Bauelements: Cost Report

Construc)on element breakdown for the ini)al 'hub' structure: M1

Materials

Labour

Total

Set up, Clearance, Demoli3ons.

Founda3ons (up to DPC)
Ground Floor Slab or Suspended Floor (including insula3on)
Drainage & Service Trenchwork
Specialist Building System (eg 3mber frame, SIPs, etc if applicable)
External & Internal Walls (including insula3on)
Intermediate Floor Zone (if applicable)
Fireplace & Chimney (if applicable)
Roof Structure, Insula3on & Covering
Joinery (Windows, doors, stairs, skir3ngs)
Specialist Products (eg; Eco products)
Electrical Installa3on
Plumbing Installa3on
Hea3ng/Ven3la3on Installa3on
Plastering (or dry-lining)
Kitchen and U3lity Units (+ appliances)
Decora3ons & Wall Ceramics
Floor Finishes
TOTAL COST FOR THE INITIAL 'HUB' MODULE

1.478,00
405,00
260,00
10.284,00
-
-
-
4.800,00
274,00
-
1.450,00
1.450,00
1.246,00
2.286,00
600,00
212,30
480,00
25.225,30

375,00
1.298,00
405,00
440,00
5.142,00
-
-
-
2.400,00
-
-
700,00
1.450,00
1.246,00
1.178,00
150,00
-
-
14.784,00

375,00
2.776,00
810,00
700,00
15.426,00
-
-
-
7.200,00
274,00
-
2.150,00
2.900,00
2.492,00
3.464,00
750,00
212,30
480,00
40.009,30

Cost of addi)onal standard rooms/modules

Size (sq m)

Shell or fully
completed?

Total

M2 Expanded Living Space

M3 Upper Level Bedroom Module
M4 Penthouse Level Bedroom Module
M5 Final Ground Floor Module

18,5
51,0
51,0
38,0

Fully Complete
Fully Complete
Fully Complete
Fully Complete

18.950,91
47.582,04
47.582,04
38.926,19

Total cost for the ini)al

one-o hub

Cost if 1,000 units

were mass
produced
38.008,83

Cost impact if the hub is mass produced

40.009,30

Bauelements: Cost Report

Detailed Construc)on element breakdown for the ini)al 'hub' structure: M1

Set up, Clearance, Demoli3ons.
Undertaken By: Building Owner

Materials

Labour

Total

375,00

375,00

1.478,00 1.298,00

2.776,00

405,00 405,00

810,00

Ground oor area of M1 = 50m approx. Double this to 100m to allow working area and parking.
Allow removal of 250mm spoil (keep 50mm topsoil for replan3ng), 25m of topsoil are therefore to
be removed.
Cost of clearing and removing oversite es3mated at 15/m.
(Digger = 6/m, Lorry = = 6/m, Tipping = 3/m)
15 x 25m = 375
Source: Homebuilding & Renova)ng
Founda3ons (up to DPC)
Undertaken By: Local Labour
Excavate 20m = 548
Bulked up to 45m, loaded into lorries = 456, Soil disposal incl 3pping charges 750,
Concrete founda3ons 10m = 892
Total = 2776
Source: Extrapolated from Data Given by Homebuilding & Renova)ng
Low skilled labour. Materials:Labour split assumed 2:1
Ground Floor Slab or Suspended Floor (including insula3on)
Undertaken By: Local Labour
Concrete Price = 90/m
Slab area = 50m, slab depth = 180mm, concrete volume = 50 x 0.18 = 9m
90 x 9m = 810
Source: Extrapolated from Data Given by Homebuilding & Renova)ng
Low skilled labour. Materials:Labour split assumed 2:1

Drainage & Service Trenchwork

Undertaken By: Local Labour

260,00 440,00

700,00

10.284,00 5.142,00

15.426,00

Excavate 88m drains (max 900mm depth): ganger and labourer for 2 days @ 220 per day
All pipes, lngs etc. assumed to be 110mm plas3c type, for underground use, 52m @ 5/m.
Source: Extrapolated from Data Given by Homebuilding & Renova)ng
Specialist Building System (eg 3mber frame, SIPs, etc if applicable)
Undertaken By: German Factory
Walls, ceiling and roof casseme delivered whole and complete with triple glazed UPVC windows
with 3lt & turn func3on. Timber is kiln dried pine. Walls pre-drilled with 40 no. voids for German
style electrical backboxes. Roof is nished to include sarking and roong membrane. Final roof
cladding to be completed within four weeks. Price calculated EXWorks (collec3on from factory)
plus aussumed 750 transport cost (0.25% of standard LKW @ 3000).

