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KEYWORDS
Insulating Concrete Forms Cost Analysis, Insulating Concrete Forms, ICF, ICFs, Cost Study, Cost Comparison, NAHB Research Center, National Association of Home Builders Research Center, ICFs to Wood, building system cost study, cost, research, PCA Research, basement costs, above-grade construction costs, ICF above-grade costs, ICF costs, 2003 PCA Research, Residential research, Residential cost analysis, SN2781, Serial Number 2781.
ABSTRACT
Insulated Concrete Forms (ICFs) have been successfully used in the United States, Canada, and Europe for over twenty years. However, builders have had to rely on experience, or proprietary software to estimate ICF construction costs. The lack of readily available installation cost data for ICF systems may be one of the barriers for greater acceptance and market share of this product. Most building materials, assemblies, and construction methods associated with residential and light commercial construction have been closely evaluated and researched to determine average installation costs. This data can be found in estimating guides, such as those published by RSMeans1, to assist owners, developers, builders, designers, and contractors in determining construction costs. These non-proprietary estimating tools do not cover ICF construction at this time. The purpose of this project is to collect and prepare construction cost data for ICF use in residential and light commercial construction. This will allow current ICF users and potential users to have a clear understanding of the construction costs involved for this type of building system; similar to how costs are estimated for other common construction assemblies. This report summarizes ICF costing data obtained by the NAHB Research Center through an extensive survey of experienced ICF builders and contractors. Average material and labor costs have been developed and presented in this report. The summarized data has been formatted similar to that of RSMeans. This information will provide owners, builders, designers, and contractors with a valuable resource for estimating the construction costs for ICF buildings.
REFERENCE
NAHB Research Center, Inc., Upper Marlboro, Maryland, USA, 2004, 47 pages.
1
Residential Cost Data, 23rd Annual Edition, RSMeans Construction Publishers & Consultants, Kingston, MA 2003
DISCLAIMER
While the information in this document is believed to be accurate, neither the authors, nor reviewers, nor the Portland Cement Association, nor the NAHB Research Center, Inc., nor any of their employees or representatives make any warranty, guarantee, or representation, expressed or implied, with respect to the accuracy, effectiveness, or usefulness of any information, method, or material in this document, nor assumes any liability for the use of any information, methods, or materials disclosed herein, or for damages arising from such use.
ii
TABLE OF CONTENTS
INTRODUCTION ...................................................................................................................... 1 OBJECTIVES ............................................................................................................................. 1 Task 1 Identify Experienced ICF Contractors ..................................................................... 1 Task 2 Develop the Cost Survey Form ................................................................................ 2 Task 3 Conduct the Contractor Cost Survey........................................................................ 2 Task 4 Summary Report of Cost Data ................................................................................. 2 SURVEY METHODOLOGY .................................................................................................... 2 Materials ................................................................................................................................. 2 Labor Tasks............................................................................................................................. 3 Special Job Costs .................................................................................................................... 3 SURVEY RESULTS .................................................................................................................. 3 ICF COST ANALYSIS .............................................................................................................. 4 Below Grade Flat ICF Walls - Materials ................................................................................ 4 Below Grade Flat ICF Walls Labor ..................................................................................... 5 Above Grade Flat ICF Walls Materials ............................................................................... 6 Above Grade Flat ICF Walls Labor..................................................................................... 7 CONCLUSION........................................................................................................................... 9 Below Grade Walls ................................................................................................................. 9 Above Grade Walls................................................................................................................. 9 ACKNOWLEDGEMENTS...................................................................................................... 10 APPENDIX A SURVEY FORM......................................................................................... A-1 APPENDIX B SURVEY PARTICIPANTS........................................................................ B-1 APPENDIX C SURVEY RESPONSE SUMMARY .......................................................... C-1 APPENDIX D ICF COSTS (RSMEANS FORMAT) ......................................................... D-1
iii
OBJECTIVES
The goal of this project was to collect accurate construction cost data for residential and light commercial buildings made with ICFs. This data may then be used for submittal to construction estimating guides such as RSMeans. There were four objectives for this project. These objectives are listed as project tasks below:
Residential Cost Data, 23rd Annual Edition, RSMeans Construction Publishers & Consultants, Kingston, MA 2003
SURVEY METHODOLOGY
The concept for the survey was to have several ICF contractors and distributors throughout the country submit construction cost estimates on the same ICF home plan (see Appendix A). The cost estimates were to be based on flat type ICF use. A standardized home was used to ensure that each contractor provided an estimate for the same structure. The home did not necessarily represent that of a typical ICF design, but was intended to include the basic elements used in ICF construction. The model was a 4,160 square foot3, two-story home derived by the NAHB Research Center. The survey participants received three simple wall layouts; one for the basement, one for the first floor, and one for the second floor. The window and door opening locations were specified on each layout and wall dimensions were shown. To further simplify the process, the total linear footage of wall was provided for each floor, along with the total linear footage of window and door buck. In addition, the wall thickness, wall height, and steel reinforcing schedule in the walls were specified for each floor. The survey was split into two sections: below grade walls, and above grade walls. Each of these sections included a material cost section and a labor cost section. In the materials section, all of the elements needed to construct an ICF wall were listed. In the labor section, all labor tasks required for constructing an ICF wall were included. Participants in the survey were to fill out the form with cost estimates for each of these items. The materials and labor tasks that were included in the survey are listed below.
