Core Construction Core Construction SystemSystemPresented By:Presented By:

Aaron RutledgeAaron RutledgeCorTek, Inc.CorTek, Inc.999 Van Buren Ave.999 Van Buren Ave.Loveland, CO 80537Loveland, CO 80537Phone: 970-663-2222Phone: 970-663-2222Fax: 970-663-9969Fax: 970-663-9969

ARutledge@corteksystems.comARutledge@corteksystems.comwww.corteksystems.comwww.corteksystems.com

Service Cores► 2+ hour fire rated 2+ hour fire rated

egress shaft required egress shaft required for buildings over 2 for buildings over 2 storiesstories

► Concrete a cost Concrete a cost effective material to effective material to create this fire create this fire separation and separation and resulting vertical resulting vertical structurestructure

►Monolithic concrete Monolithic concrete structure naturally structure naturally becomes integral part becomes integral part of buildings lateral of buildings lateral systemsystem

Problematic for Construction

► Cores must be in Cores must be in place before place before surrounding framing surrounding framing can be installedcan be installed

► Slow to construct with Slow to construct with highly unpredictable highly unpredictable schedulesschedules

►Quality issues Quality issues frequently arisefrequently arise

►DangerousDangerous

“Like rolling the dice on every project”

A better way…

► Free up site schedule and resources by Free up site schedule and resources by modularizing core off site in a specialized modularizing core off site in a specialized factory set up for quality and efficiencyfactory set up for quality and efficiency

The CorTek Core The CorTek Core Construction SystemConstruction System► Stay-in-place modular form Stay-in-place modular form

system for concrete core system for concrete core structuresstructures

► Factory built modules stack Factory built modules stack like building blocks.like building blocks.

► Custom-built to the specific Custom-built to the specific requirements of each project.requirements of each project.

Features:Features:► High tolerance, all-High tolerance, all-

steel construction.steel construction.►Modules are load-Modules are load-

bearing before bearing before concrete.concrete.

► Pre-installed: Pre-installed: Horizontal RebarHorizontal Rebar StairsStairs Embed Plates and Shear Embed Plates and Shear

TabsTabs Ledger AngleLedger Angle Elevator Divider BeamsElevator Divider Beams Optional Finishing Optional Finishing

Connectors (hat Connectors (hat channel, masonry ties)channel, masonry ties)

A Load Bearing FormA Load Bearing Form

► Vertical and horizontal Vertical and horizontal structural elements support structural elements support construction loads and allow construction loads and allow form to be modularized. form to be modularized.

► Structural skeleton allows for Structural skeleton allows for support of stairs, landings, support of stairs, landings, structural framing, scaffolding, structural framing, scaffolding, personnel, and other personnel, and other construction loadsconstruction loads

► Form does not require Form does not require strippingstripping

► Finished wall structurally Finished wall structurally equal to a conventional 8”-12” equal to a conventional 8”-12” CIP concrete wallCIP concrete wall

Optional wall thicknessOptional wall thicknessEffective thickness:8” 10”12”

Actual thickness:10”12”14”Because of the much higher tolerances of the CorTek System, the

resulting finished wall assembly can be thinner than conventional methods for many applications.

Pre-installed stairsPre-installed stairs

Railings shipped ready to Railings shipped ready to bolt onbolt on

Optional Stair & Railing Optional Stair & Railing DesignsDesigns

Pan treadsCheckered plate treadsGrating treadsParallel tube railsPicket railsWire mesh rails

Beam Attachments and Ledger Beam Attachments and Ledger Angle Pre-installedAngle Pre-installed

Benefits:Benefits:► Immediate presence of stairs allows trades early Immediate presence of stairs allows trades early

and safe access to structureand safe access to structure

► Elimination of many dangerous field operationsElimination of many dangerous field operations

► Can eliminate the need for scaffoldingCan eliminate the need for scaffolding

► Reduction of poor fit-up and coordination problems Reduction of poor fit-up and coordination problems among tradesamong trades

► Cores generally part of the critical path—the CorTek Cores generally part of the critical path—the CorTek system cannot be beat for speed--reducing overall system cannot be beat for speed--reducing overall schedule by weeks or months on most projects.schedule by weeks or months on most projects.

Job Site EfficiencyJob Site Efficiency>Enabling Lean Construction>Enabling Lean Construction

► Drastic reduction of field labor. Drastic reduction of field labor.

► Just In Time Delivery minimizes site congestion.Just In Time Delivery minimizes site congestion.

► Core construction can be concurrent with frame Core construction can be concurrent with frame construction.construction.

► Re-work from misplaced embeds, doors, bulging Re-work from misplaced embeds, doors, bulging concrete and leaning or twisted towers eliminatedconcrete and leaning or twisted towers eliminated

► Several cores can be constructed simultaneouslySeveral cores can be constructed simultaneously

Safety—A Job Site’s Most Safety—A Job Site’s Most Important ConsiderationImportant Consideration

Moving formwork to a controlled factory environment eliminates many dangerous field operations

Where’s the rest of the Where’s the rest of the structure?structure?

Framing does not wait for formwork—saving weeks to months on project schedule

Concurrent FramingConcurrent Framing

QualityQuality► Parametric modeling essentially eliminates Parametric modeling essentially eliminates

detailing mistakes.detailing mistakes.

► Controlled manufacturing environment.Controlled manufacturing environment.

►Multiple fail safing operations.Multiple fail safing operations.

► Rigid Quality Assurance ProgramRigid Quality Assurance Program

► Jigs, Fixtures and Design provide Jigs, Fixtures and Design provide extraordinarily tight tolerancesextraordinarily tight tolerances

Green BenefitsGreen Benefits►No wood forms and No wood forms and

resulting site wasteresulting site waste

►No form oilNo form oil

►Greatly minimizes Greatly minimizes site labor site labor installationinstallation

► Recycled and Recycled and recyclable steel recyclable steel used in used in construction.construction.