Statement by German House Manufacturer:
"The price of M1 is calculated at near cost, as part of a theore3cal and s3ll in-development
business strategy which involves recouping funds through the later sale of units M2-M5, as these
later units are to be bought at a 3me in client's lives when funds are more readily available. Note
also that in order for this strategy and cost model to work, adequate skills and knowledge must be
present in the UK to erect the modules."

Source: Quoted by German house manufacturer

High skilled, high eciency labour. Materials:Labour split assumed 2:1
External & Internal Walls (including insula3on) * Included in Specialist Building System
Intermediate Floor Zone (if applicable) * Included in Specialist Building System
Fireplace & Chimney (if applicable) * Not applicable
Roof Structure, Insula3on & Covering
Undertaken By: Local Labour
Covered area = 48sq.m, rate = 150
Source: Extrapolated from Data Given by Homebuilding & Renova)ng
High skilled, high eciency labour. Materials:Labour split assumed 2:1

-
-
-
4.800,00

-
-
-
2.400,00

-
-
-
7.200,00

Joinery (Windows, doors, stairs, skir3ngs)

Undertaken By: Building Owner

274,00 -

274,00

- -
1.450,00 700,00

-
2.150,00

1.450,00 1.450,00

2.900,00

1.246,00 1.246,00

2.492,00

27.8m length Skir3ng Boards at 5 rate = 139

Doors 45x3no. = 135
Source: Builder's Merchant Statement
Specialist Products (eg; Eco products) * Not applicable
Electrical Installa3on
Undertaken By: Local Labour
40no. Electrical backboxes, 40no. Faceplates, 8 switch fuseboard, 4no. Pendant outlets, 4no.
recessed LEDs, 2no.fused spurs.
Source: German Substructure Manufacturer's Statement (derived from subcontractor costs)
High skilled, high eciency labour. Materials:Labour split assumed 2:1
Plumbing Installa3on
Undertaken By: Local Labour
Kitchen: Hot, cold feeds and waste for sink. Cold feed for washing machine, waste to share sink,
stainless steen sink and draining board.
Bathroom: Hot, cold feeds and waste for shower and washbasin, waste and cold feed for WC.
450mm wall hung washbasin, pedestal pan and cistern, shower cubicle with mixer.
Source: German Substructure Manufacturer's Statement (derived from subcontractor costs)
High skilled, high eciency labour. Materials:Labour split assumed 2:1
Hea3ng/Ven3la3on Installa3on
Undertaken By: Local Labour
Hea3ng Viallant Combi-Boiler w/ speedt UFH.
Ven3la3on 'Frischanlage' non-heat-recovery mechanical ven3la3on system.
Source: German Substructure Manufacturer's Statement (derived from subcontractor costs)
High skilled, low eciency labour. Materials:Labour split assumed 1:1

Plastering (or dry-lining)

Undertaken By: Local Labour

2.286,00 1.178,00

3.464,00

600,00 150,00

750,00

212,30 -

212,30

480,00 -

480,00

25.225,30 14.784,00

40.009,30

103m of wall drylined & skimmed at 22/m = 2266

48m of ceiling drylined & skimmed at 25/m = 1200
Source: Homebuilding & Renova)ng
Low skilled labour. Materials:Labour split assumed 2:1
Kitchen and U3lity Units (+ appliances)
Undertaken By: Building Owner and Local Labour
5m of countertop & cabinets, oven, gas hob, washing machine.
Source: Builder's Merchant
Assumed 150 delivery & comissioning of cooking appliances.
Decora3ons & Wall Ceramics
Undertaken By: Building Owner
103 sq.m painted at paint materal cost of 1.10/m = 113.3
Tiled area kitchen 1.5m, 3le area bathroom 3.5m at 3le material cost of 20/m= 100

Source: Homebuilding & Renova)ng
Floor Finishes
Undertaken By: Building Owner
48m carpet or laminate at cost of 10/m = 480