Materials
3
Window and door buck Top plates Anchors Waterproofing Finishing (parging)
Labor Tasks
Placing ICFs Bracing Installing Reinforcement Pouring concrete Waterproofing Finishing
In addition to the cost-estimating questions, each participant was asked to answer several questions pertaining to their particular business. For example: materials typically used, special methodologies used, years of experience in ICF construction, and geographic area served. This allowed for an evaluation of the survey sampling. A broad geographical range of samples and knowledge of the experience level of the sample population was desired. The survey form was mailed to 137 ICF contractors, and 113 ICF distributors. The participants were given nine weeks to complete the survey. A reminder letter was sent out after the second week to encourage participation in the survey.
SURVEY RESULTS
Overall, the return rate of the survey was lower than anticipated. Only seven percent of the surveys were returned to the NAHB Research Center, and some of the returned surveys were incomplete or had been completed in error. A twenty percent return rate had been expected for this research. After nine weeks, a total of 18 surveys had been returned; 14 from contractors, and 4 from distributors. The experience level of the participants that returned the survey ranged from 1 year to 19 years in the ICF construction industry. The average experience level was 9 years. The geographic distribution of the returned surveys represented the three major regions of the Untied States well, and is shown in the map below. However, some of these surveys were incomplete, and could not be used for the final summary cost analysis.
Geographic Distribution of Returned Surveys (Shaded states indicate one or more surveys returned from that state)
and are shown with the specific material. Averages were computed with these units, and a cost per square foot of ICF wall is included to compare with standard estimating guides such as RSMeans.
Below Grade Flat ICF Walls Materials
Respondent Number Material 1 Concrete ($/CY) Flat ICF Forms ($/SF) Reinforcing Bar ($/LF) Waterproofing ($/SF) Anchor Bolts ($/each)
3 2
AVG. 4 75 6 75 7 65 8 72 9 80 11 75 14 68 16 72.86
Entry
1.80
3.38
2.93
2.73
3.40
3.62
3.00
3.00
3.00
3.13
0.27
0.21
0.24
0.13
0.14
0.20
0.66
0.42
0.41
0.70
0.53
0.54
1.00
0.28
0.65
0.60
0.63
0.02
1.40
2.50
5.80
3.75
3.36
0.09
.09
.33
.18
0.20
0.20
Special Costs Concrete Pump ($/SF) Bracing and Scaffolding ($/LF) Engineering ($/LF) 1.70
0.54
0.25
0.28
0.56
0.24
0.38
0.38
2.81
2.14
1.88
1.31
1.97
0.22
1.88 Total material cost per square foot (below grade, 8-inch, Flat ICF wall )
3.12
3.75
7.50
4.06
0.16
6.71
1 2
Converted to Cost per square foot of ICF wall #4 bar at 24 o.c. in vertical direction and 36 o.c. in horizontal direction 3 Anchor bolts placed at 4 o.c. 4 Based on 0.027 LF of buck per SF of wall 5 Assumes half of foundation wall parged (1440 / 2 = 720 SQ FT)
Entry
Total labor cost per square foot (below grade, Flat ICF wall)
1
Material 2 70 4 75 7
AVG. 11 75 14 68 16 17 75 73.12
Entry
8 72
9 80
70
1.35
3.19
2.32
2.93
2.24
2.50
2.62
3.00
2.94
3.50
2.15
2.74
0.20
0.25
0.24
0.20
0.14
0.23
0.21
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
1.00
1.00
0.75
1.20
0.99
0.03
Door and Window 4 Buck ($/LF) Parging ($/SF) Special Costs Concrete Pump ($/SF) Bracing and Scaffolding ($/LF) Engineering ($/LF)
1.40
3.50
2.42
1.79
5.77
1.75
2.77
0.21
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
0.31
0.14
0.27
0.26
0.31
0.31
0.24
0.52
0.30
0.30
3.00
4.29
1.88
1.31
2.62
0.10
1.88 Total material cost per square foot (Above grade, 6-inch, Flat ICF wall)
3.75
9.38
5.00
0.19
5.05
1 2
Converted to dollars per square foot of ICF wall #4 bar at 48 o.c. in vertical direction and 32 o.c. in horizontal direction 3 Anchor bolts placed at 4 o.c. 4 Based on 0.075 LF of buck per SF of wall
AVG 14 16.67 16 10.00 4 0.01 0.02 11.00 130 0.53 17 15.00 1.5 0.01 15.00 198 1.09 17.05 2.4 0.02 17.93 152 1.03 22.50 10
Entry
0.02
1.03
0.15
0.20
0.15 1.20
15.00 20 0.21 15.00 12 0.13 N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. N.A. 15.00 20 0.21 21.00 4 0.06 N.A. N.A. N.A.
30.00 4.53 0.05 30.00 18.13 0.20 N.A. N.A. N.A. 30.00 15.60 12 0.07 N.A. N.A. N.A. N.A. N.A. N.A. 11.00 48 0.19 N.A. N.A. N.A. 14.00 32 0.21 0.17 N.A. N.A. N.A.
22.50 12.27 0.13 18.52 18.82 0.13 N.A. N.A. N.A. 19.67 26 0.20 0.05 0.05 1.71 0.20 N.A. 0.13 0.13
CONCLUSION
The ICF construction cost estimates derived is this survey were generally higher than costs for other common construction types. Comparisons with wood construction costs, as published in the 2004 Residential Cost Data by RS Means, are shown in the tables below. For below grade use, ICF construction costs are about 38 percent higher than costs for wood foundations. For above grade walls, ICF construction costs are about double that of wood frame construction. This results in about a four percent increase in the total construction cost for a home similar to the one in the survey. However, the number of samples used to derive these values may be too low to provide a high level of confidence in this data. Many of the survey responses had not been answered, or had been inadvertently answered wrong. Therefore, some of the values presented in the final cost estimate were derived from small number of responses. It is recommended that this be used as a starting point for ICF costing data.
