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BEST(Building “Energy Saving” Technology)
Modular Building Systems
Center for Technology Management, Inc.Presenting
A Green Technology Building System
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There are two distinct types of structures designed by CTM
I. Light Weight System; using Glass Fiber Reinforced Polymer (GFRP), mostly suitable for Disaster Shelters & Rapid deployment projects, or claddings on high-rise buildings.
II. Heavier System; using Glass Fiber Reinforced Cement composite (GFRC), suitable for more permanent type buildings – residential &/or commercial.
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“Modular Building Panels made of Glass Fiber Reinforced Polymer (GFRP) and Insulating Foam Board are lighter, esthetically pleasing, more durable and less expensive than alternate products.”
Composite panels introduced by Center for Technology Management (CTM) provides a structural light-weight panel with better insulation. It provides more flexibility in design, eliminates the need for using wood or reinforcing steel or added insulation. Buildings are erected much faster and less expensively.
This is a high-tech product using glass fibers and polymer matrix as composite materials.
TYPE I – Light Weight System
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Summary:Modular Building Panels Nominal 120 cm x 275 cm size
6.7 cm thick
Inner facing surface GFRP 2 m/m textured colored fireproof
Outer facing surface GFRP 2 m/m textured colored weather-resistant
Lightweight47 pounds, compared to 3,100 pounds for concrete
Structural Panel Composite Material insulating value R= 20 2 Hr. fire rating safe, non-toxic earthquake, hurricane resistant
Built-in channels for seal strips, wiring
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A radical move from
Mass Production to Mass Customization
To Reduce costs & Increase design flexibility
Glass Fiber Reinforced Concrete(GFRC)
TYPE II – Structural Panel System
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“Modular Building Panels made of GFRC and Perlite concrete/or Foam are lighter, esthetically pleasing, more durable and less expensive than plain concrete panels.”
Perlite provides a structural light-weight concrete – lower panel weight and better insulation. It provides more flexibility in design, eliminates the need for reinforcing steel or added insulation. Buildings are erected much faster and less expensively.
This is a high-tech product using glass fibers and cement matrix as composite materials.
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A Typical Standard Design Example
A Typical 2 Bedroom Housing Unit, 1100 Sq.Ft.
Living Area
Kitchen/Dining AreaMaster BR
Bedroom 2
Bathroom
Closets
Electrical & Communications
Modules
Hot & Wet-WallApplication
Modular 4' Panels
Closets
Hot & Wet-Wall Application
Dining Area
Washer/Dryer
HV
AC
10'
2'
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A 2-Bedroom Unit in Clusters
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“Surgy Clinic”
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School
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Solid Concrete is not an ideal building solution
• Great compressive strength• Any shape desired• Grows stronger with age• Fire and termite resistant
• Poor tensile strength• Conducts heat• Heavy
• Heavy to handle• Makes heavy buildings
• Energy intensive (cement production)• Limited market range • Expensive Transportation• Environmentally Taxing
PRO CON
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Due to Hurricane & Severe Wind Loadings,What happens when a concrete wall is stressed?
External Force
InnerSurface
OuterSurface
undergoesTension
undergoesCompression
small deflection
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The problem?
External Force
Tension Compression
Crackleading tocollapse
No problemfor concrete.
Severe problem for concrete, which has low tensile strength.Need to add Steel.
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InnerSurface
OuterSurface
underTension,Glass fiberstake the Tension
underCompression
No crack
Add outer layers of Tension-Resistant material
Glass Fiber ReinforcedConcrete (GFRC) layers
Step 1Step 2
Change core to lightweight Perlite Concrete
External Force
Solution: Composite Materials!
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What isGlass Fiber Reinforced Concrete?A thin layer of concrete containing glass fibers, which have very high tensile strength. Similar to Plastic fiberglass matrix, except embedded in concrete.
GFRC layer | Insulating concrete core
The GFRC layer, applied with a spray gun, bonds to the fresh backing
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What is perlite?
A silicate mineral that pops like popcorn when heated. It expands to 16 times its volume.
Expanded perlite is essentially a foamed mineral bubble.cheap • lightweight • insulating • fire-resistant
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What is Perlite Concrete?
A mixture of 65% perlite, 35% Sand & Cement Matrix
Concrete Perlite ConcreteWeight lb/cu ft 150 55Thermal BTU/sq ft/hr 12 1.7Price $/cu yd $125 $42Compression; PSI 3,500 1,800Tensile PSI 250 1,200
Note: The loss of compression strength in the center core is not a significant factor -- no need for high strength in the core.
Buildings can actually be made lighter, using less steel, and with smaller foundations and less framework when built with Perlite Concrete.
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• Great compressive strength• Any shape desired• Grows stronger with age• Fire and termite resistant• Great tensile strength• Excellent insulator• Lightweight• Low energy cost• Expanded market range
• Poor tensile strength• Conducts heat• Heavy• Energy intensive• Limited market range
PRO CON
With GFRC & Perlite Concrete Panels,all the CONs of concrete become PROs
In addition:• Improved earthquake, fire, tsunami, hurricane resistance• Faster, less expensive to erect• Extended shipping range• No framing required
• Variety of Color, textured surfaces – no need for outer facing• Lighter buildings with less steelwork, smaller footings• Unlimited design flexibility
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Summary:Modular Building Panels Nominal 4’ x 10’ size
6” thick
Inner facing surface GFRC 1/8” thick textured colored fireproof
Outer facing surface GFRC 1/8” thick textured colored weather-resistant
Lightweight750 pounds, compared to 3,100 pounds for concrete
Structural Panel Composite Material insulating value R= 20 2 Hr. fire rating safe, non-toxic earthquake, hurricane resistant
Built-in channels all aroundFor seal strips, wiring
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Savings:• Materials• Labor• Erection Speed• Shorter Construction Time• Low Weight, Extended Shipping Range/Costs• Design Flexibility• Environmental Benefits• Better Insulation Properties (R= 15 to 20)• Better Sound Proofing• Resistant to Fire, Termite, Earthquake, Hurricane
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A typical Construction CycleFor a 12-story Office Building
2 years 1/2 year 18 months
Regional contracts CTM Modular Precast System
CTM Modular Design
28-Month Cycle Timewith CTM Products
DESIGN & Permits CONTRACT CONSTRUCT
4 - Year Cycle Timewith present conventional methods
1yr 4 Mo 1 year
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Financial Savings
• 1 step• 1 craft• 1 week• $144,000 *
• 5 steps• 4 crafts• 6 weeks• $538,000
Concrete panel Concrete block GFRC panel
• Additional savings of Interest on Construction Loans, • No need for steel framing (up to 2 stories), smaller footings• Easier to handle, and lighter building,• Earthquake / hurricane / tsunami / fire resistance, • Increased labor productivity.