Source: Homebuilding & Renova)ng
TOTAL COST FOR THE INITIAL 'HUB' MODULE

Bauelements

Delivery Report

German Offsite Manufacture + Local Labour + DIY = BauElements 40k Starter Module
Passion in wood craftsmanship remains strong in Europes forested regions. This is particularly true in Germany, a country which
has also developed a powerful manufacturing sector founded on efficiency and technological progress. Combining these two factors, numerous factories in Germany produce thousands of robust and thermally efficient houses each year using local, sustainable wood. The BauElements 40k Starter Module proposal takes the advantages of this German knowledge and combines it
with British design expertise to create a low-energy, adaptable, upgradable and affordable starter module. Those involved in the
procurement of a BauElements starter module fall into three groups; German Offsite Manufacturers, Local Labour and the Building Owner undertaking DIY. In dividing up the work, each party plays to its strengths.
Local teams offer their flexibility and access to competitive supply chains, around 50% of the total budget goes to them. Keeping
this major share of expenditure in Britain while increasing the rate of BauElements delivery through offsite manufacture ensures
that the most benefit is felt in local economies. The Germans offer their rigorous approach to performance, quality and volume.
Around 40% of the 40k spend goes to Germany. The building owner offers oversight and passion, connecting the dots between
the tradespeople and driving the project forward. Around 10% of the cost goes toward materials which the building owner him or
herself manually installs.
Step 1: Site Preparation
Prior to the manufacture of the house, local labour prepares the site with ground-works, foundations and slab. There is nothing
unusual required here, but a 180mm slab is needed into which to anchor the superstructure.
Step 2: Superstructure Manufacture
The Germans manufacture the walls, floor cassettes and roof cassettes. These elements are prepared to precise tolerances in
Bavaria and are delivered on a single truck to site in the UK. The walls feature all insulation and are complete with windows and
external doors. They are finished externally to the point of waterproof, reinforced render and internally, wooden panels are visible.
Historically, German personnel would have erect the house itself to the point of wind and water tightness, but in the interests of
keeping within the 40k price envelope, it is proposed that UK personnel would be trained to do this. On departure of the truck,
the input of the Germans on this starter module ceases, as they focus their attention on the next one the production line.

Step 3: Installation
The building elements arrive on site, are craned into position whole and are bolted together by local labour. The whole process
is over by lunchtime. The starter module has its form but is naked, still needing external render and zinc roof cladding. As the
fundamentals of a BauElements starter module are always the same, production volumes can be maximised. It is like a car chassis
awaiting personalisation.

Step 4: Dressing the Module

In the four weeks which follow, local labour provides external rendering of walls, roof cladding in zinc, and the slab-perimeter
insulation. From the outside, the house itself is complete. Meanwhile inside, the interior is lined with plasterboard. A gas boiler is
installed, serving underfloor heating. Mechanical ventilation, first- and second-fix electrical and sanitary-ware are undertaken by
local labour. Internal doors are fitted together with ironmongery. The kitchen is chosen by the owner and installed over two days.
Many elements fitted by local labour refer to local architectural and interior design typologies. Cladding materials are possible
such as brick-slips or timber weatherboarding. Inside, ornament and style can widely vary to reflect the background and ambitions
of the owner.

Step 5: Finishing Touches

Finally, the building owner undertakes the personalised finishing touches such as tiling, painting and laying of the external
landscaping. These are low-skilled tasks, done this way to maximise the budget and further ensuring that the each BauElements
starter module develops its own identity.

Bauelements

Delivery Report continued

System Materials, Construction Methods and Junctions

A BauElements starter module is designed for very low levels of energy use of around 60kW/m/a, in contrast the current, typical
UK energy usage of 240kW/m/a. It does this using two principles. Firstly heat cannot escape due to ample insulation. Secondly
air does not escape, carrying heated air with it, due to an unbroken vapour barrier enclosing the house. Walls are made from a
heavier-duty version of SIPs. The German version comprises closed OSB panels, internally lined with the vapour barrier and plasterboard, externally bonded to rigid insulation which itself is faced with a through-colour reinforced render. The assembly gives
a U value of 0.11 W/mK. Roof and floor cassettes are based around similar structural principles to each other, using 24cm deep
beams spanning between walls below. If the cassette is a roof, the cavities are filled with glass fibre insulation and sarking boards
above are clad in zinc. In the case of floors, insulation between joists need only be half as deep, as this is enough to provide the
required sound insulation.

Price Reductions through Volume Manufacture

The BauElements makes use of volume production methods to enable maximisation of quality and performance through volume
manufacture. As long as the supply chain remains as described, production is scaled up or down with little effect. As production
grows and reached hundreds of starter module per year, it is expected that there will come a tipping point at which a factory can
be built in the UK. This could be a subsidiary of the German manufacturer, a licensee or a standalone company. At this point, savings in transport and logistics drop the overall price by an estimated 5%. The entire 40k expenditure remains in the UK while the
British workforce has benefitted from profit-making knowledge which diversifies and adds stability to the UK economy.
Upgrade Options
Based around the BauElements system and without compromising the advantages offered by standardised, volume manufacture,
upgrade options are possible. Further emphasis can be placed on thermal insulation, perhaps in colder, more northern regions
or where a Passivhaus is wanted, which uses only 15kW/m/a. The outer layer of rigid thermal insulation is increased in depth by
10cm, giving a wall U Value of 0.09 W/mK. For those who wish to go a step further to become energy producers, the German
Plusenergie concept can be employed. The heating system is specified as technology which is powered by electricity such as a heat
pump. Photovoltaic panels are then installed on the roof to provide the required juice. A Plusenergie House offers greater independence from energy price rises by using its own free solar energy. As battery technology progresses, it is anticipated that BauElements communities will be able to enjoy complete independence from fossil fuels.