Below Grade Walls Wood Foundation1 Labor Hours3 Materials Installation Total Cost4
(hrs/ft ) ($/ft )
2 2 2
0.057 3.65
($/ft ) 2.32 2.33 2 ($/ft ) 5.97 8.26 1 Based on 2004 Residential Cost Data by RS Means for: 2x8 treated studs at 16 o.c., double top plate, single bottom plate, 3/4 treated sheathing, 15# asphalt paper, 4 mil polyethylene vapor barrier, 9 R30 insulation batts, and headers for openings (2% of total wall SF). 2 Based on PCA survey data for: 8 flat ICF wall, reinforcing, damproofing, parging, door and window bucks (2% of total wall SF), and engineering. 3 Labor hours required to construct one square foot of wall. 4 Total cost in dollars to construct one square foot of wall.
Above Grade Walls 2x4 Wood Wall System1 Labor Hours5 Materials Installation Total Cost6
1
($/ft ) Based on 2004 Residential Cost Data by RS Means for: 2x4 studs at 16 o.c., double top plate, single bottom plate, let-in corner bracing, 1/2 sheathing, 3.5 R11 insulation batts, and headers for openings (8% of total wall SF). 2 Based on 2004 Residential Cost Data by RS Means for: 2x6 studs at 24 o.c., double top plate, single bottom plate, let-in corner bracing, 1/2 sheathing, 6 R19 insulation batts, and headers for openings (8% of total wall SF). 3 Based on PCA survey data for: 4 flat ICF wall, reinforcing, parging, door and window bucks. 4 Based on PCA survey data for: 6 flat ICF wall, reinforcing, parging, door and window bucks. 5 Labor hours required to construct one square foot of wall. 6 Total cost in dollars to construct one square foot of wall.
ACKNOWLEDGEMENTS
The research reported in this paper (PCA R&D Serial No. 2781) was conducted by NAHB Research Center, Inc, with the sponsorship of the Portland Cement Association (PCA Project Index No. 03-15). The contents of this paper reflect the views of the author, who is responsible for the facts and accuracy of the data presented. The contents do not necessarily reflect the views of the Portland Cement Association. NAHB Research Center, Inc extends special appreciation to all of the individuals that helped to complete this project; Nicky DeVeny, Nader Elhajj, P.E., Joanne McAlpin, Stuart Denniston, and Jay P. Jones, for work on the survey and report. Special appreciation is also extended to the following individuals for their participation and contribution to this document: David Shepherd and Michael H. Weber, Portland Cement Association; Mark Ingle, Piedmont Wall Systems (aka Ingle Builders); David Hahn, 21st Century Building Systems; Lee Morton, Morton Construction; Frank Palmer, Advance Foam Plastics, Inc; Frank Brock, Brock & Weigl Construction, Inc.; Mark Leardi, Suncon, Inc; Jerry Yoder, Reward Wall Systems of Ft. Wayne; W. L. Mayen, A&S Steel Framing, Inc.; Rick Hansen, Reddi-Form ICF LLC; Jim Lane, Blackhawk Southwest, Inc.; Ian Giesler, ICF Builders; William Schoenleber, Old World Builders, Inc.; David Mcliwain, Creative Building Products, Inc.; Jim Prichard, Northwest Wall Systems; Randall Oke, Oke Woodsmith Building Systems, Inc.; Benjamin Daniel, Engineered Concrete Products, Inc.; Paul Schelm, Island Coast Distributors; Steve Kay, Project Net, Inc.,
10
A-1
yes
no
BELOW-GRADE MATERIAL COST Sample Estimate- Provide your current materials and labor unit costs in the following tables-use this data to bid off the attached sample house plan. 15. Do you set the footings for your foundation walls? yes no
15.a. Please fill out the following table based on the sample job:
Sq. ft. Quantity (number) Cost No. of 90 Corners Outside Cost Inside No. of 45 Corners Inside Outside Cost
Standard Forms*
*Including shipping cost Quantity Required Accessories Item Height adjusters End caps Door and window bucks Corner straps and clips Bracing system Scaffolds Anchor bolts Price/Form Extended Cost/Form
A-3
Quantity Foundation Protection Parging roll bag Concrete Waterproofing Rebar Miscellaneous roll bag Cu. yd Sq. ft. Linear feet
Item
Price/Form
Extended Cost/Form
Fiber mesh PrepCoat Concrete Please specify: (check one): #3, #4, #5, #6
1 Filament Tape Corner Straps & clips Engineering Concrete pump Forklift Skid steer Misc. Zip Ties
A-4
Labor Activity Unload ICFs Set up ICFs (including cutting) Align ICF Walls Place re-bars Fill w/concrete Finish/apply sole plates Window/door bucks service penetration Waterproofing/damp proofing
Crew (number)
Productive hours
Cost/sq. ft.
panel
block
15.d. What is your typical rebar spacing for: Vertical Rebar Spacing: On Center Horizontal Rebar Spacing: On Center
For your rebar do you: order precut/bent cut/bend in field?
15e. What type of ledger board do you use? Wood sole plate extended brick ledger Taper top What is the installation cost per linear foot for the one you selected above?
