mainly mesh): Supplied $1,500.00/t Laid $400.00/t Slab formwork 116.9m $70.00/m 2 2 Dincel Wall Concrete supply (20MPa) 6.4m $165.00/m 3 Concrete pump 61.3m $4.00/m 2 (including operator for concrete placement) Steel supply $1,500.00/t 110mm Dincel Form for party walls 61.3m $85.00/m 2 Straight Dincel Party Wall top-down installation (no bracing), reinforcement placement 61.3m $25.00/m 2 TOTAL $3, $2, $2, $ $8, $1, $ $46.00 $5, $1, TOTAL COST $24, Per Square Metre of Floor Area Cost $24, $211.00/m 2 Note: Floor finishes and wall paintings are not included in the costs. DCS COST EFFECTIVENESS [(1 ($211.00/m 2 $296.60/m 2 )] = 0.29 = 29% THIS MEANS THAT DCS IS 29% CHEAPER THAN THE AAC WALL SYSTEM Note: Floor finishes, internal partition walls, plasterboard, insulation, metal studs, finishes at party and façade walls are not included in the above cost analysis as they are common to both Dincel andaac Wall systems. 26

27 DINCEL CONSTRUCTION SYSTEM WITH ULTRAFLOOR 1 Ultrafloor (104.3m 2 ) + Conventional Formed Slab (12.6m 2 ) = 116.9m 2 Concrete Supply (25MPa) = (0.11m x 104.3m 2 $187.00/m 3 Concrete Laid (including pump) = 104.3m $20.00/m 2 Reinforcement (mainly mesh 6 kg/m 2 ) Supplied 626 $1.50/kg Laid 626 $0.40/kg Ultrafloor Deck (incl. Temporary Propping) 104.3m $80.00/m 2 Miscellaneous Formwork $30.00/m 2 Balcony Slab ( ) = 12.6m 2 Conventionally Formed Slab Concrete Supply = (12.6m 2 x $200.00/m 3 Concrete Laid (including pump) = 12.6m $20.00/m 2 Formwork = 12.6m $70.00/m 2 Reinforcement Supplied $2,000.00/t Laid $800/t Courtesy of Ultrafloor $2, $2, $ $ $8, $ $ $ $ $ $ Dincel Wall (as per Dincel with Conventional Slab Calculations) $8, TOTAL COST $24, Per Square Metre of Floor Area Cost $24, $212.1/m 2 Note: Floor finishes and wall paintings are not included in the costs. DCS COST EFFECTIVENESS [(1 ($212.1/m 2 $296.60/m 2 )] = 0.28 = 28% THIS MEANS THAT DCS IS 28% CHEAPER THAN THE AAC WALL SYSTEM Note: Floor finishes, internal partition walls, plasterboard, insulation, metal studs, finishes at party and façade walls are not included in the above cost analysis as they are common to both Dincel andaac Wall systems. 27

28 NET BENEFIT WITH DINCEL INCLUDING SPACE SAVING Time Saving between 30% up to 50% SPACE SAVING (0.226m 0.189m) = 0.037m VALUE GAINED IN SPACE SAVING = 14m x x $8,000.00/m 2 = $4, per unit = $4,144.00/116.9 m 2 per unit = $35.00 / m 2 MATERIAL AND LABOUR COST SAVING = 1 [($211 $35) $296.60] = % SAVING 40% MATERIAL AND LABOUR COST SAVING 28

29 FURTHER SAVINGS TRANSFER SLAB DINCEL SYSTEM DINCEL CAN ELIMINATE COSTLY TRANSFER SLABS Transfer slabs are eliminated if party walls are placed in a right angle direction to the car parking aisle way below. Result: 150mm thick slabs Steel Rate is 77kg/m 3 instead of conventional 450mm to 600mm thick slabs with posttensioning or very heavy steel bars. 29

30 TRANSFER SLAB AAC WALL SYSTEM AAC WALL SYSTEM WILL ALWAYS RESULT IN VERY COSTLY AND TIME CONSUMING TRANSFER SLABS WHEN CAR PARKING COLUMNS AND SUPERSTRUCTURE COLUMNS ARE NOT ALIGNED. Result: To carry 8 storeys above: 450mm to 600mm thick slabs with post-tensioning and/or very heavy steel bars. More bulk excavation/more columns. 30

31 SUMMARY DINCEL CONSTRUCTION SYSTEM STRUCTURAL EFFICIENCY TYPICAL BUILDING CROSS SECTION 31

32 56 LUXURY APARTMENTS, 3 & 5 11 MERITON STREET, GLADESVILLE Refer Dincel Website (download) Pinnacle TESTIMONIAL 32

33 40 RESIDENTIAL UNITS, AUBURN ROAD, YAGOONA Refer Dincel Website (download) Gondella TESTIMONIAL 33

34 200 APARTMENTS, BRUCE, ACT 77 WEEKS CONSTRUCTION TIME REDUCED BY 26 WEEKS = 30% TIME SAVING Refer Dincel Website (download) CHC Housing TESTIMONIAL 34

35 133 APARTMENTS : 5 11 PYRMONT BRIDGE ROAD, CAMPERDOWN 52 WEEKS CONSTRUCTION TIME REDUCED BY 26 WEEKS Refer Dincel Website (download) Ceerose TESTIMONIAL 35

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37 DINCEL SYSTEM vs AAC SYSTEM DCS IS CLEARLY A FASTER Construction. Slabs are minimum 50mm thinner and utilise mesh reinforcement which take significantly less time than slabs with post-tensioning. True posttensioned slab design should not incorporate top and bottom mat reinforcement. Dincel Walls and floor slabs can be installed simultaneously. The AAC System requires columns to be installed first, then the floor slabs and then the AAC walls are installed between the columns. Column forming and steel reinforcement placement for 3 columns of the Cost Study will take more time than installing Dincel Wall. (AAC walls yet to be installed). SPACE SAVING when 110 Dincel Walls are used. Minimum 28% (40% with Space Saving) COST EFFICIENCY at typical floor levels. Minimum 75% COST EFFICIENCY at the transfer slab level. 37