► Perfect delivery Perfect delivery method for high method for high volume fly ash volume fly ash concreteconcrete

Target ProjectsTarget ProjectsMULTI-STORY BUILDINGS OF ALL TYPES . . . . . .MULTI-STORY BUILDINGS OF ALL TYPES . . . . . . • Structural steel framed buildings. Structural steel framed buildings. • Wood framed buildings.Wood framed buildings.• Concrete framed buildings.Concrete framed buildings.• Industrial Structures.Industrial Structures.• Current production equipment tooled Current production equipment tooled

for 8” - 12” thick walls to target 3-12 for 8” - 12” thick walls to target 3-12 story buildings.story buildings.

Attachment can be made to all Attachment can be made to all floor framing materialsfloor framing materials

DesignDesign► Direct Replacement for Conventional Cast-In-PlaceDirect Replacement for Conventional Cast-In-Place

—no extra work required for Architect or Structural —no extra work required for Architect or Structural Engineer.Engineer.

► Conventional concrete rebar configurations.Conventional concrete rebar configurations.

► No proprietary design methods or material No proprietary design methods or material strengths.strengths.

► No requirement for special code approvals.No requirement for special code approvals.

Complete Detailed Complete Detailed Shop DrawingsShop Drawings

► Stair and Railing LayoutsStair and Railing Layouts

► Rebar detailsRebar details

► Framing and Floor ConnectionsFraming and Floor Connections

► 3D Revit model available for each project.3D Revit model available for each project.

CompetitionCompetitionPrice for a typical stair core story Price for a typical stair core story

with 2 flights of stairs, 8 with 2 flights of stairs, 8 embeds and ledger angle at embeds and ledger angle at floor perimeter. Price includes floor perimeter. Price includes placed concrete and all placed concrete and all installation costsinstallation costs

► Conventional MethodsConventional Methods Cast-In-Place: $38,574/Story*Cast-In-Place: $38,574/Story* Pre-Cast: $49,219/Story*Pre-Cast: $49,219/Story* Masonry: $34,346/Story*Masonry: $34,346/Story*

► CorTek: $36,786CorTek: $36,786*Based on independent estimate provided by the Icon *Based on independent estimate provided by the Icon

Group September 2008Group September 2008

Installation Sequence and Installation Sequence and DetailsDetails

Foundation EmbedsFoundation Embeds

Base ModuleBase Module

Core Leveling DetailCore Leveling Detail

Install Vertical ReinforcementInstall Vertical Reinforcement

Vertical Reinforcement In Vertical Reinforcement In PlacePlace

Base Connection WeldBase Connection Weld

Going VerticalGoing Vertical

Module Alignment DetailModule Alignment Detail

Non-contact Vertical Splice Non-contact Vertical Splice BarsBars

Non-contact Vertical Rebar Non-contact Vertical Rebar SplicesSplices

Vertical steel attached to Vertical steel attached to each moduleeach module

Vertical Bar Alignment Vertical Bar Alignment GuidesGuides

Contractor drops in steel Contractor drops in steel beam and bolts it together.beam and bolts it together.

Concrete PlacingConcrete Placing

Form designed for approximately 6 feet/hour of concreteUp to 18 foot lifts can be poured at a time. Removable weep hole plugs aid placing concrete to correct pour heightsWeb bar spacing allows for easy penetration of pumper tip hose and vibrator

Interior and Exterior finishesInterior and Exterior finishes►ExteriorExterior► Exposed MetalExposed Metal►DrywallDrywall►MasonryMasonry► StuccoStucco► Thin set brick Thin set brick

►Interior Interior ► Exposed MetalExposed Metal►DrywallDrywall►Hardboard PanelHardboard Panel► Tile Tile

Optional pre-installed hat channel Optional pre-installed hat channel accommodates exceptionally thin accommodates exceptionally thin

finish facefinish face

Hat-channel can be field shot directly Hat-channel can be field shot directly on to walls and finished conventionallyon to walls and finished conventionally

Optional pre-installed masonry tie Optional pre-installed masonry tie backs accelerate masonry field workbacks accelerate masonry field work

Exposed metal interior is an Exposed metal interior is an aesthetic alternate to aesthetic alternate to

concreteconcrete

Difficult/slow/error-prone Difficult/slow/error-prone field work brought into a field work brought into a controlled factory controlled factory environment set up for environment set up for efficiency and quality.efficiency and quality.

Computer aided Computer aided parametric design used parametric design used for rapid parametric for rapid parametric structural and structural and architectural design.architectural design.

Decreased site Decreased site congestion increases congestion increases project flow.project flow.

Freeing site schedule Freeing site schedule from concrete core from concrete core schedule increases schedule increases “battle plan” options.“battle plan” options.

An Advanced An Advanced Building SystemBuilding System

ConclusionConclusion► Eliminates the need for Eliminates the need for

scaffolding and forms scaffolding and forms ► Reduces Critical Path Reduces Critical Path

construction time construction time associated with associated with building coresbuilding cores

► Pre-installed stairsPre-installed stairs► Pre-installed floor and Pre-installed floor and

beam connectionsbeam connections►Modules do not require Modules do not require

stripping.stripping.

► CorTek cores are CorTek cores are individually designed individually designed for each job in a for each job in a controlled environmentcontrolled environment

► Simultaneous Simultaneous construction with floor construction with floor framingframing

► Structurally equivalent Structurally equivalent to 8”-12” CIP concrete to 8”-12” CIP concrete shear wall.shear wall.

► Cost effective Cost effective

Questions & CommentsQuestions & Comments

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