A-5
B. ABOVE GRADE FLAT ICF WALLS Sample Estimate- Provide your current materials and labor unit costs in the following tables-use this data to bid off the attached sample house plan. 17.a. Please fill out the following table based on the sample job: Sq. Quantity Cost No. of 90 Corners ft. (number) Inside Outside Cost Standard Forms*
*Including shipping cost
Item
Price
Extended Cost
Height adjusters End caps Door and window Buck Corner straps and clips Bracing system Scaffolds Anchor bolts
Quantity Item Price Extended Cost
Concrete Rebar
yd
Concrete
Misc
roll 1 Filament Tape bag Corner Straps & clips Engineering Concrete pump Forklift
Skid steer
ABOVE-GRADE LABOR COST: 17.c. Labor Activity Crew (number) ~Hourly rate/crew member Productive hours/sq. ft. Cost/sq. ft.
Unload ICFs
Set up ICFs (including cutting) Set Rebars Window/door bucks service penetrations Align walls Place concrete Rough electrical/plumbing
SECTION III.
A. MATERIALS (FLAT ICFS ONLY) 18. What type of cement do you use? High flow concrete mix Portland Type I Plain/air entrained Other: 19. What type of bracing do you use for your flat ICF walls? Wood Manufactured Metal Site built Metal Other: 20. Do you use a waterproofing material? If yes, what is the cost/sq. ft.? 21. Do you use a termite shield? If yes, what is the cost/sq. ft.? 22. Are you required to use borate treated foam? If yes, what is the cost premium for this addition?
A-7
B. PREMIUMS FOR TRADE CONTRACTORS 23. What trade contractors do you use and is there a premium charged? (check all that apply and circle or specify premium(s) charged) Siding: Plumbing: Premium charged Premium charged <1% 1-5% 5%+ <1% 1-5% 5%+ Drywall: Electric: Premium charged Premium charged <1% 1-5% 5%+ <1% 1-5% 5%+ Carpentry: Premium charged <1% 1-5% 5%+ C. ICF COST ESTIMATOR 23. Do you use a computerized estimating tool? (If yes, please circle method) Developed it yourself Provided by supplier
D. STRUCTURAL SYSTEMS: WALL, FLOOR, AND ROOF STRUCTURES 24. When building with ICFs what materials do you typically use for: a) Floors (check all that apply) Wood/engineered wood joists Wood/engineered wood trusses Light-Gauge Steel Joists Light Gauge Steel trusses Open web steel joists Other: b) Exterior above grade walls (check all that apply) Wood/engineered wood Light-Gauge Steel ICFs Other: c) Interior walls/partioned walls (check all that apply) Wood/engineered wood Light-Gauge Steel Other: d) Roof trusses (check all that apply) Wood/engineered wood Light-Gauge Steel Other:
A-8
__ __ __ __ __ __ __
Energy Efficiency Mold/Mildew Resistance Sound/Noise management Fire Characteristics Extended home warranties Affordability (Price) Durability Other ________________
__ __ __ __ __ __ __
Greater need for choice/options in the homes you provide Disaster resistance (High wind and earthquakes) Termite/Rodent Resistance Recyclable, or Green, building products Ease of handling and installation Consumer Demand Strength
25. Which of the following are issues for you concerning flat ICF walls? (please check all that apply) Above Grade Below Grade Installation Training/Skilled Labor ___ ___ Lack of Homeowner demand ___ ___ Termite Issues ___ ___ Material Cost ___ ___ Code Approvals ___ ___ Engineering Cost ___ ___ Other (specify) ___ ___
26. Have you ever used, or do you currently use the Prescriptive Method for Insulating Concrete Forms in Residential Construction? Frequently Sometimes No Never heard of it
27. Do you think the current ICF provisions in the International Residential Code (2003 IRC) need improvement? Yes No No Opinion
A-9
SAMPLE PLAN
Please Use for Cost Estimate
16'
16'
1 6 ' 16'
8' 8 '
32" X 16"
32" X 16"
32" X 16"
32" X 16"
8'
8'
W 8 X 18 STEEL W8 X 18 B E A M STEEL
BEAM
12'
12'
2 X J O IS T S @ 1 6 " O C
16'
2X JOISTS @16" OC
36" X 60"
16'
36" X 60"
32" X 16"
4'
32" X 16"
4'
F O U N D A T IO N P L A N
FOUNDATION PLAN
9 ' C E IL IN G H E IG H T W A T E R P R O O F W A L L S T O 8 ' A B O V E F O O T IN G
C A L C U L A T IO N S
8" CONC. W/ #4 REBAR @ 24"OC VERTICAL & #4 REBAR @ 6", 36", 72", 102" ABOVE FOOTING (HORIZ)
G R O SS W A LL SQ U A R E FO O TA G E = 1440 W IN D O W B U C K L IN E A R F O O T A G E = 3 8 W IN D O W O P E N IN G S Q U A R E F O O T A G E = 2 5 .7
A-10
5050
3040
6050
7040 2050
FIR ST FL O O R PL A N
9' ceiling height 6" thick concrete #4 rebar @ 48" vertical #4 rebar @ 32" horizontal block outs (1) (1) (1) (1) 14-1/2" x 24" electrical panel 4" dryer vent 3" bath fan 8" fireplace vent (through w all)
C A L C U L A T IO N S
G R O SS W A L L SQ U A R E FO O TA G E = 1440 W IN D O W B U C K L IN EA R FO O T A G E = 112.7 W IN D O W O PEN IN G SQ U A R E FO O TA G E = 108.8
A-11
3040
3040
6040 TRUSSES
5040
6050
CALCULATIONS
GROSS WALL SQUARE FOOTAGE = 1280 WINDOW BUCK LINEAR FOOTAGE = 103.2 WINDOW OPENING SQUARE FOOTAGE = 101.4
A-12
B-1
ICF Contractors Company Name 21st Century Building Systems A&L Eastern Agricultural Labs, Inc. A&S Steel Framing, Inc. A.M. Enterprises ABCO Superior Built, Inc. ABS Supply Company Adams Trucking & Supply, Inc. Advance Foam Plastics Advance Foam Plastics, Inc. Advanced ICF Products Advantage Wall Systems, Inc. Alby Supply Company Allied Foam Products, Inc. Arizona Radiant Heat Barrier/Quad-Lock SW Bailey Construction Company Blackhawk Southwest, Inc. Bozeman Brick, Block & Tile Brick & Supply Company Brock & Weigl Construction, Inc. Brock White Co. Builders Mart Building Block Systems Canyon State Homebuilders, LLC Central Concrete Inc. Chaney Enterprises Cody Construction Columbus Coal and Lime Company Combs Construction Co. Con-Core Systems Concrete Building Supply Concrete Special Ties, Inc. Concrete Supply of Topeka, Inc. Creative Building Products, Inc. D&W Construction of Alexandria, Inc. D.L. Schmidt Companies DACS Industries Daowaga Polysteel Dixie Distribution Drury Supply Company E.I. Industries, Inc.