Crafts include Drywalls, masons, insulators, equipment operators (Estimates are based on a 120 x 40 ft, 4 story building shell)
* At production cost; market price to be determined
• 4 steps• 3 crafts• 3 weeks• $422,000
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Products Cost Summary
Panels, 4’ x 10’ x 6” Floor Decks, 4’ x 8’
(one layer GFRC)
Material: $48.00 $40.00Direct Labor $64.80 $33.60Joinery $34.00 ---------TOTALS: $146.80 $73.60
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CTM TechnologiesEnergy Saving Building System
Products: External Wall Panels & Floor Decks
Production Plant Costs: $25 milProduction Labor rate = $28/hr
In one year,Plant Operating @ 80% Capacity can supply:
• 120 Town Houses• 80 Single Family Homes• 4 Conventional High Rises• 5 Shopping Centers; 80’ x 480’ long; 24 stores (producing 1.2 million sq.ft. of buildings/year)
Generating Savings of about $8.5 mil/year+
Yield a Net Profit (before taxes) of about $11 mil/year
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Samples of existing buildingsSingle story & High-Rise
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What is the advantage?Concrete panel
Gypsum wallboard Insulation Concrete panel Facing panel
CTM panel
All in OneOperation
Gypsum wallboard Insulation Concrete block
Mortar Facing panel
Concrete block
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Surface Finishes(GFRC)
Inner Surface Appearance • Plain, smooth cement• Stone• Wood• Wallboard• Tile• Colors, textures
Outer Surface Appearance • Plain concrete• Stone• Stucco (shown here)• Brick• Aggregates• Wood• Inlays• Colors, textures
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A typical composite panel(GFRP or GFRC)
Surface Finishes • Plain, smooth cement• Stone• Wood• Brick• Stucco in different Colors, textures
Structure • Stress Skins• Insulating Core• Size: 4’ x 10’ x 4”-6” thick• Weight: 40 lbs to 1200 lbs
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ConstructionA crane sets the panels in place.
Panels are locked together using steel bars (joinery)
Panels are supported by special connectors
No other operations are required.
ONE-STEP INSTALLATION
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Production & Delivery
1. Automatic spray of GFRC layer into form
2. Perlite concrete is poured in and leveled
3. Top layer of GFRC is added
4. Forms are stacked to cure for 10 hours
5. Shipment.
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Products being marketed, using CTM Technologies
1) Customized Wall Panels – Residential & Office Buildings
2) Customized Ceiling/Floor Panels - “ “ “
3) Insulated Claddings; stone/brick patterns4) Disaster Shelters, using light composites
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Market Potentials
• Application for Disaster Shelters• Residential, community, commercial, industrial, government, and military markets
• Huge new markets created by new building codes in tsunami, hurricane, earthquake areas
• International markets
• Diverse building components: roof panels; interior walls; structural external panels
• Disaster reconstruction projects
• Energy efficient building projects
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Financial Summaries
• Materials cost $2.95 / sq.ft.• Total production cost $6.85 / sq.ft.• Market price $13-20 / sq.ft.• U.S. target market size 29 million pnl/yr.
1.2 bil.sq.ft./yr.• Potential Revenues /Factory $57.6
million/yr.• Potential Net Operating Profit $24.7 million/yr.
(at $12/Sq.Ft. market price)
For a typical Factory; 120,000 panels/yr @ $12/sq.ft.
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Advantages of a Manufacturing Facility
Considering the rapid growth of energy costs, and the desire for “Energy Saving” products, BEST products can serve such a
market with the following advantages:
• Increased job opportunities• Lower Construction Costs• Higher Speed of Construction• Less Cement is used for Buildings• Tremendous Savings of Energy • Higher Building Quality & Durability • Lower Maintenance Costs• Expanded Market Reach• Increased Export Potential
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What’s needed?Start-up tasks
• Meeting local Building Codes
• Fabricate panels for marketing
• Carry out a pilot project – Design & Build
• Secure sales agreements
• Startup financing
Production
• Factory at U.S. location: 120,000 panel/year capacity
• Equipment and setup
Capital financing required: $22 mil to 28 million, depending on capacity
65% Debt, 35% Equity at 122% IRR
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MANAGEMENT
Dr. B. Bahramian is the founder and developer of BEST building system. He has 30 years of experience in the design, development and manufacturing of building systems and holds a number of patents and copyrights in this field. He has been responsible for a number of development projects involving design and construction of housing projects and commercial buildings. He graduated from University of Birmingham, England with Ph.D. in Civil Engineering, and M.A. in Political Economics (major in Business Administration) from the University of Dayton, Ohio. He is serving as a Director & Professor of Construction Management Technology at University of Maryland.