1
City Palm Harbor Richmond Niceville Falmouth Coppell Butler Barboursville Denver Murray Bend Montreal Burlington Gainesville Tucson Metropolis Silver City Bozeman Appleton Reno St. Cloud Boyceville Philomath Prescott Mankato Waldorf Ellwood City Lexington Madison Baxter Mapleton Gresham Topeka Glen Allen Alexandria Oronoco St Paul Tahoe Vista Louisville Cape Girardeau San Jose
State FL VA FL Maine TX OH WV CO UT OR NC WI GA AZ IL NM MT WI NV MN WI OR AZ MN MD PA OH IN MN MN OR KS VA MN MN MN CA KY MO CA
Res.1 2 8
10
13
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-2
ICF Contractors Company Name E.R. DupruisConcrete Co. & Polystell Forms Engineered Concrete Products, Inc. Engineered Housing Industires Inc. Enviroclean Services EPS Building Systems, LLC Erb Supply, LLC FASTFORM Concrete Forming Florida Polysteel, Inc. Foam Forming Supply Force One Walls Formosa Garden Homes Gentry Commercial Contracting, Inc. (dba Gentry Builders) Georgia Foam, Inc. Glacier Lite-Form Glossners Concrete, Inc. Goedecke Co., Inc. Heartland EPS HiCaliber Inc. Hi-Energy Walls High Plaines Foam Building Systems, Inc. High Plains Foam Building Systems, Inc. HOLDFAST Technologies, LLC ICF Building Products, LTD. ICF Supply ICF Technologies, Inc. Innovative Construction Technologies Insulating Concrete Homes Insulation Solutions, Inc. IntegraSpec Nebraska, LLC Integrated Building Products Island Coast Distributors J.M. King Engineering Corporation J.W. Bird & Co., Ltd. JEB Contractors Kerr's Redi-Mix Larison Family Builders Livingston's Concrete Service, Inc. Lloyd's Development Company Lower Columbia Reward Wall Systems
1
State Res.1 Vidor TX 16 Mt. Pleasant SC Miami FL Wilmington NC Brighton CO Sarasota FL Orangeville ON Winter Garden FL Commerce City CO St. Augustine FL Kissimmee FL Morehead City NC Gainesville GA Kalispell MT Beech Creek PA Decatur IL Waukegan IL St. George UT Portland MI Berthoud CO Berthoud CO Medway OH Millfield OH Kimberly WI Fridley MN Wichita KS Oklahoma City OK East Peoria IL Gretna NE Inglefield IN 17 Port Charlotte FL Amarillo TX Dartmouth NS Hamilton OH Centre AL Martinsville IN North Highlands CA Malibu CA Longview WA City
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-3
ICF Contractors Company Name Malone Lumber & Ready-Mix, Inc. Manning Materials Corp. Mass Building Products, Inc. MaxxBilt, Inc. Mid Atlantic Foam Mike Pilley Enterprises, Inc. NAPPI, Inc. New York Polysteel Northwest Wall Systems NW Reward Wall Systems Oke Woodsmith Building Systems, Inc. Panel Tech Building Systems Paramont Ready Mix Concrete, Inc. Performance Building Systems Piedmont Wall Systems (aka Ingle Builders) Polycon, Inc. Polysteel of Minneapolis/St. Paul Polysteel Building Supply, Inc. Polysteel Distributing, Inc. Polysteel Midwest, LLC Polysteel of West Central Indiana Polysteel Southeast Distributors Project Net, Inc. Quality Concrete Store Quality Sytems, Inc. Reddi-Form ICF LLC Reddi-Wall, Inc. Reg Wood & Associates Reward Wall System of Tyler Reward Wall Systems of Ft. Wayne Reward Wall Systems of N.M., Inc. Riefler Concrete Products Robb Construction Company Schvetz Enterprises, Inc. Seadore Masonry, Inc. Shelly Enterprises, Inc.
1
City Malone Birdsboro Brimfield Clemson Fredericksburg Marble Falls Rockford Amityville Bend Silverton Hensall Miami Sante Fe Springs Sugarland Iron Station Redmond Blaine Fort Worth Richfield Jacksonville Lafayette Toccoa South St. Paul Woodburn Nashville Bozeman Oakland Ventura Tyler Ft. Wayne Santa Fe Hamburg Afton Burlington Long Pine Perkasie
State Res.1 NY PA MA SC VA TX IL NY 14 OR OR 15 ON FL CA TX 1 NC OR MN TX UT IL IN GA 18 MN OR TN 9 MT MI CA TX 7 IN NM NY VA WI NE PA
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-4
ICF Contractors Company Name Shoffner Construction, Inc. SIPbuilder, Inc. Southern Concrete Materials, Inc. Spencer Polysteel Walls Stitt Energy Systems, Inc. Tara Contracting, Inc. Tech Building Systems Polysteel The Decorative Concrete Store Thermal Foams, Inc. Thermal Innovations Tidewater Polysteel, Inc. Transit-Mix Concrete Company Tri County Insulated Building Systems Inc. Tri-State Insulated Concrete Forms US Insulated Forms VanHaren Insulated Concrete Forms Virginia Polysteel Wall Systems LLC Vista Custom Homes, Inc. (dba Amvic) Wagner & Sons Construction, Inc. Walltech Products, LLC Wisconsin Insulated Forms Wyoming Concrete Industries, Inc.
1
City Greentown Nevada City Fletcher Oskaloosa Rogers Greenfield Hillpoint Cincinnati Buffalo Primghar Virginia Beach Johnson City Burton Mabel Raleigh Farigault Harrisonburg Cedar Hill Ludington Petoskey Brodhead Wyoming
State IN CA NC IA AR NJ WI OH NY IA VA TN OH MN NC MN VA TX MI MI WI DE
Res.1
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-5
ICF Distributors Company Name A. Anderson Building Systems A.M. Enterprises ABCO Superior Built, Inc. Advanced Building Technologies, Inc. Arid Resources Basement Systems, Inc. Baur Building Products Benn Masonry Construction, LLC Better Builders of Oregon, Inc. BFJ Construction, Inc. Block & Bean Construction Blue Horse Building & Design Bob Miller Masonry Boss Building Systems (aka Ranger Concrete) Brehmer Enterprises, LLC C & A Construction Capital City Development Category Five Wall Systems Classic Conservatories Combs Construction Co. Construction PS Continental Homes, Inc. Cotton's Concrete Foundations Cozy Crete Construction Custom Assembly Services, Inc. D.L. Schmidt Construction D.O.C.'s Construction Dan Thomas Builders Danmark East Metro Polysteel Dave Carr Construction, Inc. DBA J. Pirro Construction/Remodeling Dee Construction Co., Inc. Derrick Builders DNC Companies Doug Ripley's Inno-Craft Design ... DuBrook Concrete, Inc. Ed Chun Architectural & Construction Eggert Construction, LLC Eker Brothers, Inc. Energy Efficient Healthy Construction Commercial/Residential
1
City State Res. 1 Petersburg IL Falmouth Maine Coppell TX Jupiter FL Elkhorn NE Seymour CT Cincinnati OH Sauquoit NY Corvallis OR Palm Harbor FL Lincoln NE Dripping Springs TX Sarasota FL Covington OH Cheyenne WY Bloomington IL Columbus OH Baker FL Mountainside NJ Madison IN Grafton IL Logan UT St. Athens PA Oak Harbor WA Anderson SC Oronoco MN Owatonna MN Winterville NC Conyers GA Mount Hope ON Woodstock IL State College PA New Cumberland PA Owatonna MN Tualatin OR Chantilly VA El Centro CA Branford CT Albuquerque NM Milford MI
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-6
ICF Distributors Company Name Energy Management & Engineering, Inc. Energy Smart Solutions LLC Engineered Concrete, Inc. Eternity Building Systems, Inc. Evans Construction Company Firebird Remodeling, Inc. Foam-Form, Inc. Francis N. George, Inc. & Sons Gentry Commercial Contracting, Inc. (dba Gentry Builders) Greenblock of the Ozarks Greg Varner Contracting, Ltd. Gust Construction Harrison Developers, LLC HBR Building Supplies Howe Construction ICF Builders ICF Builders ICF Building Products ICF Construction Company ICF Construction of MD ICF Custom Building ICF North Building Solutions Insulated Concrete, Inc. Insulating Concrete Forms California Insulating Concrete Forms of Beaumont John Jackson Masonry JP & Sons Kevin Phillips Construction KH Construction, Inc. Lucida Homes, Inc. Mass Building Products, Inc. MDR Construction, Inc. Medelpad Construction Midwest ICFs Millenium Builder's Service Miller Homebuilders, Inc. Morton Construction N E L Builders Nelson Concrete Homes. LLC New Mexico Polysteel Nickerson Construction
1
City Libertyville Arlington Clemson Evans El Dorado Hills Glendale Tipton Strykersville Morehead City Springfield Bridgewater Alta Brimfield Holland Landing Newaygo Richmond Chilton Houston Jacksonville Hampstead Waubaushene Torrance Lexington California City Beaumont Sacramento Bend Cedar City Owatonna Port Isabel Brimfield Spencerport Owosso Cridersville Summerville Hutchinson Santa Rosa Lebanon Middleton Farmington Ely
State IA TX SC CO CA AZ GA NY NC MO NS WY MA ON MI ME TX TX FL MD ON ON NC CA TX CA OR UT MN TX MA NY MI OH SC KS CA NH WI NM MN
Res. 1
11
Response number. Indicates the order in which the surveys were returned to the NAHB Research Center.
B-7
ICF Distributors Company Name Old World Builders, Inc. Pandion Group, Inc. Peoria County Concrete Company Renaissance Building Products Richlyn Construction, Inc. River Oaks Builders RiverStone Design & Build, Inc. RKC, Inc. Rock Solid Walls Scardina Builders, Inc. Schultz Foundations Schvetz Enterprises, Inc. Secure Comfort Homes Sellers Group Sherwood Engineering & Construction Simpson Burke Construction StahlBeton Homes, L.P. Standard 895 Direct Standard ICF Steffes Concrete Construction Structural Resistance Suncon, Inc. Superior Built Construction The Pinnacle Grp. Inc. Thermal Concept Builders and Distributors Thermalwall Structures Tim Savage Construction Tri City Thermo-Form, Inc. Universal Contractors Van Wieren Bros. Construction Wheat City Concrete Products, Ltd. Zetah Construction, Inc. City Ivyland Gilbert Peoria Ellwood City Mandeville Searcy Denfield Cincinnati Margate San Jose Mapleton Burlington New Berlin West Jordan Clarksville Warrenton Houston Welch Gray Beaver Dam Myrtle Beach Alton Coppell Beckley Colgate Eden Prairie Groveton Bay City Northwood West Winfield Brandon Bemidji State PA AZ IL PA LA AR ON OH FL CA MN WI IL UT AR VA TX MN ME WI SC IL TX WV WI MN NH MI IA NY MB MN Res. 1 12
B-8
C-1
Quantity
172
Cost
$18.00
1440 1040 1113 12 1408 1012 5.33 5.33 5300 5.33 218 1000 210 210 93 352 190
10 6 21 60 90 70
10 18 49
$415.00 a $324.00 $1,260.00 $16.00 Included $16.00 0 0 0 0 0 0 $0.00 $0.00 $0.00 $16.00 90 90 $15.00 0 0 $0.00
70 90 90
$16.00 $15.00
C-2
Respondent
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
End Caps
Qty Price Form Ext Cost
Bracing System
Qty Price Form Ext Cost
680 LF $0.40 $272 ? LF $0.33 60 $360 $450 28 30 35 2/day $210 $60 40 1.75/day $10.00 $343 $300
Scaffolds
Qty Price Form Ext Cost
10 sets $6.00 $60 0 1 $150.00 $187 inc $60 inc 3
Anchor Bolts
Qty Price Form Ext Cost
35 $1.00 $35 92 $1.00 40 $0.28 $14 166 $0.65 $108 0 400 $0.60 $0.60
Parging
Qty Price Form Ext Cost
CY $5.00 .5 rl $55.00 $68.00 SF $2.00 $240 $65.00 $130
Concrete
Qty Price Form Ext Cost
36 CY $75.00 $2,700 CY $75.00 35 CY $65.00 $81 37 CY $72.00 $2,664 54 CY $80.00 $4,320 38 CY $75.00 $2,850 27 CY $68.00 $1,836
Water Proofing
Qty Price Form Ext Cost
1040 SF 1255SF 1328SF 1280SF $0 $658 $823 $93 $560 $528 1440SF .42/.28 $1,008 1400SF $93 $744 1300SF $5.30 $1.00
Rebar
Qty Price Form Ext Cost
6240LF 1450LF 2202LF $0.27 $246 $308 $0.24 $528 $268 1520LF $0.13 $203 2300LF $0.14 $322 1600LF $1.50 $1.35
C-3
Engineering
Qty Price Form Ext Cost
0 $500 $5,000 $300 $500 $600 1 1200 $1.50 $1,200
Concrete Pump
Qty Price Form Ext Cost
0 5 hrs $625 $781 4 hrs $90 $360 $400 $800 $350 1 2000 $2 $0
Forklift
Qty Price Form Ext Cost
$700 1 0 0 0 0
Skid Steer
Qty Price Form Ext Cost
1 0 0 0
Misc
Qty Price Form Ext Cost
0
Glue
fast
glue
pamduits 1600
$100 $125
$0.10 $500
$13 $52
$0.30 $0.30
Zip Ties
Qty Price Form Ext Cost
0 0 0 0
C-4
Respondent
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Set Up ICFs
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 16 $960 4 $16.00 160 4 $15.00 40 $0.42 .08 x SF $21.00 3 $30.00 ? $1.50 3 $15.60 16 $0.52 3 $12.00 24 $0.78 5 3 3 18/15/11 $15.00 600 $2.00 66 16
Align ICFs
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 2 $120 4 $16 160 4 $15 20 $0.21 2 $21 1 2 $30 ? $0.20 2 $16 1 3 $12 3 $0.09 2 15/11/ 4 $0.06 3 3
Place Rebar
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 2 $120 4 $16 160 4 $15 20 $0.21 1 $21 1 $30 ? $0.05 inc 3 $12 24 $0.78 2 15/11/ 200 $2.50 3 2
Fill w/Concrete
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 4 $240 4 $16 16 4 $15 12 $0.12 4 to 6 $21 1h/9CY 3 $30 ? $0.15 4 $16 4 3 $12 4 $0.12 4 15/11/ 48 $0.25 3 3
Waterproofing
Crew (nember) $ / hr Productive Hrs Cost / SF
4 $16.00 16 4 $15.00 40 $0.42 $0.84 4 $21.00 2 $30.00 ? $0.10 $2.30 4 $15.60 2 3 $12.00 8 $0.24 2 $11.00 16 $0.50 6 2
C-5
Quantity
300 537
Cost
$17.00 $6,434.00 $4,220.00
30 60 170 70
70
130 40 21 30 49
C-6
Respondent
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
End Caps
Qty Price Form Ext Cost
0 0 0 0 0
20 $1,000 $2,000
25/8/35 $386
Bracing System
Qty Price Form Ext Cost
$0 ru 53 $8.00 $480 ru 28 $1.75 $686 30 $10.00 $300 $210 35 inc 33 $1.50 $50
Scaffolds
Qty Price Form Ext Cost
$0 ru 0 inc 3 $20.00 $60 $45 54 45 $2.00 $180 25 $1.00 $25
Anchor Bolts
Qty Price Form Ext Cost
70 $1.00 $70 0 0 83/166 1.35/.65 $220 50 $0.75 $38 60 $1.20 $72 $100 50
Parging
Qty Price Form Ext Cost
Concrete
Qty Price Form Ext Cost
46 CY $70.00 $3,220 36.9CY $70.00 $2,581 $100 27 CY $75.00 $2,025 27.6CY $1,794 $2,243 40 CY $72.00 $2,880 42 CY $80.00 $3,360 27 CY $75.00 $2,055 51 CY $68.00 $3,468 24 CY $1,680 $3,500 26 CY $75.00 $1,950
Water Proofing
Qty Price Form Ext Cost
Rebar
Qty Price Form Ext Cost
1800LF 1868LF $0.20 $360 $0.25 $467 1050LF 4160LF 2456SF $178 $223 $0.24 $998 $442 1200 $0.20 $240 $0.14 $970 2400 $250 $500 2142 $0.23 $493
C-7
0 0
Engineering
Qty Price Form Ext Cost
$5,000 $300 0 0 0 1 $600 $600 $1,500 1200
Concrete Pump
Qty Price Form Ext Cost
2 $450 $900 4 hrs $100 $400 5 hr $625 $781 8 hrs $95 $760 $900 $900 2 $350 $700 $1,000 $1,500 3 $90 $225
Forklift
Qty Price Form Ext Cost
0 0 0 0 0
Skid Steer
Qty Price Form Ext Cost
0 0 0 0 0
Misc
Qty Price Form Ext Cost
2 $150 $300
foam
fast
glue 8
$100 $125
$0.10 $500
$13 $104
Zip Ties
Qty Price Form Ext Cost
inc 0 1 0 0 0 50 0.08 $4.00
C-8
Respondent
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Set Up ICFs
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 40 $2,400 3 to 4 8 to 20 ? $2.50 4 $15.00 40 $0.42 4 $21.00 0.08 $1.68 3 $30.00 ? $1.75 3 $15.60 16 3 $50.00 40 $0.40 4 $11.00 130 $1.80 3 $15.00 66
Set Rebar
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 3 $180 3 to 4 8 to 20 ? $2.50 4 $15 20 $0.21 inc 1 $30 ? $0.05 inc 3 $50 40 $0.40
Align Walls
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 4 $240 3 to 4 8 to 20 ? $2.50 4 $15 10 $0.10 inc 2 $30 ? $0.20 inc 3 $50 5 $0.05 2 $2 4 $0.05
Place Concrete
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 8 $480 3 to 4 8 to 20 ? $2.50 4 $15.00 12 $0.12 4 $21.00 1 $0.24 3 $30.00 ? $0.20 3 $15.60 4 3 $50.00 10 $0.10 4 $11.00 48 $0.06
Rough Elec/Plumb
Crew (nember) $ / hr Productive Hrs Cost / SF
3 $60 1 $60 2 $35.00 50 $1.21 ? 1 $40.00 ? $0.05 $0.01 none
C-9
D-1
2 | FOUNDATIONS
##
Cost per S.F. System Description Quan. Unit Labor Hrs Material Inst TOTAL
Concrete, 8" thick, 2500 psi ICFs Reinforcing (#4 Bar) Vertical @24"o.c. Horizontal @36" o.c. Concrete Pump Waterproofing (to 8' above footing) Anchor Bolts, 1/2" diamter, 4' o.c. 1 Door and Window Bucks Bracing System Parging Engineering
CY Ea LF LF Hr SF Ea LF Ea SF Hr
1.99 4.33 0.18 0.14 0.38 0.82 0.02 0.47 0.22 0.33 0.16
TOTAL
SF
0.139
5.95
2.33
9.04
D-2
2 | WALLS
##
Cost per S.F. System Description Quan. Unit Labor Hrs Material Inst TOTAL
Concrete,6" thick, 2500 psi ICFs Reinforcing (#4 Bar) Vertical @48"o.c. Horizontal @32" o.c. Concrete Pump Rough Electric / Plumbing Anchor Bolts, 1/2" diamter 1 Door and Window Bucks Bracing System Parging Engineering
CY Ea LF LF Hr Ea LF Ea SF Hr
1.48 3.94 0.11 0.15 0.30 0.05 0.03 0.41 0.10 0.20 0.19
0.03 0.078 1
0.027 0.009
0.20 0.10
TOTAL
SF
0.129
4.56
1.81
6.96
D-3
2 | WALLS
##
Cost per S.F. System Description Quan. Unit Labor Hrs Material Inst TOTAL
Concrete,4" thick, 2500 psi ICFs Reinforcing (#4 Bar) Vertical @48"o.c. Horizontal @32" o.c. Concrete Pump Rough Electric / Plumbing Anchor Bolts, 1/2" diamter 1 Door and Window Bucks Bracing System Parging Engineering
CY Ea LF LF Hr Ea LF Ea SF Hr
1.03 3.94 0.11 0.15 0.30 0.04 0.03 0.41 0.10 0.20 0.19
0.03 0.072 1
0.027 0.009
0.20 0.10
TOTAL
SF
0.129
4.11
1.81
6.5
D-4